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BacT-3D 60 Service Manual Rev A

1. 198 Domestic UPS with Battery Cover 199 Domestic UPS Peripheral Connections eze 200 APC UPS International Model BackUPS 650 240V Front and Rear View 4 169 201 3D 60 System Rear Communications Ports UPS Cable 4 169 202 International UPS Battery Connection Preparation 203 International UPS Battery Cover Removal 204 Connecting UPS Battery Cable to Terminal 205 International UPS with Battery Cables Connected 206 International UPS with Battery Cover Secured 207 International UPS Peripheral Connections Si az 208 Instrument Status Code 710 Service Manual xvii TABLE OF CONTENTS BacT ALERT 3D 60 THIS PAGE INTENTIONALLY LEFT BLANK xviii Service Manual BacT ALERT 3D 60 TYPOGRAPHY AND GRAPHIC CONVENTIONS 0 4 TYPOGRAPHY AND GRAPHIC CONVENTIONS The following is a comprehensive list of the typographical and graphic elements of this manual 0
2. Fig 31 Quick Reference Card Front Side Fig 32 Quick Reference Card Rear 22444444 1 1 1 1 48 Service Manual xiii TABLE OF CONTENTS BacT ALERT 3D 60 Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig xiv CHAPTER 2 BACKGROUND INFORMATION 33 ModSig PCBA Diagram 34 ModSig Block ieiuniis at i e a au aa 35 Thermistor POBA scie ii iti an ia ia e iti iti 36 Power Distribution Block Diagram 37 CPU POBA Diag a iai ai eat KAKE az Ki u a lt k UH wa aia a di 38 CompactFlash Adapter 39 Quad Serial Interface PCBA Diagram dak 40 Rack Controller PCBA Diagran 41 Rack Controller PCBA Block Diagram 42 Rack Address Concept 43 Step 5 PCBA Diagram 44 Step 5 PCBA Bl
3. 3 8 Table 3 2 3 Setup and Connections 3 9 Table 3 3 3 Restraint HardWare eccere eo mnn 3 14 Table 3 3 4 Table of Equivalent Dimensions 3 15 Section 4 Table 4 2 1 Required Tools and me 4 3 Table 4 7 1 Symptomatic Problems 4 13 Table 4 10 18 Facility Power Rating and Fuse Conversion 4 135 Appendices Table C 1 2 Disinfection p ka kd bh n A C 1 Service Manual xi TABLE OF CONTENTS BacT ALERT 3D 60 THIS PAGE INTENTIONALLY LEFT BLANK xii Service Manual BacT ALERT 3D 60 TABLE OF CONTENTS 0 3 LIST OF ILLUSTRATIONS CHAPTER 0 FRONT MATTER I mEZm1d cm e Q xxi Fig 2 USA 115 nus a cede Ei nere xxvi Fig European 230 VAC 4 4 2 11 2 1 1 2 44 6 traten tenen tenta tentata tta xxvi CHAPTER 1 GENERAL INFORMATION Fig 4 BacT ALERT 3D 60 Instrument ssssscsssssessessesseessesesseseeseeesensensensensaeentententsseestentensensensensatententenesseeatsateneeneenseneaens 1 3 Fig 5 3D 60 Power Panel Assembly 6
4. 4 9 4 6 PREVENTIVE na anna na ener na ana na AA HA KA HA KA HAAA HAAA KA HA AA HA A WAR 4 11 4 6 1 St a ey Me dede dace ca Ker c eyaz 4 11 4 6 2 Perform Data kun Ez k ze kewa k n suk ken k r b kan 4 11 4 6 3 Barcode Reader Functional Test EKE nana eee 4 11 4 6 4 Printer Maintenance b kun k n M sa Xe k ku Ree b kun k nan 4 11 4 6 5 Temperature Verification essien b n Ga eee aaa 4 11 4 6 6 Disabled Cell Check 4 11 4 6 7 5 DC Voltage 4 11 4 6 8 Blu 4 11 4 6 9 Door Open Test sai a l lay ede x aede CUR a ieee 4 12 4 6 10 Completing the Preventive Maintenance 4 12 4 7 DIAGNOSTICS AND TROUBLESHOOTING eere ee ener e ener nennen 4 13 4 7 1 eR M EE 4 13 4 7 2 Symptomatic Errors s c she dieses eite EO ae du oe ie vee eee 4 13 Service Manual V TABLE OF CONTENTS BacT ALERT 3D 60 vi 4 8 SOFTWARE DIAGNOSTICS 4 15 4 8 1 Button Legend yu TRU RU EN MEM 4 15 4 8 2 Purpose of the Section
5. 3D 60 INSTALLATION 3 3 3 2 1 Verification of Site 3 8 3 2 2 Record Lines Noise acea eter e e wan D Yaw wena vo e Eu un 3 3 3 2 3 Unpacking 3 3 3 2 4 tete teet EP oeque en S date tede md a a ua 3 3 3 2 4 1 Verification of 3 6 3 2 4 1 1 3D 60 Instrument 3 6 3 2 5 at dr d de e oe itv Ee Mg Eg dl 3 7 3 2 6 Instrument Placement 3 9 3 2 7 Instrument UPS iiie e vice i e ide oai de Duta ba ag dvd EE Ld E 3 9 3 2 8 Power sute te ac eine 3 11 3 2 9 Instrument Configuration iiec oni ita ir oci ot oce tt ir o ER 3 11 3 2 10 TTempetatulte 2 cs ace za a oer Eo am tesa sr eta Ltd eee D 3 11 3 2 11 Error Chieck idi ie aie dint utt ie IEEE sete 3 11 3 2 12 Modem Functional Test E be n ee up ies 3 12 3 2 18 Barcode Reader Functional 3 13 3 2 14 UPS Functional Test 3D 60 Only APC UPS 650 3 13 3 2 15 Complete the Installation 3 13 3 3 RESTRAINT INSTALEA TION oa cca baia ts een eria edet na ie enitn ceu KA WAR 3 14 3 3
6. EHE 7 amp cont i i i a i i ii a i pi Fig 8 Step 5 Motor Assembly Fig 9 Fan Assembly adina i a a ai a Fig 10 BacT ALERT 3D 60 System Control Rear View w Comm Ports Figs d 1 CPUIRGBA cazare ma o ii it aia Fig 12 ModSig PCBA Fig 13 Qu d Serial a e i aaa ia ia Fig 14 Thermistor PCBA sait c i c a ai a a i a a ii ii Fig 15 CompactFlash Memory Disk Fig 16 CompactFlash Adapter 22 BEKA KEK Step 5 PCBA Fig 18 BacT 3D 60 Incubator Chamber Fig 19 Rack Assembly ss Fig 20 Operator Display Monitor Fig 21 Barcode Fig 22 Keyboard ss Id 23 ZIP Drive mm Fig 24 Uninterruptible Power Supply UPS Domestic Model Front and Rear Views Fig 25 Uninterruptible Power Supply UPS European Model Front and Rear Views Fig 26 Instrument Configuration Screen Fig 27 Main Screer needles ee i ua Fig 28 Setup Screen w Field Engineer Password Activation Fig 29 Instrument Configuration Screen Fig 30 X Box Selection Checkbox
7. 89 7 6 Instrument Cntrl Software Test Screen Scan 90 7 6 Instrument Cntrl Software Test Screen Misc 91 Diagnostic Test Selection Screen Flag Check 92 Incubator Flag Check Cell Differences 93 Flag Check Cell Calibration 94 System Power Panel and DC Supply ssssscsscsssssssssessssessneesseseeeseseeseseeesseseenenseeseasensnsaeseeneseaeenenseeeeeenenenaneneee 95 Step 5 PCBA at Connector J4 96 ModSig PCBA with 5 VDC Test Points 222 2 1 4 42 2 4 1 2 1211 0 0 KARAR KAK KAK KAR RA 97 DC Power Supply 98 Door Micro Switches and Magnets 99 Top Panel Screw Locations Removal ssssssssesessesssesesseseeeseseeeseeseteseesenseeseseeeseeseseeneneeenensneeeeeeeneenaneeed 100 CPU PCBA w Quad Serial PCBA plugged it sssssssssseseesesssesesseseseseeseseenseeeseseseeeanenseeseeesneneneaseneeeaeeees 101 CPU PCBA Screw Remowval 102 CPU PCBA J27 and J7 Cable Routing 103 Quad Serial PCBA Removed from CPU PCBA 104 CPU PCBA Cable Connections 105 WinSystems CPU C
8. 042 4 117 4 10 11 Inlet Thermistor PCBA P N 32300 1 4 119 4 10 12 Zip Drive P N 895 0004 38 mccain eee ceea e 4 120 4 10 13 System Power aa eee aa eee aa ana 4 124 Service Manual 4 79 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 80 4 10 14 4 10 15 4 10 16 4 10 17 4 10 18 4 10 19 4 10 20 4 10 21 4 10 22 4 10 23 4 10 24 4 10 25 4 10 26 4 10 27 4 10 28 4 10 29 4 10 30 4 10 31 4 10 32 4 10 33 Power Supply Transformer P N 851 0015 01 4 126 Power Supply MOV Metal Oxide Varistor P N 43116 2 4 128 Power Panel Solid State Relays P N 845 0018 01 4 130 DC Power Supply P N 852 0010 01 4 132 Power Entry Module Fuses P N 870 0008 14 17 24 25 4 135 Fari P N 941 0009 07 kiry de Avi basa ZE AWA VD Va cb vo dd 4 138 Heater P N 847 0009 01 4 140 Blower Assembly P N 48411 nn 4 142 Blower Motor Capacitor P N 601 0001 02 4 143 Digital Reference Thermometer P N 848 0004 01 4 148 Rack Assembly P N 43147 921 922 923 4 149 Step 5 Drive Agitation Linkage Assembly P N 48
9. eee eee emana xxvi 0 5 5 Hazardous Voltages e e abg a uev dene Y dde ka uv dnas xxvi 0 5 6 Cleaning Agents e e t et toe at DS i p S at AA d n xxvi 0 5 7 Healtti RISKE y k tota a A SR dp d AR d ctis xxvii 0 5 8 ESD Precautions vies ise the he a en i a he ee ee eco xxvii 0 5 9 MOVING ee RA de rode ds xxvii 0 5 10 Heating Ment eiie Ep ere i e Rad den xxvii Service Manual i TABLE OF CONTENTS BacT ALERT 3D 60 GENERAL INFORMATION san k ka kena ku k kake k kayan aia R a 1 1 Tek INTRODUCTION uiii tuts ker yi sk da beka ker xi aki den beka u otita Sit Sco xi an Sava ees 1 1 1 2 REFERENCE ici y n eicere ka xaneya b oa HEY a RR d ka kan Bey E LV ak h aque Qe AT e kud kk a 1 2 1 3 EQUIPMENT DESCRIPTION nn en nana na unse na ana na anna ea anan en ananenananananan anume anume sananae 1 3 1 4 ASSEMBLY DESGHIPTIONS 5 recuso za doo lao al data lb di oa AA ad acra 1 4 1 4 1 Electrical nene eee aka n a emana nennen nana nea 1 4 1 4 1 1 Power Panel 0 00 1 5 1 4 1 2 Transformer 1 5 1 4 1 3 X 1 5 1 4 1 4 Eloy p Sola al ar ale hea 1 5 1 4 1 5 Step 5 Motor Assembly 41 4600 1 7 1 4 1 6 ED
10. a 23 12 3 12 99 92 8 8 B Ww N 22 x23 76 92 8 12 96 87 8 12 8 12 5 42 Heap left 15469616 Free blocks 1 Largest block size 15469616 ime of last shutdoun Internal 24 84 81 14 52 52 Local 24 84 81 14 52 52 Reset 1 Debug 2 Excep 3 SHX 4 Hoden 5 Rssoc 6 BPTbIs E7 CFG 8 Scan 9 Misc Fig 89 7 6 Instrument Cntrl Software Test Screen Scan Scandisk as its name implies is a function that runs periodically to check the integrity of the C and D drives For the C drive an addition set of checks is made to verify the size of the fixed size files associated with the 3D application This is not done for the D drive The output of this operation is displayed on the screen Below is an example of that output ScanDisk Log Kee Fe e he he e ehe hehe e he ke ee e He He e e e e ke ke e e ke ke e e e e eee eee eee ee DRIVE INFO for C OEMName MSDOS5 0 Bytes Sec 512 Secs Cluster 4 Rsvd Secs 1 Num of FATS 2 Root Ent Cnt 512 TotSec16 0 Media OxF8 FATSz16 245 Secs Trk 32 Num of Heads 8 Hidden Secs 32 TotSec32 250336 DrvTypeNum 128 Reservedi 0 0 BootSig 0x29 4 62 Service Manual BacT ALERT 3D 60 VolID 981014277 Vol Label NO NAME FileSysType FAT16 Computed data FAT Type 16 FAT Size 245 Total Secs 250336 Bytes FATEnt 2 RootDirSector 491 RootDirSectrs 32 DataSector
11. remove the wires from each terminal on the defective relay by removing the screw Write down tape or diagram the wire IDs and colors and what terminals they are installed on As you remove and reinstall the wiring ensure that the terminal ID markings and orientation of the relays new and defective are the same Refer to Figure 150 in previous Subsection 4 10 15 for relay wiring diagram 7 Once all wires are installed on the new relay secure the relay to the chassis by aligning the holes in the relay to the threaded studs Secure the relay with the lock washer on the top stud gt 4 130 Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 16 Service Manual Power Panel Solid State Relays P N 845 00 18 01 Continued 8 Reinstall the Right Side Panel of the instrument 9 Close the Top Panel and install the two 2 screws that secure it Refer to Figure 99 10 Refer to Subsection 4 3 3 and perform the 3D 60 Power Up procedure 11 Refer to Subsection 4 11 and perform the Post Service Validation procedure 12 Annotate the appropriate maintenance and lab logbooks 13 Return the system to normal operation 4 131 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 17 DC Power Supply P N 852 0010 01 NOTE Individual power supply subassembly components are not repaired or replaced in Domestic 3D 60 s Individual components are spared as parts and replaced in
12. 1 18bEF34968868894 FF4 lt CR gt lt LF gt OUT 13EC823265889RFF CR LF IH 13EC2EB2888188888888888881888188888888888888888188818B98846F7 lt CR gt lt LF gt OUT 16E9623265669AFF lt CR gt lt LF gt IH 16E92EB288888888888888888888888488888888888888888888884884BF7 lt CR gt lt LF gt OUT 19E6823265889RFF CR LF 19E62EB2888188888888888888888888888888888888888888868553884fF7 lt CR gt lt LF gt OUT 1CE3823265889RFF CR LF IH 1CE32EB28888888888888888888888888888888888888888888884884BF7 lt CR gt lt LF gt GE6761466BB Fig 77 1 4 Inc Module 1 Message Log Test Screen Service Manual 4 27 4 SERVICING SOFTWARE DIAGNOSTICS BacT ALERT 3D 60 1 5 Inc Module 1 Temperature Log Screen Special equipment Display history or heater temperature sensors and sensor on the racks Impact Bottle testing is not affected by this diagnostic Keyboard functions a Runs continually and adds new temperature readings to end of display as they occur 1 5 Inc Module Log 23 04 01 53 52 ofs 8 35 in 35 73 out 35 97 avg 35 85 51 35 29 52 35 30 ofs 8 56 in 35 74 out 36 88 avg 35 87 s1 35 33 s2 35 36 ofs 8 53 in 35 74 out 35 95 avg 35 84 s1 35 28 52 35 20 ofs 8 68 in 35 73 out 35 97 avg 35 85 23 04 01 51 35 49 s2 35 51 ofs 8 35 23 84 81 in 35 74 out 36 88 avg 35 87 51 35 57 s2 35 54 ofs 8 32 in 35 74 out 36 8
13. See Display Configuration Circuit Breaker RAM Communications Ports 1 8 1 9 CompactFlash Adapter 1 12 2 15 HL IS Kl TON t N N DD DD pate cama sata 2 14 REMOVAl Dr 4 91 CompactFlash Memory Card Installed 4 91 CompactFlash Memory Disk 1 12 1 13 Initialization ter trees Our ls yon Hiseyn na aaa Replacemeni CompactFlash PCBA INDEX 3 INDEX Computer Interface Port 1 20 1 22 4 164 Domestic UPS I e 4 168 International 4 173 Configuration e tee tace ER S 1 27 5 er DUE 1 27 PASS WOT BER ES 1 27 Configuration Screen sse 1 26 Configuration Tables sse 4 60 Connecting Link sse 4 153 Conversion Clip 4 137 See PEM Fuses See PEM Fuses Countertop Mounting sse 3 14 CPU POBA 3 ax n yen n E e ca 1 10 1 11 4 81 Cable Connections nenea enma nenea nenea 4 86 Cable Routing diniya caiac i 4 84 Dia STAM ci i 2 12 Remoya l s amoniac do a a aa at 4 83 Data Backup Restore 4 9 DC Power 1 2 9 4 74 4 75 4 132 Cable Disconnection eerte 4 133
14. Service Manual BacT ALERT 3D 60 TABLE OF CONTENTS Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig 170 Power Supply Panel BHP1 171 Power Supply Panel HBJ1 HBP1 Connector 172 Power Supply Panel Mounting Screw 173 Blower Motor Capacitor Boot and Clamp Removal 174 Reference Thermometer 25 175 Rack Blocks Installed 176 Rack Assembly w Cable Cover Removed 177 Rack Cable Clamp Removed p 178 Rack Cable Disconnection 179 Rack Assembly Captive Screw Removal 180 Step 5 Drive Agitation Linkage Assembly 181 Drive Linkage and Bushings Specs 182 Gas Spring Assembly 183 Gas Spring Assembly Remov
15. 10 Refer to Subsection 4 3 3 and perform the 3D 60 Power Up procedure Do Steps 11 15 below only if the CompactFlash Memory Card is defective and requires replacement 11 Insert the BTASD Installation and Utilities Disk into the Zip drive 12 Initialize the new CompactFlash Memory Disk by typing D INITBTL at the gt prompt 13 Refer to Subsection 4 5 2 and restore the 3D 60 backup data according to the Data Restore Procedure 14 Remove the Zip disk that s in the Zip drive and return it to its storage location 15 Reboot the system by recycling the system power 16 Refer to Subsection 4 11 and perform the Post Service Validation procedure 17 Annotate appropriate maintenance and logbooks 18 Return the system to normal operation Service Manual 4 93 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 5 Software Installation and CompactFlash Memory Card Replacement Use the following steps to replace the BacT ALERT 3D 60 software in situations where memory and backup are current known to be good and you are updating the CompactFlash Memory Disk Omit the steps marked with an asterisk if the CompactFlash Memory Card is known to be defective or if the data is known to be corrupt 10 11 13 Note the contents of the bottle table from the Main Screen Note the version of software shown in the instrument pictorial on the Main Screen Perform a backup Refer to Secti
16. Accessory Surge Receptacle Test Switch amara Fig 25 Uninterruptible Power Supply UPS European Model Front and Rear Views 1 22 Service Manual 1 GENERAL INFORMATION BacT ALERT 3D 60 1 4 5 Uninterruptible Power Supply UPS Continued The European UPS model is very similar to the US domestic model The voltage rating power cord and fuse ratings however are for the European power conversions Refer to Figure 25 for International European UPS components Service Manual 1 23 1 GENERAL INFORMATION BacT ALERT 3D 60 1 5 OPERATOR DISPLAY CONFIGURATION SCREENS Fig 26 Instrument Configuration Screen 1 24 Service Manual 1 GENERAL INFORMATION BacT ALERT 3D 60 1 5 OPERATOR DISPLAY CONFIGURATION SCREENS CONTINUED The BacT ALERT 3D 60 s Operator s Manual describes most of the screens displayed on the display monitor Specifically it describes the screens used to load unload bottles set the date and time enable disable cells calibrate incubation temperature perform single cell calibration set maximum test times set audible alarm options and change passwords For detailed information on these screens refer to the BacT ALERT 3D 60 Operator s Manual 1 5 1 Instrument Configuration Screen This screen is primarily used when an instrument is being installed It allows the field service engineer to enter information regarding rack installation Refer to Figure 26 1 5 1 1 Access
17. sese 1 20 1 22 V ATIS TOPi enc ERR DENN dt 2 9 Verification of Contents eese 3 6 eese See 5 phase Stepper Motor Voltage serene 4 75 WARNING tee xxv See Typography ee 2 13 2 15 2 17 WinSystems Computer essere 1 11 WinSystems CPU Connector Locations 4 87 Wiring Connections ru 4 138 X Box Button i4 e ree tes 1 27 Zip DIVE eere 1 16 1 17 Mounting Sled eee 4 122 Removal onere p eter 4 120 Zap Drive Test eget eed 4 35 D 7 INDEX BacT ALERT 3D 60 Service Manual BacT ALERT 3D 60 NOTES NOTES Cover Sheet Service Manual NOTES BacT ALERT 3D 60 Service Manual BacT ALERT 3D 60 NOTES NOTES Service Manual NOTES 1 NOTES BacT ALERT 3D 60 NOTES NOTES 2 Service Manual
18. M aa 1 7 1 4 1 7 Quick Reference 1 7 1 4 2 Communications Ports Input 1 8 1 4 2 1 COMM ss 1 9 1 4 2 2 Printer Port eoe lad tee en ete Ene 1 9 1 4 2 3 Internal Speaker w external Speaker 1 9 1 4 2 4 Power Entry Module PEM ON OFF Switch 1 9 1 4 2 5 Modem 1 9 1 4 2 6 do 1 9 1 4 2 7 Monitor d 1 9 1 4 2 8 UPS POM DD nm nnnBnp mma 1 9 1 4 2 9 UPS Serial heel eed RR E An k d 1 9 1 4 2 10 MOUSE urere 1 9 1 4 2 11 Keyboard 1 9 1 4 2 12 Barcode Scanner 1 9 1 4 3 Electronic Components aseaza rrr ee ete 1 10 1 4 3 1 CPU PCBA winter eae es 1 11 1 4 3 2 ModSig POBA i nece ou petet M K A tisa cols 1 11 1 4 8 3 Quad Serial PGBA eee dde e dur ex een 1 11 1 4 3 4 Thermistor PCBA Input Output eem 1 11 1 4 3 5 CompactFlash Memory Disk 0 1 13 1 4 3 6 CompactFlash Adapter 1 13 1 4 8 7 Step S POBA ioo rd p gets 1 13 1 4 3 8 Incubator Chamber 1 15 TASET S Hac
19. Connect the mouse cable into the Mouse port on the Communication panel Table 3 2 3 Setup and Connections 3 9 3 INSTALLATION PROCEDURES BacT ALERT 3D 60 Installation and Set up Diagram Port and Power Connections PRINTER 10 mic OUS ODEM ERIAL UPS KEYBRD rome de 2 EXTSPKR A Surge outlets with Battery Telephone Line Jack 3D 60 Communications Panel See detailed view Surge outlets without Battery Backup Fig 51 Installation and Setup Diagram 3 10 Service Manual BacT ALERT 3D 60 3 INSTALLATION PROCEDURES 3 2 8 Power Up Press the top of the UPS toggle power switch to ON Power up the display monitor Power on the 3D 60 instrument by turning on the Main Power switch on the rear of the instrument Refer to Figure 51 for Main Power switch and PEM location on the rear of the unit Power up the modem and printer 3 2 9 Instrument Configuration 1 Verify that the screen title Select is correctly displayed 2 Set up and verify maximum test times Refer to BacT 3D Operator s Manual 3 Ensure that the lab supervisor is able to log onto the system with the password 1 2 3 4 Refer to BacT 3D 60 Operator s Manual for entering password default 4 Set the displayed date time to reflect the current date and time in the lab Refer to BacT 3D Operator s Manual NOTE The microprocessor BIOS clock is set to and must remain at the Universal Coordinated Time UTC f
20. Spills Any blood or test specimen spills within the unit need to be removed immediately Procedures outlining disinfection for spills are in the BacT 3D Operators Manual Instrument Shipping Should the instrument require shipment to another location perform the following procedure REQUIRED EQUIPMENT Gloves Cleaner Brush 5 25 Bleach Mask Decontamination Certificate 700PPM free chlorine solution 13 ML of 5 25 bleach in 1 liter of tap water Table C 1 2 Disinfection Equipment e Remove and discard approved biohazard receptacle all tubing and trays Remove crusted materials blood reagents etc using a 700 PPM free chlorine solution 13 ml of 5 25 bleach to 1 liter of tap water and brush e Dried and caked blood should be removed with a mild detergent and or diluted bleach solution before disinfection C 1 APPENDIX C DISINFECTION PROCEDURES BacT ALERT 3D 60 C1 2 Instrument Shipping Continued e Using disinfectant of 700 PPM free chlorine solution 13 ml of 5 25 bleach added to 1 liter of tap water wipe down the exterior of the instrument Pay particular attention to areas that are frequently touched e Place instrument in sealed plastic bag before packaging NOTE Solutions of sodium hypochlorite household bleach are the recommended concentrations and have demonstrated to have broad spectrum germicidal properties Fresh dilutions should be used to prevent the loss of germicidal actions that o
21. Table 2 5 1 Power Supply Data 2 10 Service Manual BacT ALERT 3D 60 2 BACKGROUND INFORMATION 2 5 DC POWER SUPPLY CONTINUED The BacT ALERT 3D 60 s power supply is a quad output switcher intended for small to medium sized digital systems These power supplies also contain built in over voltage protection and a power fail detect signal Universal input voltage allows these supplies to be powered in any country of the world without changing any jumpers or individual switch settings The unit is capable of supplying the high peak currents necessary to start disk drives and peripheral devices An integral filter reduces line conducted noise below FCC and VDE limit B The over voltage protection circuits are designed to activate at 6 25 VDC 0 75 VDC for 5 VDC output The power supply has a Power Fail Detection circuit that produces a power fail detection PFD output The PFD signal occurs within milliseconds following an abnormal AC line condition The delay between the abnormal AC line condition and the PFD output varies depending on AC line variation and power supply load If this condition is met the PFD signal will go to a low state within approximately 3ms Once the output returns to the 4 75 VDC the PFD signal will return to a high state in 50ms to 200ms Refer to Table 2 5 1 on the previous page for Power Supply data and output pin locations Service Manual 2 11 2 BACKGROUND INFORM ATION BacT ALERT 3D
22. View is looking down on the work surface in this illustration Positive Battery Terminal with Red cable connected Plug Negative Black cable lt lead into the Ground Terminal RAUS na Fig 204 Connecting UPS Battery Cable to Terminal 5 With the UPS case on its side with battery cover open slide the battery out on its side as shown in Figure 204 above 6 The black positive Red cable lead should already be connected to the battery s positive terminal Refer to Figure 204 Figure 205 shows the negative Black cable connected to the ground terminal 7 Connect the black negative wire to the battery s negative terminal Refer to Figure 204 Fig 205 International UPS with Battery Cables Connected Service Manual 4 171 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 33 APC UPS International Model P N 957 0060 03 Continued Install two 2 Screws Fig 206 International UPS with Battery Cover Secured 8 Secure the battery cover with two 2 screws and place the UPS in its permanent location Refer to Figure 206 Connect 3D 60 Instrument and the Display Monitor to one of the UPS Surge amp Battery Backup Outlets EIE ieee ai 1 EN Fig 207 International UPS Peripheral Connections 9 Connect the 3D 60 Instrument s power cord into one of the Surge and Battery Backup Outlets Refer to Figure 207 1
23. u eee 1 14 1 15 Incubator Configuration uE erer 1 27 Inlet ThermiStOT u rere reke ereke eke 4 119 Inline Surge Protection 2 9 Input POWEL eter tee re 2 9 Input Surge Current sse 2 10 Input Thermistor sees 1 11 Input Voltage Input Output Ports See Communications Ports Installation ilo SN DD ND ng n 4 142 Blower Motor 4 143 deno EROR eee 3 18 a s 3 10 Requirements a eS 3 3 Installation Procedures eese 3 1 Instrument Configuration Screen 1 24 Instrument Controller CPU eee 2 3 Instrument Fault and Status Codee 1 30 Instrument Fault Codes esee 1 31 Instrument Parts List eese 3 6 interlock switches n 2 3 Interlock oya sa otet ode toe 2 25 International Fax Modem See Fax Modem Isolation Transformer eese 2 9 Italicized Text se REESE xxii Keyboard ettet 1 16 1 17 4 160 Keyboard Port ree eere 1 8 EED Check eter tte tte 4 33 LEDs D55 56 neat SER 4 12 Line eerte ena 3 3 Linkage Assembly 4 154 LIS POPE xway kak n Kek sime ate ea 1 8 Load Unload Bottles See Display Configuration
24. Mouse Port Parallel Printer Port UPS Control VGA Monitor 5V CompactFlash Zip Drive Remote Speaker Serial UPS LIS Modem 2 5 2 BACKGROUND INFORM ATION BacT ALERT 3D 60 2 3 THERMISTOR PCBA INPUT OUTPUT Fig 35 Thermistor PCBA 2 6 Service Manual BacT ALERT 3D 60 2 BACKGROUND INFORMATION 2 3 THERMISTOR PCBA INPUT OUTPUT CONTINUED The Thermistor board uses an Analog device AD592BN temperature transducer ib produce current flow proportional to temperature The voltage source is 9VDC The temperature transducer has a nominal flow of 298 2 25 C There are two Thermistors PCBAs in the 3D 60 instrument The Input and Output Thermistors measure input and output air temperature respectively The Input and Output temperature readings are averaged together to comprise the Incubation Chamber s temperature used by the temperature control logic Service Manual 2 7 2 BACKGROUND INFORM ATION BacT ALERT 3D 60 2 4 3D 60 POWER SUPPLY ASSEMBLY Power Distribution Block Diagram Facility Power UPS pm Isolation is Transformer S Common Logic Ground Return 3 gt DC Power B Supply 12 VDC Power Entry Module Heater Relays Blower Relays Power Enable ModSig PCBA Power Panel Agitation Motor Fig 36 Power Distribution Block Diagram 2 8 Service Manual BacT ALERT 3D 60 2 BACKGROUND INFORMATION 2 4 3D 60 POWER SUPPLY
25. XXV SAFETY SUMMARY BacT ALERT 3D 60 0 5 0 5 3 0 5 4 0 5 5 0 5 6 xxvi SAFETY SUMMARY CONTINUED Electrical Grounding An electrical ground is required and must be in place for this instrument Before installing the instrument ensure that a grounded wall receptacle is available for each unit It must be plugged into a mating grounding type wall receptacle in accordance with National Electrical Codes US Domestic and or applicable local codes and ordinances domestic or international for this type of installation Reference Figure 2 below WARNING UNDER NO CIRCUMSTANCES IS THE GROUND PRONG TO BE REMOVED IF THE GROUND PRONG THE PLUG OR THE CORD HAVE ANY PHYSICAL DAMAGE THE CORD IS TO BE REPLACED IT IS EXTREMELY HAZARDOUS TO OPERATE THIS OR ANY INSTRUMENT WITH A MISSING GROUND PRONG OR A FAULTY CABLE IN PLACE 7 Fig 2 USA 115 VAC Standard Fig 3 European 230 VAC Standard Fuse Replacement Warning There are no user serviceable fuses in the BacT ALERT 3D 60 Only trained and qualified service technicians are to replace any fuse within the instrument The only exception to fuse installation will be during the initial installation of the unit At the time of installation the customer does install PEM fuses according to steps outlined in the nstallation section of the BacT ALERT 3D 60 Operator s Manual Hazardous Voltages DC voltages used within the instrument are low voltage and low cur
26. Blower For the incubation process the blower circulates heat produced by the heater throughout the 3D 60 instrument Refer to Figure 7 1 GENERAL INFORMATION BacT ALERT 3D 60 1 4 1 Electrical Components Continued Fig 8 Step 5 Motor Assembly Fig 9 Fan Assembly 1 6 Service Manual 1 GENERAL INFORMATION BacT ALERT 3D 60 1 4 1 Electrical Components Continued 1 4 1 5 Step 5 Motor Assembly This Step 5 Motor Figure 8 provides agitation to the racks unless the incubation chamber has been converted to MB and the motor has been disconnected to bypass this process Refer to Subsection 4 4 2 Figures 59 60 and 61 for MB Conversion 1 4 1 6 Fan A fan circulates air over the electronic components within the Electronics Compartment to help prevent overheating This fan may also be called the E Fan Refer to Figure 9 1 4 1 7 Quick Reference Card This card identifies specific error codes and outlines instructions regarding system operation Refer to Section 1 6 Figure 31 Front Side and Figure 32 Rear Side Service Manual 1 7 1 GENERAL INFORMATION BacT ALERT 3D 60 1 4 2 Communications Ports Input Output 1 BARCODE KEYBRO RES Ses qm C mem qii Fig 10 BacT ALERT 3D 60 System Control Rear View w Comm Ports 1 8 Service Manual 1 GENERAL INFORMATION BacT ALERT 3D 60 1 4 2 1 4 2 1 1 4 2 2 1 4 2 3 1 4 2 4 1 4 2 5 1 4 2 6 1 4 2 7 1 4 2 8 1 4 2 9
27. Reference dot Conversion Clip S XL 24 j WS j 4 1 fic IN mj Aie pi hi Y I m ee J eee j Iur UJ 1 ini 4 Lie ay 5 0A 250V 1 6 3A 250V time delay Fuse A 1 time delay QE B Wi 2 required Fig 49 PEM w 115 VAC Version Fig 50 PEM w 230 VAC Version Service Manual BacT ALERT 3D 60 3 INSTALLATION PROCEDURES 3 2 6 3 2 7 Setup Steps Service Manual Instrument Placement Assemble and install the 3D 60 Instrument in the specified installation location NOTE If countertop or other permanent bolted installation is required see Section 3 3 Restraint Installation Instrument UPS Place the UPS near the 3D 60 Instrument Connect the UPS 9 pin control cable from the Accessory Kit to the 9pin connector on the rear of the UPS labeled Computer Interface Port Connect the other end of the cable to the port connector labeled UPS Not Serial UPS on the 3D 60 s rear bulkhead Note Discard the cable 9pin cable that comes shipped with the UPS DO NOT USE See Figure 51 for bulkhead connections Connect the barcode scanner mouse monitor modem and keyboard to the instrument before powering up Refer to Table 3 2 3 below and Figure 51 Installation and Setup Diagram Setup Steps shown in Table 3 2 3 below correspond to the numbered setup steps listed in Figure 51 Instructions Connect the 9 pin UPS cable into the UPS por
28. The remote user is able to download and upload information including seeing what is on the display screen that the local operator views The Technical Support Center is able to perform remote diagnostics and other troubleshooting of the instrument The modem interfaces the 3D 60 instrument through a connection to the Modem port on the rear of the unit Digital signals are converted to tones by the modem for sending to the telephone system through the telephone jack connection and to a remote modem at on the receiving end Conversely tones from the remote modem are converted to digital signals and sent to the instrument through the Modem port Power for the modem is supplied by a wall mounted power supply that supplies low voltage required by the modem The wall mounted power supply plugs directly into a standard electrical outlet 56K Fax Modem International The international fax modem differs slightly from the domestic version by having CE markings and is shipped with a 220V AC adapter It also has two additional DIPswitch settings 9 amp 10 ee Subsection 3 2 12 Figure 53 for instructions on International Fax Modem DIP switch settings The fax modem serves as an interface to the BacT 3D 60 instrument for remote access The remote user is able to download and upload information including seeing what is on the display screen that the local operator views The Technical Support Center is able to perform remote diagnostics and other tr
29. This screen groups the cells by the amount Delta that their flag reading differs from its expected reading i e the flag value when the cell was calibrated A given cell may appear in multiple groups For example a cell whose difference is 1 596 will appear in the 1 0 and 1 5 groups Groupings are shown for percentages of 0 5 1 0 1 5 and so on up to 10 No data is displayed for cells that are loaded since a flag reading cannot be taken on those cells No data is displayed for cells in racks or drawers that are uninstalled Note that keyboard input is accepted at this point Pressing the C key brings up the Calibration screen as shown below In this manner a cell can be calibrated without leaving the diagnostic screen When the Exit X button is pressed on the calibration screen operation returns to the Flag Check diagnostic screen Pressing 2 key causes detailed data to be displayed This data shows the current flag reading the expected flag reading and the difference and percentage difference for each cell If a cell is loaded the word LOAD is shown on the current reading line Pressing the 1 key returns to the diff display or the C can be pressed to bring up the Calibration Screen Difference Z 1 8 1B15 Difference 2 gt 2 8 19024 1 17 lt 3 17 13146 2 1822 1 07 1A23 TET 1841 1 02 1845 1 17 1R48C 1 a ele whose 1854 1 2
30. UNLOAD 6281 j 1031 Status Reading Poly lt lt UNLOAD 2173 used to normalize the reading 1032 Status Reading Poly BCUNLOAD 2164 1033 Status Reading Poly lt UNLOAD gt 6652 1034 Status Reading Poly lt UNLOAD gt 6841 2626 The following reading values rii esa indicate a fault condition and you a 523 2126 A Tez ONUS ea Le GL NUNG MUN Tia ae e de da bu la amp amp will see a 51 57 fault reported on the operator screen 20000 polynomial 0 used but FE ZEN not initialized 21000 polynomial 1 used but not initialized 22000 polynomial 2 used but not initialized 23000 polynomial 3 used but not initialized 30000 or 30000 normalized reading too large 1040 Status Reading Poly 8XUNLORD ee Status Reading Poly 6 UNLOAD Fig 79 1 6 Inc Module 1 Reading Log Test Screen Service Manual 4 29 4 SERVICING SOFTWARE DIAGNOSTICS BacT ALERT 3D 60 1 7 Inc Module 1 Flag Check Screen Description This diagnostic gathers calibration information for all the cells in an incubation module Specifically the current flag reading and the flag reading at calibration time are obtained The percentage difference Delta between the current and calibrated readings is calculated and displayed Impact Bottle testing is not affected by this diagnostic Test Procedure a Enter this diagno
31. or UPS International or UPS Japan UPS Comm Cable Discard the cable shipped with the UPS DO NOT USE CRT Monitor Optional or Flat Panel Monitor Optional Speaker Set For 110V BacT 3D 60 Optional or Speaker Set For 220V BacT 3D 60 Optional Fax Modem Domestic Optional or Fax Modem International Optional Madam Cahla Ontinnal Table 3 2 1 3D 60 Instrument Parts 3 6 Service Manual BacT ALERT 3D 60 3 INSTALLATION PROCEDURES 3 2 BACT ALERT 3D 60 INSTALLATION PROCEDURES CONTINUED 3 2 5 Set AC Power Perform the Power Entry Module PEM fuse replacement procedure to set proper voltage settings Refer to steps 1 8 below After setting proper voltage and installing proper fuse s discard the remaining fuse s NOTE The Power Entry Module 805 0017 02 is located in the rear and lower left corner of the instrument See Figure 51 Installation and Setup Diagram When configured for 115VAC the PEM has one 6 3 Amp 250V timed fuse 870 0008 25 In addition a conversion clip is located across the neutral line in the fuse holder Refer to Figure 49 When configured for 230 each has two 5 0 Amp 250V timed fuses 870 0008 24 Refer to Figure 50 CAUTION This instrument comes configured for 240V operation For other voltage settings replace fuse s as instructed in this section and according to Table 3 2 2 Facility Power Rating and Conversion C
32. secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs Bottle Types 0x6000 0x6000 0x2000 0x2000 0x2000 0x2000 0x2000 0x2000 0x4000 0x6000 0x2000 0x2000 0x2000 0x2000 Type Type Type Type KI coco Tracking Display Display Display Display Display Display Display Display Display Display Display Display Display 4 SERVICING SOFTWARE DIAGNOSTICS Q46 46 47 47 048 48 049 49 BTA I AST 50 BTA I NST 51 BTA I LYM 52 Q53 53 Q54 54 Q55 55 Q56 56 Q57 57 Q58 58 Q59 59 Q60 60 Q61 61 Q62 62 063 63 Q64 64 Q65 65 Q66 66 Q67 67 Q68 68 Q69 69 Q70 70 Q71 71 Q72 72 Q73 73 Q74 74 Q75 75 Q76 76 Q77 77 Q78 78 Q79 79 080 80 Q81 81
33. 16 2 ZPPC 5 15 29 2 ZPDC 5 15 28 2 ZEMB 5 15 25 2 ZSTR 5 15 24 2 ZINH 5 15 22 2 ZRIF 5 15 21 2 ZPZA 5 15 20 2 ZBMB 5 8 18 2 ZBMP 5 8 17 2 ZBPF 5 8 15 2 ZBFN 5 8 14 2 ZBFA 5 8 13 2 ZBSN 5 15 12 2 ZBSA 5 8 11 2 ZPC 5 15 27 2 ZDC 5 15 26 2 ZGD 5 15 19 2 ZMB 5 15 9 1 Prefix Min Max BottleType Container Type ZMS 5 15 8 1 ZPN 5 15 7 1 ZPA 5 15 6 1 ZFN 5 15 5 1 ZFA 5 15 4 1 Q0 8 8 29 2 QA 8 8 28 2 ec 8 8 27 2 QD 8 8 26 2 QE 8 8 25 2 85 8 8 24 2 Qr 8 8 22 2 Q2 8 8 23 2 QR 8 8 21 2 QP 8 8 20 2 8 8 18 2 8 8 17 2 11 8 8 16 2 8 8 15 2 16 8 8 14 2 Prefix Min BottleType Container Type 8 8 13 2 8 8 12 2 8 8 11 2 SB 8 8 18 3 5 8 8 17 3 SL 8 8 16 3 SP 8 8 15 3 SG 8 8 14 3 SF 8 8 13 3 SN 8 8 12 3 SA 8 8 11 3 MB 0 0 8 1 MS 10 10 8 1 PN 10 10 7 1 PE 10 10 6 1 FN 10 10 5 1 FA 10 10 4 1 ZN 5 15 3 1 Service Manual 4 49 4 SERVICING SOFTWARE DIAGNOSTICS 4 50 2 5 8 2 1 IA 8 8 50 2 Prefix Min Max BottleType Container Type IN 8 8 51 2 IL 8 8 52 2 9 0 0 0 0 8 0 0 0 0 7 0 0 0 0 6 0 0 0 0 5 0 0 0 0 4 0 0 0 0 3 0 0 0 0 2 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 U 0 0 1
34. 3D 60 1 4 3 1 4 3 8 1 4 3 8 1 1 4 3 8 2 1 4 3 8 3 1 4 3 8 4 Service Manual Electronic Components Continued Incubator Chamber Components The Incubation Chamber Reference Figure 18 contains three specimen racks relays power supply ModSig PCBA rack controller PCBAs heater and blower As viewed by the operator the bottles are loaded into the front of the 3D 60 instrument Rack Each rack contains 20 bottle cells Unless the instrument is designated as an MB unit the racks are continuously rocked to provide agitation for the specimen bottles Also three fascia plates identify the bottle locations and are not interchangeable between replacement racks Refer to Figure 19 Cell There are 60 cells per instrument with cells identified as 1 through 20 in the first top rack 21 through 40 in the middle rack and 41 through 60 in the bottom rack Cell Flag The cell flag serves as a clip securing the bottles into their cells The cell flag is also a key component in bottle detection and cell diagnostics Cell Indicator Lamp A lamp is located next to each cell and provides feedback to the operator Depending on the function selected by the operator illuminated lamps identify the positions of positive or negative bottles cells that can be loaded and so on A flashing indicator lamp indicates an operator error 1 GENERAL INFORMATION BacT ALERT 3D 60 1 4 4 Input Output Devices Fig 20 Operator
35. CHAPTER 2 BACKGROUND INFORMATION BacT ALERT 3D 60 THIS PAGE INTENTIONALLY LEFT BLANK Service Manual BacT ALERT 3D 60 2 BACKGROUND INFORMATION 2 BACKGROUND INFORMATION 2 1 INTRODUCTION The following is a comprehensive list of items outlined in this chapter Included are the system PCBAs and the function of each as well as the Incubation Chamber and Power Supply 2 BACKGROUND INFORMATION 2 1 2 1 INTHODUGTION inti Liyan ito patte meia eroe esp Cat e 2 1 2 2 SYSTEM CONTROL MODSIG 2424 2 2 2 9 1 2 2 23 THERMISTOR PCBA 1 144 0 1 00 2 6 24 3D 60 POWER SUPPLY ASSEMBLY ertt dte sede 2 8 25 DO POWER SUPPLY titi oce 2 10 26 CPU POBA 2 12 2 7 COMPACTFLASH ADAPTER 4 4 2 4444 1 1 nnne tnnt nnns 2 14 2 8 QUAD SERIAL INTERFACE PCBA eren nennen nnn 2 16 2 9 RACK CONTROLLER PCBA nsira e hee m bestie me divae it d 2 18 2 10 STEP 5 ec 2 24 Service Manual 2 1 2 BACKGROUND INFORM ATION BacT ALERT 3D 60 2 2 SYSTEM CONTROL MODSIG PCBA 2 2580585 no a Ca ei HETI El as jr FE lys WE ee d 5b ues GI ap gt LE r d 20 i ati S mgl s a A i Re m UL ND T LIEST Fig 33 ModSig PCBA Di
36. Mounting Screws eee 4 134 Diagnostics Setup Screen Buttons esse 4 15 SOMWALE secte teh RR EI EHE a EU eee euet 4 15 Diagnostics and Troubleshooting 4 13 Barcode Scanner ee eee 4 161 Keyboard ees 4 160 Digital Reference Thermometer 4 148 DIP Switch Settings Domestic 56K Fax 4 162 International 56K Fax 4 163 Disabled Cell Check See Preventive Maintenance Display Configuration serre 1 25 Display Monitor eee 1 16 1 17 DMA Channels ee eet W Re K 2 13 Domestic Fax See Fax Modem Door een SERERE 4 77 Micro Switch Check and Adjustments 4 77 Door Switch LE DS 4 159 Door Switches 2 25 See Magnetic Door Switches DRAM Controller eese 2 13 Drive Linkage Assembly sse 4 154 E ania etre eite et EDO Re derek aa EEPROM ta eere t Electrical Ground Electrical Power Electronics Compartment see 1 11 BacT ALERT 3D 60 Enable Disable Cells See Display Configuration Environmental Characteristics See Operating Reference Data PEPROM geaca e
37. Q82 82 083 83 084 84 Q85 85 Q86 86 Q87 87 088 88 089 89 Q90 90 Q91 91 Q92 92 Q93 93 Q94 94 Q95 95 Q96 96 Q97 97 Q98 98 Q99 99 Data GENERIC UNKNOWN AEROBIC ANAEROBIC FAN AEROBIC FAN ANAEROBIC PEDI BACT LYM BACT MB BACT MB BACT BLOOD BACT ALERT SA BACT ALERT SN BACT ALERT FA 4 57 4 SERVICING SOFTWARE DIAGNOSTICS 4 58 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 LES Glass LES Plastic LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass 0x2000 0x2001 0x2000 0x4000 0x6000 0x4000 0x4000 0x4000 0x4000 0x4000 0x4000 0x40
38. Refer to Figure 178 Service Manual 4 151 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 24 4 152 Rack Assembly P N 43147 921 922 923 Continued 15 16 17 18 19 20 21 22 23 24 Secure the cable assembly in the Cable Clamp Replace the Rack Cable Cover and secure it with two 2 mounting screws Close the door of the instrument Close the System Top Panel and secure it with two 2 screws Refer to Figure 99 Refer to Subsection 4 3 3 and perform the 3D 60 Power Up procedure Enable the Rack Refer to the 3D 60 Operator s Manual Enabling and Disabling Racks and Cells Recalibrate the Rack according to Rack Calibration instructions in the Operator s Manual Refer to Subsection 4 11 and perform the Post Service Validation procedure Annotate the appropriate maintenance and lab logbooks Return the system to normal operation Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 25 Step 5 Drive Agitation Linkage Assembly P N 48418 1 1 Refer to Subsection 4 3 2 and perform the 3D 60 Power Down procedure 2 Remove the two 2 screws securing the Top Panel and secure it into the Up position Refer to Figure 99 for screw removal locations 3 Remove 3D 60 Instrument s Left Side Panel and set the panel aside Motor Offset Round Top Bushing and Screw i Drive Motor i Linkage Assen biy wy Connect
39. Sensor readings should be within 3 of the set point value 7 Press Esc twice to exit the utility program 8 At the D gt prompt type C and press the Enter key 9 Type xbta3d and press the lt Enter gt key 10 Once the 3D program starts running wait approximately 15 minutes and verify that there are no errors reported by the 3D 60 Instrument s Main Screen Service Manual 4 175 4 SERVICING POST SERVICE VALIDATION BacT ALERT 3D 60 THIS PAGE INTENTIONALLY LEFT BLANK 4 176 Service Manual BacT ALERT 3D 60 APPENDICES APPENDICES Service Manual APPENDICES BacT ALERT 3D 60 Service Manual BacT ALERT 3D 60 APPENDIX A GLOSSARY APPENDIX A GLOSSARY 0 Glossary Listing in Alphabetic Order A D CONVERTER A device that transforms analog electrical signals to a digital format ACCESSION A sample collected from a patient during a single event ACCESSION ID Synonym for Accession Number ACCESSION A number that uniquely identifies the sample or patient specimen NUMBER AGITATION The rocking motion of the racks within the Incubation Chamber Required process in order to produce the growth of Microbes AGITATION MOTOR The device within the Incubation Chamber that produces agitation Step 5 ANONYMOUS A bottle that has been placed in an Incubation Chamber without going through the formal BOTTLE bottle loading process Bottles loaded anonymously must eventually be identified and assigned a
40. Web Strapping Continued vei 25 erey n SS Ay r 4 D Li 2 A beter Fig 46 3D 60 Instrument Repack Web Strapping Diagrams Service Manual 3 5 3 INSTALLATION PROCEDURES BacT ALERT 3D 60 3 2 BACT ALERT 3D 60 INSTALLATION PROCEDURES CONTINUED 3 2 4 1 Verification of Contents After unpacking the unit and parts inspect contents of the BacT ALERT 3D 60 for shipping damage Refer to Table 3 2 1 below for parts content listing 3 2 4 1 1 3D 60 Instrument Parts These parts are shipped separately or with the unit These part numbers and spares may be found in Appendix B 3D 60 Parts Listing of this manual Recommend tools for parts installation are Small flat plane blade screwdriver Phillips screwdriver e e e e e e e e e e e e e e e e e e e e BacT 3D 60 Instrument Parts 3D 60 Instrument BacT ALERT 3D 60 Operator Manual CD Multi language 2 ea 5 amp fuse 1 ea 6 3 amp fuse 2 ea ZIP Disk Decontamination Procedure Decontamination Certificate Anonymous BTL Labeling Set WARNING Rack Bottle Carrier BTA Mouse and Mouse Pad Barcode Scanner and Manual Barcode Scanner Stand Keyboard UPS Serial Cable System Power Cord Domestic System Power Cord International Parallel Printer Parallel Printer cable Printer Cordset International Euro 220V and UK 240V only V4 X20X5 screw V4 flat washer UPS Domestic
41. between the ModSig PCBA and the Step 5 PCBA and the 5VDC power This removes false agitation Stepper Motor errors in the software Refer to Figure 59 5 Remove the screw shown in Figure 60 Hole 1 6 Insert the screw that was removed in Step 5 above and insert it into Hole 2 Refer to Figure 61 to disable the rocking agitation of the rack assembly You may have to shift the racks slightly forward or backward to align the screw with the screw hole in the linkage Refer to Figure 61 Note Clip J1 and J4 connectors to one J1 Connector Disconnect from Step 5 PCBA wire of the five Step 5 Motor wires connected to J3 as shown below Fasten to one of the Step 5 Motor wires J4 Connector Disconnect from Step 5 PCBA Fasten to one of the Step 5 Motor wires Step 5 Motor wires connected to J3 connector Fig 59 Step 5 Motor PCBA Power Disconnect Service Manual 4 5 4 SERVICING BacT ALERT 3D 60 4 4 MB CONVERSION PROCEDURE CONTINUED Move Agitation Arm to lowest position as shown here to install the Lock Screw in Hole 2 for MB Conversion MB Conversion Lock Screw Hole 2 MB Conversion Installation Location Remove the screw from this location and install into Hole 2 Fig 60 MB Conversion Lock Screw Removal 4 6 Service Manual BacT ALERT 3D 60 4 SERVICING 4 4 MB CONVERSION PROCEDURE CONTINUED Ensure Agitation Arm is at
42. ili kan klein eee 59 Step 5 Motor PCBA Power Disconnect 60 MB Conversion Lock Screw Removal 61 MB Conversion Lock Screw Installation 42 44 4 2 2 2 2 22 1 2412417 0 4 01 01 1 2 2 2 0 AA AA ARK AA AA ARK 62 Backup Management Button ssssssscssessessessesessesesssseeseenseeseeeenseeseseeneseseeesnsseseaeenensasaeseeseaeaneneneseaeeneneneaeaneeee 63 Cancel Button 64 ModSig PCBA LED 55 and 56 location 65 Scanner Default Settings Barcode 66 Diagnostics Setup Screen 67 Diagnostic Test Selection Setup Screen 68 1 7 Inc Module Flag Check sss 69 1 5 Inc Module 1 Temperature Log Find Text String Service Manual BacT ALERT 3D 60 TABLE OF CONTENTS Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig 70 1 5 Inc Module 1 Temperature Log Text String Output eee 1 2 22 2411244
43. oco ec eie o e ti dalan 4 16 4 8 8 Special Equipment aa aA Pa a a 4 16 4 8 4 Accessing the Diagnostics Screens 4 17 4 8 5 Diagnostic Screens 4 18 4 9 ALIGNMENTS AND 4 69 4 9 1 OVEIVIOW tn 4 69 4 9 2 System Power SUpply x hy ett tie arb rubei te 4 69 4 9 3 iene nai PD a a a ieee 4 69 4 9 4 enc 4 69 4 9 5 Rack Single Cell Calibration eem 4 69 4 9 6 System Power Supply Check and Adjustments 4 74 4 9 7 Door Micro Switch 1 amp 2 KA KK KA KA KK A KA 4 77 4 10 REMOVE AND REPLACE PROCEDURES c neon eere e nennen entente 4 79 4 10 1 enie EE 4 79 4 10 2 CPU PCBA Assembly P N 750 0070 01 4 81 4 10 3 Quad Serial Interface PCBA P N 750 0066 01 4 89 4 10 4 CompactFlash Adapter PCBA P N 957 0004 356 4 91 4 10 5 Software Installation and CompactFlash Memory Card Replacement 4 94 4 10 6 ModSig PCBA P N 48300 1 Order Spare P N 48300 901 4 95 4 10 7 ModSig PCBA Fuses P
44. wires onto the terminal TB1 4B Refer to Figure 150 9 Ensure all four 4 of transformer wires are reconnected to the PEM from left to right looking from the rear of the instrument Refer to Figure 150 Brown Orange Red and Yellow 10 Reverse the steps in the previous section to install the Power Panel Assembly back into the 3D 60 instrument Refer to Section 4 10 13 System Power Panel 11 Reinstall the Right Side Panel of the instrument Place a piece of cardstock over the foam gasket material in the front of the instrument to prevent damage to the foam when reinstalling the Right Side Panel 12 Close the Top Panel and install the two 2 screws that secure it Refer to Figure 99 13 Refer to Subsection 4 3 3 and perform the 60 Power Up procedure 14 Refer to Subsection 4 11 and perform the Post Service Validation procedure 15 Annotate the appropriate maintenance and lab logbooks 16 Return the system to normal operation Service Manual 4 127 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 15 Power Supply MOV Metal Oxide Varistor P N 431 16 2 NOTE Individual power supply subassembly components are not repaired or replaced in Domestic 3D 60 s Individual components are spared as parts and replaced in International 3D 60 instruments only CAUTION Proper ESD precautions must be observed whenever working on or around any PCBA 1 Refer to Subsection 4 3 2 and perform the 3D
45. 0 9 9 3 1 9 9 2 1 gt Bottle Types Table 100 entries Type Name UTT Disp Drw Cnt Disk LES Glass LES Plas 0 GENERIC 1 3 0 10 5 11 1 UNKNOWN U 1 5 O 10 5 11 2 AEROBIC A 1 2 1 10 10 10 3 ANAEROBIC N 1 2 1 10 10 10 4 FAN AEROBIC FA 1 2 1 10 10 10 5 FAN ANAEROBIC FN 1 2 1 10 10 10 6 PEDI BACT PE 1 2 1 10 10 10 7 LYM BACT PN 1 2 1 4 4 4 8 MB BACT MS 1 1 1 2 2 2 9 MB BACT BLOOD MB 1 4 1 3 3 3 10 BACT ALERT SV BA O 2 0 5 5 11 11 BACT ALERT SA BA 0 2 0 5 5 11 12 BACT ALERT SN BN O 2 0 5 5 11 13 BACT ALERT FA BFA 0 2 0 6 6 12 14 BACT ALERT FN BFN 0 2 0 5 5 11 15 BACT ALERT PF BPE 0 2 0 5 5 11 16 BACT ALERT LYM BLYM 0 2 0 9 9 15 17 BACT ALERT MP BMS 0 1 0 7 16 13 18 BACT ALERT MB BMB 0 4 0 8 17 14 19 GENERIC DRUG GD 0 1 4 3 17 17 Type Name UTT Disp Drw Cnt Disk LES Glass LES Plas 20 PYRAZINAMIDE PZA 0 1 4 2 16 16 21 RIFAMPIN RIF O 1 4 3 17 17 22 ISONIAZID INH O 1 4 3 17 17 23 ISONIAZID HI INHI 0 1 4 3 17 17 24 STREPTOMYCIN STR 0 1 4 3 17 17 25 ETHAMBUTOL EMB 0 1 4 3 17 17 26 DIRECT CONTROL DC 0 1 4 3 17 17 27 PROP CONTROL PC 0 1 4 3 17 17 28 PZA DIRECT CONTROL PDC 0 1 4 2 16 16 29 PZA PROP CONTROL PPC 0 1 4 2 16 16 30 030
46. 030 0 3 0 10 5 11 31 Q31 031 0 3 0 10 5 11 32 032 032 0 3 0 10 5 11 33 Q33 Q33 0 3 0 10 5 11 34 034 034 0 3 0 10 5 11 35 Q35 Q35 0 3 0 10 5 11 36 Q36 Q36 0 3 0 10 5 11 37 Q37 Q37 0 3 0 10 5 11 38 038 038 0 3 0 10 5 11 39 039 039 0 3 0 10 5 11 Type Name UTT Disp Drw Cnt Disk LES Glass LES Plas 40 040 040 0 3 0 10 5 11 41 041 041 0 3 0 10 5 11 42 042 042 0 3 0 10 5 11 43 043 043 0 3 0 10 5 11 44 O44 Q44 0 3 0 10 5 11 45 045 Q45 0 3 0 10 5 11 46 046 046 0 3 0 10 5 11 BacT ALERT 3D 60 Service Manual BacT ALERT 3D 60 4 SERVICING SOFTWARE DIAGNOSTICS 47 Q47 047 0 3 0 10 5 11 48 048 048 0 3 0 10 5 11 49 049 049 0 3 0 10 5 11 50 BTA I AST ISA 0 2 0 5 5 11 51 BTA I NST ISN 0 2 0 5 5 11 52 BTA I LYM ILYM 0 2 0 9 9 15 53 053 053 0 3 0 10 5 11 54 Q54 Q54 0 3 0 10 5 11 55 055 055 0 3 D 10 5 11 56 Q56 056 0 3 0 10 5 11 57 Q57 Q57 0 3 0 10 5 11 58 Q58 Q58 0 3 0 10 5 11 59 Q59 Q59 0 3 0 10 5 11 Type Name UTT Disp Drw Cnt Disk LES Glass LES Plas 60 060 060 0 3 0 10 5 11 61 061 061 0 3 0 10 5 11 62 062 062 0 3 0 10 5 11 63 063 063 0 3 0 10 5 11 64 064 064 0 3 0 10 5 11 65 065 065 0 3 0 10 5 11 66 066 066 0 3 0 10 5 11 67 067
47. 0x503 IMTCal 36 00 36 86 136 This event is logged any time that the incubation chamber s temperature is calibrated Remote User software 0x700 RUOn This event is logged any time that the software detects that the Remote User software has connected Remote User software connection dropped This event is logged any time that the software detects that the Remote User software connection has been dropped Service Manual 4 45 4 SERVICING SOFTWARE DIAGNOSTICS BacT ALERT 3D 60 7 6 INSTRUMENT CNTRL Software Screen Special equipment None COC Description DI RSS WL software Also displaye data used to debug verify and validate instrument software Also displays logs of exception conditions detected by the software Impact Bottle testing is not affected by this diagnostic Keyboard functions Selects the specific type of information to display 1 Software debug information 2 Software exception log 3 Operating system exception log 4 Modem activity log b Association tables 6 Bottle processing tables 7 Configuration tables 8 Other Run status Runs continually and updates display when new information needs to be displayed 1 Debug Displays software debug messages intended for development activity and is intended for the 3D software development team The format and content messages put in this log are left up the software implementer and no design specifications are imposed 2 Soft
48. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 41 O O OC O O O O O O 000 O O O O O O O O O OC O O OC O O O O O O O O O O O OC O O O O O O O O O O O O O O O O O 0 LES Glass 1 LES Glass 2 LES Glass 3 LES Glass 4 LES Glass 5 LES Glass 6 LES Glass 7 LES Glass 8 LES Glass 9 LES Glass 10 LES Glass 11 LES Glass 12 LES Glass 13 LES Glass Service Manual days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days RRR RAR ARR RRR RRR RRR RRR 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs
49. 1 OVEIVIOW caii n ette re DL 3 14 3 3 2 2 ue etd utm Ee m hes euet eum 3 14 3 4 SOFIWAREINSTALLUATION sis iaca la i d e baa KA HAAA HA AA HA KA WAR 3 17 39 SWITCHING ON rei 3 17 3 5 1 Birre 1 3 17 Service Manual BacT ALERT 3D 60 TABLE OF CONTENTS M 4 1 INTRODUCTION 4 1 4 2 SPECIFIC TOOLS AND enne nennen KA KA KA KA nnn nnn nnn nnn WA A 4 3 4 3 POWER UP DOWN 6 2 4 4 4 1 1 0 AA AA AA KA KA WARA KAWA KA HA nn 4 3 4 3 1 IT GOLG G wad cesar ao Ex 4 3 4 3 2 3D 60 Power rur kn ki ka Lee xen a ek Pega aaa 4 3 4 3 8 3D 60 Power Up dice ete pa Boa ee VAKE NE etia iden 4 4 44 22 2 44 0 2 1000110 nnn nnn nnn nnn xn nnn nnn nn 4 5 4 4 1 OVGIVI OW M Da a 4 5 4 4 2 4 5 45 DATA BACKUP RESTORE 4 9 4 5 1 BacT ALERT 3D 60 Data Backup Procedure 4 9 4 5 2 BacT ALERT 3D 60 Data Restore
50. 10 7 ModSig PCBA Fuses P N 870 0008 14 17 22 Continued NOTE The ModSig PCBA P N 48300 1 contains seven fuses F1 F7 F1 amp F6 are 3 15 Amp 5X20mm type FST Time Lag 870 0008 22 F2 F4 amp F7 are 1 Amp 5X20mm type FST Time Lag 870 0008 17 F5 is a 0 5 Amp 5X20mm type FST Time Lag 870 0008 14 CAUTION Proper ESD precautions must be observed whenever working on or around any PCBA CAUTION The new fuse must be the same amperage and voltage rating as the removed fuse Over fusing could damage the equipment and create a potential fire hazard 3 Determine and locate which fuse is defective Refer to Figure 125 Figure 126 and Figure 127 for fuse locations Remove the defective fuse from the retaining clip and install the new fuse Fuse F1 3 15A Fig 126 ModSig PCBA Fuse Locations 1 4 106 Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 7 ModSig PCBA Fuses P N 870 0008 14 17 22 Continued Fig 127 ModSig PCBA Installed Fuse Locations 2 Close the System Top Panel and secure it with two 2 screws Refer to Figure 99 Refer to Subsection 4 3 3 and perform the 3D 60 Power Up procedure Refer to Subsection 4 11 and perform the Post Service Validation procedure Annotate appropriate maintenance and logbooks Return the system to normal operation Service Manual 4 107 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALER
51. 11 Insufficient Charge in UPS Cause Solution The UPS battery is low Call bioM rieux 112 LIS Communication Fault Cause Solution Cause Solution The LIS is not responding to the instrument Check the LIS The fault automatically goes away when communication with the LIS resumes The message from the instrument is not reaching the LIS Check the cable connections between the instrument and the LIS 19 Software Exception Cause Solution Service Manual A software exception has occurred Call bioM rieux immediately System performance may be compromised APPENDIX D ERROR CODES BacT ALERT 3D 60 20 Door Open for Too Long Cause The door has been left open or ajar for an extended period Solution Make sure door is tightly closed Cause Door sensors have failed or become misaligned Solution Call bioM rieux Cause Fault in the ModSig board Solution Call bioM rieux 21 Agitation Failure Cause Mechanical failure in the agitation linkage Solution Call bioM rieux Cause Agitation motor either disconnected or inoperative Solution Call bioM rieux Cause Fault in bottom rack Solution Call bioM rieux 22 Unexpected Agitation Cause Instrument not configured properly Solution Call bioM rieux 39 Rack Temperature Fault Cause The door has been left ajar for an extended period or there is a system failure Solution Perform the following
52. 2 Details C Calibrate Fig 68 1 7 Inc Module Flag Check Diagnostic Name Displays the name of the diagnostic that is executing Diagnostic Output Display Area The contents of this area depend on the particular diagnostic that is running The diagnostic output display area can display 27 lines at a time but can actually hold up to 2000 lines of output data Buttons just above and below the screen and the slider bar located at the left of the display area are used to scroll the data See section titles Display Area Navigation farther down in this chapter Identifying Module Racks and Cells M Identifies an incubation module where M is the module number 1 MD Identifies a drawer where M is the module number D is the drawer letter A MDCC CC Identifies a rack where M is the module number D is the drawer letter CC CC is the cells belonging to that rack e g 1A01 20 is the top rack in drawer A 1421 40 is the middle rack in drawer A 1441 60 is the lower rack in drawer A MDCC Identifies a cell where M is the module number D is the drawer letter and CC is the cell number 1 20 Service Manual BacT ALERT 3D 60 4 SERVICING SOFTWARE DIAGNOSTICS Date and Time DD MM YY HH MM SS Date and time displayed is the local time displayed in day month year hour minute and second order regardless of the settings on the SET DATE TIME menu Help line Some diagnostic accept keystroke data to invoke special function
53. 4 43 4 SERVICING SOFTWARE DIAGNOSTICS BacT ALERT 3D 60 Backup started 0x100 BkupStart This event is logged any time a backup has started Backup completed successfully 0x101 BkupOk This event is logged any time that a backup is completed successfull Backup failed 0x102 BkupFailed This event is logged any time that a backup has started but failed to complete successfully Operator cell calibration Module Drawer Rack Cell started Number Number Number Number 0x300 CCalSt 3 uo rr oou This event is logged any time that the operator starts a single cell calibration Operator cell calibration Module Drawer Rack Cell successful Number Number Number Number 0x301 CcalOK EZ 2 2 DD GINE This event is logged any time that the operator successfully completes single cell calibration Instrument controller power up 0x600 ICPwr This event is logged any time that the instrument controller is powered up Normal shutdown 0x200 NrmSD This event is logged any time that the software is shutdown in the normal fashion Power loss shutdown 0x201 PwrLossSD This event is logged any time that the software is shutdown due to a loss of power Abnormal shutdown Shutdown comment without NVRAM save This event is logged any time that the software is shutdown for an abnormal reason without saving the NVRAM For example if during power up the software detects that the
54. 60 to stop the instrument 3 Refer to Subsection 4 3 2 and perform the 3D 60 Power Down procedure 4 Remove the two 2 screws securing the Top Panel and secure it into the Up position Refer to Figure 99 below for screw removal locations CAUTION Proper ESD precautions must be observed whenever working on or around any PCBA Top Panel Screw Fig 99 Top Panel Screw Locations Removal Service Manual 4 81 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERTG 3D 60 4 10 2 CPU PCBA Assembly P N 750 0070 01 Continued Quad Serial PCBA i Nes CPU PCBA Remove two support standoff screws from Quad Serial PCBA Cut Tie Wraps on Bundled Cables Fig 100 CPU PCBA w Quad Serial PCBA plugged in 5 Cut and remove the tie wraps from the bundled set of cables 6 Remove the two 2 screws securing the Quad Serial PCBA to the CPU PCBA Refer to Figure 100 7 Unplug the Quad Serial PCBA from the CPU PCBA and lay it down Refer to Fig 101 8 Unplug cables from the following locations preferably in the following order WinJ3 from connector J3 WinP2 from connector J2 WinP7 from connector J7 Refer to Figure 104 and Figure 105 for Steps 9a P18 from connector J18 thru 9g CPU PCBA cable connections P27 from connector J27 J5 from connector J5 J4 from connector J4 e 4 82 Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10
55. 7 Italicized Whether Bold or Not Text Whenever text is in talics or Bold Italics it provides for emphasis or identifies key words or concepts Whenever this format is seen it is an important operative part of the meaning of the text or added notation Bold Italics designate STRONG emphasis and is not to be ignored or taken lightly xxii Service Manual BacT ALERT 3D 60 SAFETY SUMMARY 0 5 SAFETY SUMMARY The following is a comprehensive list of the safety issues outlined in this chapter 0 5 SAFETY SUMMARY miei ei ai ac au xu k ia ie i i XXIII 0 5 1 General Information to Follow XXV 0 5 2 Electrical Warnings iicet ea e e ev de e dde ed XXV 0 5 3 Electrical Grounding hp kate ee itae ite er Ero dat xxvi 0 5 4 Fuse Replacement xxvi 0 5 5 Hazardous Voltages ay Bae a xad k xxvi 0 5 6 Cleaning Agents eec Re ER C Re DRE ELE D as BRE ERE Ue a d xxvi 0 5 7 Healtti ec FER late te Ei xwee a WA ka xxvii 0 5 8 ESB Precautiors cae oaie HERE RR NI RR HARI EMEN Eis xxvii 0 5 9 Moving Parts xxvii 0 5 10 Heating Element a eine at eerie a va pl i xxvii Service Manual xxiii SAFETY SUMMARY BacT ALERT 3D 60 THIS PAGE INTENTIONALLY LEFT BLANK xxiv Service Manual BacT ALERT 3D 60 SAFETY SUMMARY 0 5 1 General Information to Follow This
56. 912 913 921 923 930 931 932 940 941 942 943 944 945 960 961 Note If the problem cannot be corrected using the solutions listed or a code is displayed which does not appear in this list call the Tech Support Center Service Manual D 1 APPENDIX D ERROR CODES D 1 1 BacT ALERT 3D 60 Instrument Fault Codes Instrument Fault Codes appear in the Instrument icon A description of each Fault Code is provided The following is an example of an Instrument icon with Instrument Fault Codes 2 10 and 20 Fault Codes are displayed on the particular components where the errors are located Locate specific bottles with fault by clicking the Incubation Chamber on the instrument icon on the Main screen to display the View Cell Status screen Fault codes referring to loss of incubator temperature may adversely affect bottle testing and should be addressed immediately 1 Power Fault in Incubation Chamber Cause Solution Fuse has been blown Contact bioM rieux Communication Lost with Incubation Chamber Cause Solution Internal cables may be loose or hardware problem Contact bioM rieux Incubation Chamber Temperature Is Too High Cause Solution Cause Solution The instrument optimal temperature Set Point has been changed and has not yet equilibrated at the new temperature Wait for the chamber temperature to equilibrate Bottle testing may be adversely
57. 913 921 923 930 QUICK REFERENCE CARD CONTINUED BacT ALERT 3D 60 Card P N 955 0500 03 RevA OPERATION ERROR CODES Refer to Operator Manual for detailed error description and troubleshooting instructions Description Code CORRUPTED BOTTLE RECORD HAS BEEN SELEC TED 932 REQUIRED DATA MISSING INVALID CELL LOAD 940 INVALID CELL UNLOAD 941 INVALID CELL RELOAD BOTTLE ID JUST SCANNED MATCHES THAT OF A 942 CURRENTLY LOADED BOTTLE 943 BARCODE SCAN NOT ALLOWED IN THIS MODE 944 INVALID BARCODE ENTRY 945 INCORRECT OR UNEXPECTED BARCODE SCANNED 960 AFTER UNLOADING A BOTTLE 961 DETECTION ALGORITHM HAS BEEN CHANGED Description BOTTLE ID SCANNED MATCHES THAT OF A PREVIOUSLY UNLOADED BOTTLE BOTTLE DETAIL NOT FOUND BOTT CUR BOTT ILE ID ENTERED MATCHES THAT OF A BOTTLE THAT IS RENTLY LOADED IN A DIFFERENT CELL ILE TYPE CHANGE REQUIRES DIFFERENT ALGORITHM IDENTIFIED BOTTLE CHANGED TO ANONYMOUS MAN BOTI UAL UNLOAD OF ANONYMOUS BOTTLE ILE ID ENTERED MATCHES THAT OF A PREVIOUSLY UNLOADED BOTTLE DUP LICATE ENTRIES INVALID BLANK FIELD SEE REVERSE FOR INSTRUMENT FAULT CODES Fig 31 Quick Reference Card Front Side Detailed error descriptions and troubleshooting instructions may also be found in Appendix D of this manual 1 30 Service Manual 1 GENERAL INFORMATION BacT ALERT 3D 60 1 6 QUICK REFERENCE CARD CONTINUED INSTRUMENT FAULT AND STATUS CODES Ref
58. AK ec AK KK KK KK KK KK ae 3 1 3 1 INTRODUCTION oai EK ku Y kl HS E EYO ues 3 1 3 2 BACT ALERT 3D 60 INSTALLATION 3 3 39 RESTRAINT INSTALLATION reri ie ctm a ai ea 3 14 3 4 SOFTWARE INSTALLATION cerent nnn nnn aaa manea nea tnis 3 17 35 SWITCHING ON iiiter etri aia ac Ewn a 3 17 Service Manual 3 1 3 INSTALLATION PROCEDURES BacT ALERT 3D 60 THIS PAGE INTENTIONALLY LEFT BLANK 3 2 Service Manual BacT ALERT 3D 60 3 INSTALLATION PROCEDURES 3 2 3 2 1 3 2 2 3 2 3 3 2 4 Service Manual BACT ALERT 3D 60 INSTALLATION PROCEDURES Verification of Site Requirements For detailed information refer to the Standard Lab Operating Requirements form to ensure the following are met 1 Lab environment temperature and humidity are within specified tolerances a Temperature is between 10 C to 30 b Humidity is between 2096 9096 non condensing 2 Data unit is positioned away from direct sunlight and bright overhead lights 3 Telephone line for modem access is located within 25 4 Floor or bench that s capable of supporting 126 0 Lbs 57 2 Kg per instrument installed 5 Ensure that there is an unobstructed clearance of 4 behind and 12 above the module 6 Verify that a dedicated AC circuit with proper voltage and current ratings for the data unit
59. Continued 9 Set the drive down on a clean work surface Remove the drive from the mounting sled Typically four 4 to six 6 screws secure the Zip Drive to the sled The mounting screws may be installed from the side Refer to Figure 142 or bottom Refer to Figure 143 of the Zip drive depending on how the vendor assembles and ships the drive assembly to bioM rieux manufacturing d Drive Mounting Sled with Bezel Fig 142 Zip Drive Sled Removal Side Screws Fig 143 Zip Drive Sled Removal Bottom Screws 10 Install the new Zip drive into the mounting sled with mounting screws as shown above 11 Lower the Top Panel about half way From the bezel of the Zip drive push the drive through the cutout hole as shown in Figure 141 12 Reinstall the four 4 screws securing the zip drive to the chassis Hold on to the Zip drive until you install at least one mounting screw Refer to Figure 141 13 Plug in the Zip drive s main power connector Blue Black wires Refer to Figure 144 14 Plug in the IDE cable Refer to Figure 144 Power Connector Keyed IDE Cable Connector Fig 144 Zip Drive Reconnecting IDE Cable and Power Connector 4 122 Service Manual BacT ALERT 3D 60 4 10 12 Service Manual 4 SERVICING REMOVE AND REPLACE PROCEDURES Zip Drive P N 895 0004 38 Continued 15 16 17 18 19 20 Reinstall the four 4 screws that secure the Caompa
60. Display Monitor Fig 21 Barcode Scanner Note figure above shows a flat panel monitor and may not represent the model or type of monitor actually shipped with the 3D 60 instrument Fig 22 Keyboard Fig 23 Zip Drive NOTE The photos of output devices shown above may not necessarily reflect the models being installed Service Manual 1 GENERAL INFORMATION BacT ALERT 3D 60 1 4 4 Input Output Devices Continued 1 4 4 1 Operator Display Monitor The display monitor is a standard VGA monitor used for displaying diagnostic and module setup information Reference Figure 20 1 4 4 2 Barcode Scanner The QuickScan 6000 Barcode Scanner scans bottle labels identifying the bottles whenever loading or unloading Reference Figure 21 1 4 4 3 Keyboard This is a standard sized 101 key keyboard It is used as an alternative input device to the barcode scanner or mouse Reference Figure 22 1 4 4 4 Zip Drive This drive provides an internal resource for loading new operating system software and performing system data backup Reference Figure 23 Service Manual 1 17 1 GENERAL INFORMATION BacT ALERT 3D 60 THIS PAGE INTENTIONALLY LEFT BLANK 1 18 Service Manual 1 GENERAL INFORMATION BacT ALERT 3D 60 1 4 4 1 4 4 5 1 4 4 6 Service Manual Input Output Devices Continued 56K FAX Modem Domestic The fax modem serves as an interface to the BacT 3D 60 instrument for remote access
61. FastDgdr 0 93E0 FastSlopProp 0 825E0 FastMayThres 3 SlowStupThres 12 SlowCntrThres 16 SlowBcktThres 15 SlowBcktInc 1 SlowDgdr 0 98E0 SlowSlopProp 0 9083E0 ID G2 BltFact 0 1667E1 Resv 1320 MinSkipPts 216 MinAvgPts 24 MinAvgMed 1 SlopProp 0 1E0 SlowSlopProp 0 2E 1 FastDgdr 0 75E0 SlowDgdr 0 9E0 AcelSlopThres 20 SlowSlopThres 10 PosDlyThres 1 DltThres 32767 NumAlg2Pts 576 PosSlopDly 720 DltDgdr 1 0E 32 Embedded E2 Parms ID E2 BltFact 0 1667E1 Resv 1320 AdjThres 70 AdjLim 4 StupPts 5 StupSumx 15 StupDenom 50 FastPts 17 FastSumx 153 FastDenom 6936 InitThres 6000 FastStupThres 6 SlopStupThres 0 1E1 FastCntrThres 12 FastBcktThres 0 105E2 FastBcktInc 1 FastRateThres 32 FastRateInc 3 FastDgdr 0 93E0 FastSlopProp 0 825E0 FastMayThres 3 SlowStupThres 12 SlowCntrThres 16 SlowBcktThres 15 SlowBcktInc 1 SlowDgdr 0 98E0 SlowSlopProp 0 9083E0 ID H2 BltFact 0 1667E1 Resv 1320 AdjThres 70 AdjLim 4 StupPts 5 StupSumx 15 StupDenom 50 FastPts 17 FastSumx 153 FastDenom 6936 InitThres 6000 FastStupThres 6 SlopStupThres 0 1E5 FastCntrThres 12 FastBcktThres 0 105E2 FastBcktInc 1 FastRateThres 32 FastRateInc 1 FastDgdr 0 93E0 FastSlopProp 0 825E0 FastMayThres 3 SlowStupThres 12 SlowCntrThres 16 SlowBcktThres 15 SlowBcktInc 0 SlowDgdr 0 98E0 SlowSlopProp 0 9083 0 MinSkipPts 6 ID H2 BltFact 0 1E1 Resv 1320 AdjThres 70
62. In Telco cable to the fax modem Refer to Figure 190 Ensure modem DIP switch setting are as shown in Figure 190 Connect the AC Adapter to the modem and return the system to normal operation 9 Service Manual 4 163 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 32 APC Back UPS Model 650 Domestic Model P N 957 0060 02 Computer Interface Port 120V Surge and Battery Backup Receptacles without Battery Backup Fig 192 APC UPS Domestic Model Back UPS 650 120V Front and Rear View Fig 193 3D 60 System Rear Communications Ports UPS Cable Connection 1 Refer to Subsection 4 3 2 and perform the 3D 60 Power Down procedure 2 Unplug the UPS cable from the UPS Port on the rear of 60 Instrument and the opposite end of the cable from the Computer Interface Port on the defective UPS Set the UPS aside Refer to Figures 192 and 193 Service Manual 4 164 BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 32 APC Back UPS Model 650 Domestic Model P N 957 0060 02 Continued Set the UPS flat on a work surface Fig 194 UPS Battery Connection Preparation 3 Unpack the new UPS from the box Refer to Figure 194 Roll the UPS over on its side and remove two 2 screws that secure the battery compartment cover Remove two 2 Screws Fig 195 UPS Battery Cover Removal 4 Lay the UPS on its side and remov
63. International 3D 60 instruments only DC Power Supply installed on Power Supply chassis Fig 154 Power Supply Assembly w DC Power Supply 1 Refer to Subsection 4 3 2 and perform the 3D 60 Power Down procedure 2 Remove the two 2 screws securing the Top Panel and secure it into the Up position Refer to Figure 99 for screw removal locations CAUTION Proper ESD precautions must be observed whenever working on or around any PCBA 4 132 Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 17 DC Power Supply P N 852 0010 01 Continued Remove 3D 60 Instrument s Right Side Panel and set the panel aside Remove the Power Supply Panel from the 3D 60 instrument Refer to Section 4 10 13 for System Power Panel removal Unplug J1 Connector Fig 155 DC Power Supply J1 and J2 Disconnection Disconnect J1 and J2 connectors from the DC Power Supply s PCBA Refer to Figure 155 Remove four 4 mounting screws from the rear of the Power Panel Assembly Ensure that you hold on to the DC supply as you remove the final mounting screw Set the defective Power Supply aside Refer to Figure 156 Service Manual 4 133 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 17 4 134 DC Power Supply P N 852 0010 01 Continued Remove the DC Power Supply mounting screws Fig 156 Power Panel Assembly DC Supply Screw Removal Align the new
64. LIS Mouse and Barcode ports on the rear bulkhead Refer to Figure 123 Remove the knurled nut from the Ext Speaker port Refer to Figure 123 Service Manual 4 97 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 6 ModSig PCBA P N 48300 1 Continued Order Spare P N 48300 901 Fig 116 ModSig PCBA Bundled Cable Disconnection 4 98 Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 6 ModSig PCBA P N 48300 1 Continued Order Spare P N 48300 901 Service Manual rper Bh Unplug MS JP11 amp 12 ra Unplug MS JP31 Keyed with tab lock ka Keyed with tab lock Unplug JP21 Power Blue Black E Fig 118 ModSig PCBA JP21 MS JP11 JP12 amp JP31 Cable Removal 4 99 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 6 ModSig PCBA P N 48300 1 Continued Order Spare P N 48300 901 Unplug MS JP1 Blue Black amp Yellow Brown 1 i m e ERE Kan Fig 120 ModSig Rear Panel Screw Removal 4 100 Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 6 ModSig PCBA P N 48300 1 Continued Order Spare P N 48300 901 Fig 121 ModSig PCBA Mounting Screw Locations Service Manual 4 101 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 6 ModSig PCBA P N 48300 1 Continued Order Spare P N 48300 901 Unplug
65. Liquid Crys tal Display device that s used to display video images of software and firmware functions Typically called Flat Panel Display LIS Acronym for Laboratory Information System METAL OXIDE MOV An electronic device that provides inline surge protection for the internal circuitry of VARISTOR the Instrument MODSIG A PCBA that serves as a control interface for data communications between all of the internal and external devices peripherals of the Instrument MOV Acronym for Metal Oxide Varistor MICROBE Simply put it s a Microorganism or germ Service Manual A 3 APPENDIX A GLOSSARY BacT ALERT 3D 60 An Instrument display screen button which remains activated appears to be pressed only BUTTON as long as the corresponding screen area is being clicked Acronym for Microsoft Disk Operating System DOS An abbreviated term for Mycology a branch of botany dealing with fungi Incubation Module rack configuration designed to grow and detect Mycobacteria This conversion disables the agitation processes and is not required for the bacteria growth Describes a culture bottle that has no evidence of microbial activity Any step or actions that may need further clarification or explanation NVRAM Non Volatile RAM Random Access Memory that is capable of retaining data when power is removed from de system The BacT ALERT 3D contains NVRAM in the CPU PCBA Module Controller PCBA and the Rack Controller OPTI
66. Logic Ground eee tette a ia 2 9 Loopback user ees 4 23 Magnetic Door Switches sse 4 158 MB Conversion pice eerte terret ee 4 5 4 6 Measured Voltage sss 4 75 Mechanical Reed Switches sss 2 25 MGMT Ys sce r n y VAR 2 13 Message Logom i r hii anise cadets 4 27 Message Stats Test 4 26 Service Manual INDEX Metal Oxide Varistor essen 4 128 MiGrO S With serena caiete cb ceia toat a par 4 77 Microbial Detection System sss 1 3 Modem ACUVI y Configuration Ye Kirs eX ORO DIP Switch Settin gS8 E rere Port Connection is Modem Loopback Test Modem Port Modem Test case Hire ya a Gede Da i ai it ee ERR RR iet Block Diagram ModSig Configuration ModsSig Bundled Cable Disconnectioa Cable Connections eee Cable Removal Kya RR d e Diagram RE Rte eee etse Fuse Locations Mounting Screw Locations Rear Panel Screws Removal siete teret eee e Tie Wrap Removal a Wien n KA KAN Monitor Motor Offset Round Spacing TOOL Mounting Surface Diagrami Ai y
67. MCJ4 from J4 connector on Step 5 PCBA Fig 122 ModSig Stepb MCJ4 Connection 4 102 Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 6 ModSig PCBA P N 48300 1 Continued Order Spare P N 48300 901 Remove Hex Nuts on LIS Mouse and Barcode Ports PRINTER WEYBHEI EXT SEKI Remove Knurled Nut on Ext Speaker Port w Fig 123 ModSig Rear Panel Hex Nut amp Knurled Nut Removal ADOR NOTE Ensure no cables are pinched under the new ModSig PCBA when aligning for installation NOTE JP21 Blue Black JP1 Flat Ribbon Cable and Ground Ribbon Cable must be pulled up before installing new PCBA wr Fig 124 ModSig JP10 1 and Ground Cable Service Manual 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 6 4 104 ModSig PCBA P N 48300 1 Continued Order Spare P N 48300 901 11 17 18 19 20 21 22 23 24 25 Align the Rear Bulkhead to the mounting holes and peripheral ports on the ModSig PCBA Reinstall the two 2 screws that secure the Rear Bulkhead to the ModSig board Reinstall the two 2 each hex nuts from the left and right sides of the LIS Mouse and Barcode ports on the Rear Bulkhead Refer to Figure 123 Reinstall the knurled nut on the Ext Speaker port Refer to Figure 123 Align the ModSig PCBA to the support s
68. Mark the wires as appropriate to facilitate proper reinstallation 4 138 Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 19 Fan P N 941 0009 07 Continued Pull the fan power wires up and out of the Power Supply chassis 6 Make note of the direction of the fan blades prior to removal of the fan 7 Remove the four 4 screws nuts and washers securing the fan to the System Power Panel Refer to Figure 164 NOTE Washers can fall into the chassis so hold on to them as you remove the nuts and screws Also note that the nuts and washers go over the fan grill and there are plastic clamps that hold wiring in place 8 Remove the defective fan from the chassis and replace it with a new one 9 Reinstall the four 4 screws from the back side of the Power Supply Chassis push the new fan onto the screws and install the grill over the fan 10 Push the two 2 wire clamps over the top of the grill on the bottom two fan screws Install the washers then tighten the nuts Both washers and screws are mounted on top of the nylon wire clamps 11 Install washers and nuts on the top two 2 fan screws 12 Route the fan power wires underneath the relays Secure the wires to TB1 2A and TB1 4A then install the other two wires connected to the terminals on top of the fan power wires Tighten the screws on terminals TB1 2A and TB1 4A 13 Ensure that all wire connections are properly made If the T
69. N 870 0008 14 17 22 4 105 4 10 8 Step 5 PCBA P N 48301 1 Order Spare P N 48301 901 4 108 4 10 9 Step 5 Motor P N 48104 1 aaa 4 111 4 10 10 Outlet Thermistor PCBA P N 32300 1 4 117 4 10 11 Inlet Thermistor PCBA P N 32300 4 119 4 10 12 ZipTM Drive P N 895 0004 38 4 4 1 0 4 120 4 10 13 System Power Pal yy itte tea od eee Ea 4 124 Service Manual BacT ALERT 3D 60 TABLE OF CONTENTS 4 11 4 10 14 Power Supply Transformer P N 851 0015 01 4 126 4 10 15 Power Supply MOV Metal Oxide Varistor P N 43116 2 4 128 4 10 16 Power Panel Solid State Relays P N 845 0018 01 4 130 4 10 17 DC Power Supply P N 852 001 0 01 4 eee 4 132 4 10 18 Power Entry Module PEM Fuses P N 870 0008 14 17 24 25 4 135 4 10 19 Fan P N 941 0009 07 4 138 4 10 20 Heater P N 847 0009 01 4 140 4 10 21 Blower Assembly P N 48411 1 4 142 4 10 22 Blower Motor Capacitor P N 601 0001 02 4 143 4 10 23 Digital Reference Thermometer P N
70. SERVICING Service Manual CHAPTER 4 SERVICING BacT ALERT 3D 60 THIS PAGE INTENTIONALLY LEFT BLANK Service Manual BacT ALERT 3D 60 4 SERVICING 4 SERVICING 4 1 INTRODUCTION This paragraph presents the Servicing chapter contents Subjects include tools required for servicing PMs Power Up Down Procedures Software Diagnostics and general maintenance or repair 4 SEBVICINQ s co agate s lav a keke OPS S VAKA HEWE UR Ed dM 4 1 JNIHODUGTIQN 20 oi elada cs uu ivo sten etur CE SEN da 4 1 4 2 SPECIFIC TOOLS AND 111 AA AK AA KAKA KAKA KA AA 4 3 43 POWER UP DOWN sanno sanam HAAA WARA HAAA KA HA WA A 4 3 44 MB CONVERSION PROCED YURE e neoane nana nasa enne nennen nunt WEKA WARA KAWA KA HW WA A 4 5 45 DATA BACKUP RESTORE 5 0 nennen nennen nnne 4 9 4 6 PHEVENTIVE MAINTENANCE d ceri viv AA AA KA AA HAAA HAAA HAAA KA HA KA HA AA WAR 4 11 4 7 DIAGNOSTICS AND 5 4 13 4 8 SOFTWARE DIAGNOSTICS 4 15 4 9 ALIGNMENTS AND CALIBRATIONS neoane axxx eene kK Ak AA KA KA AA KA KA KA HA KA WAR 4 69 4 10 REMOVE AND REP
71. and corresponding wire connection to the ModSig PCBA Micro Switch and corresponding wire connection to the ModSig PCBA LEDs D55 amp D56 for each micro switch are near its respective connector Fig 98 Door Micro Switches and Magnets 4 With the instrument s door open check LEDs 055 056 on the ModSig board to ensure they are not lit 5 Close the door and check the LEDs to ensure both are illuminated If either LED is not illuminated follow the Repair and Replace procedures outlined in Subsection 4 10 27 Magnetic Door Switches to replace the defective switch 6 Close the Top Panel and replace the two 2 screws that secure it Refer to Figure 99 7 Return the system to normal operation Service Manual 4 77 4 SERVICING ALIGNMENTS AND CALIBRATIONS BacT ALERT 3D 60 THIS PAGE INTENTIONALLY LEFT BLANK 4 78 Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 REMOVE AND REPLACE PROCEDURES 4 10 1 Introduction This section describes the procedures for the repair and replacement assembly and disassembly of the various components of the instrument Typically the component repair list below will coincide with the components in the system s spare parts list in Appendix B of this manual Included below is a comprehensive list of the components that may require repair and or replacement The assembly and disassembly of each component is co
72. and UPS are available and located within 8 Record Line Noise Using line viewer or power probe and oscilloscope note the common mode CM and normal mode NM line noise observed on the AC wall receptacle and record values on the checklist Acceptable values are 0 5 V CM noise ground to any other point and 5 0 V NM noise hot to neutral Record these measurements on the checklist CM NM Using a digital voltmeter DVM measure the potential between neutral and ground This voltage should be 5VAC Unpacking Precautions are to be taken when unpacking the equipment There should be a comprehensive list of items contained in the box es in which the equipment is delivered Unpacking instructions are illustrated on every instrument s shipping carton The unpacking instructions may also be found in the BacT ALERT 3D 60 Operator s Manual Repacking Defective 3D 60 instruments demo and show units will require carton repacking for return shipments Figure 45 3D 60 Instrument Repacking Sequence and Figure 46 3D 60 Instrument Repack Web Strapping Diagrams on the following pages illustrate how to repackage the 3D 60 in the return shipping carton and how to properly secure the carton s web strapping 3 3 3 INSTALLATION PROCEDURES BacT ALERT 3D 60 3 2 4 Repacking Continued Fig 45 3D 60 Instrument Repacking Sequence 3 4 Service Manual BacT ALERT 3D 60 3 INSTALLATION PROCEDURES 3 2 4 Repacking
73. bottle readings are not processed while the fault is present Solution Perform the following procedure 1 Click the Unload Positive Bottlesbutton and unload the affected bottle 2 Subculture the bottle 3 Reload the bottle via the Load Bottle function on the Main screen to restart testing The original first loaded date and time are maintained 4 If the fault code persists call bioM rieux 78 Incomplete Test Data Cause This fault occurs when an identified bottle is reloaded anonymously and later is identified and reloaded in the instrument The original bottle data cannot be merged with the data collected when the bottle was anonymous and therefore the test data is incomplete Bottles with fault are flagged positive and bottle readings are not processed while the fault is present Solution Perform the following procedure 1 Unload bottle with fault via Unload Positive Bottle function on the Main screen Subculture the bottle Reload the bottle via the Load Bottle function on the Main screen to restart testing The original first loaded data and time are maintained 4 If the fault code persists call bioM rieux Service Manual D 7 APPENDIX D ERROR CODES BacT ALERT 3D 60 D 8 99 Incomplete Test Data Cause A bottle is currently loaded in either e A cell that has been disabled or the rack in which the cell is located is disabled Anenabled cell that is not taking bottle reading
74. comments are shown in italics and do not actually appear on the diagnostic screen Patient Name Dictionary 17 AH3HID 18 AH4HID AH4FIRST AH4LAST HID to Acc Container 17 AH3HID AH3ACC 8895AFA 18 AH4HID AH4ACC 1 ACC to HID Dictionary 83 AH3ACC 8895AFA AH3HID 95 1 AH4HID ACC to BID Container 83 AH3ACC 8895AFA AH3BID1 95 AH4ACC 1 AH4BID1 relates a hospital ID to the patient name hash table index hosptial id first name last name relates hospital ID to accessions that share that hid ash table index id accession relates accession back to its hospital ID ash table index accession ospital id relates accession to bottle IDs that share that accession ash table index accession bottle id BarCodeDictionary relates bottle ID to bottle record key values from that record are displayed a 1003600 n 28 s 28 p 60 r 2 s P x 1 loc a address of bottle record 1A20 1d 1 n bottle record index 1 1920 5 bid AH3BID1 acc AH3ACC 8895AFA hid AH3HID pn a 1003800 n 29 s 29 p 61 r 3 s I x 1 loc 1 40 14 1 bid AH4BID1 acc AH4ACC 1 hid AH4HID pn AH4LAST AH4FIRST to ACC Container 3 AH3ACC AH3ACC 8895AFA 4 AH4ACC AH4ACC 1 PRELOAD ACC to RecNums Container 2 ACC 1 11 14 ACC43 6 PRELOAD BID to RecNum Dictionary 171 AH2BIDA 12 Service Manual bottle record sequence num p ha
75. door open condition motor rotation stops System design uses open switch position to indicate open door so that disconnected switch will also prevent motor operation LED 55 amp 56 are located on the ModSig PCBA The LED is on when a switch is closed e Start Stop signal The start stop signal will go high to indicate that the STEP 5 should run the agitation motor This signal generated by the ModSig PCBA goes high to enable agitation The input signal is optically isolated on the STEP 5 e Position Sensor A Hall Effect sensor is located at the edge of the Step 5 board and detects the magnet installed in the motor s drive wheel Both motor motion and drive wheel position tracking is performed in the Step 5 board Also when the door is opened the sensor is used to determine how long to drive the motor so that the racks become stationary in the correct position If the position sensor is not functioning a fault output will be generated If the position sensor is not working the STEP 5 will stop the motor when the door is opened but the position will be undefined 3 Outputs A Fault Code is sent to the ModSig PCBA if certain conditions occur The four conditions that initiate this code are e Motor over current e Door switch one door switch indicates open the other indicates closed e Position sensor not changing state e Safety timer not functioning doesn t go high after door opened Also See internal Output Codes Ser
76. fo Terminates the diagnostic exits this screen and returns to the Diagnostic Selection screen Display Output Area Navigation The buttons located just above and below the diagnostic output display area allow the user to scroll through the display data Scroll Anchor buttons a th Anchor display Scroll one line Scroll one page Goto Home or End Top Bottom Up Down Up Down Controls whether Moves display area Moves display area Positions display display stays one line at a time one page up or area to the first or anchored on the up or down down last line of the first or last line of diagnostic output the diagnostic Same function canbe Same function can Save function can output performed by pressing be performed by be performed by the or keys on pressing the pressing the the keyboard PAGE UP or HOME or END PAGE DOWN keys on the keys on the keyboard keyboard Fig 72 1 5 Inc Module 1 Temperature Log Scroll Anchor Buttons Service Manual 4 21 4 SERVICING SOFTWARE DIAGNOSTICS BacT ALERT 3D 60 Slide bar The raised section of the Slidebar indicates the position of the displayed data and is relative to the amount of total display data area The size of the raised portion of the Slide bar is proportional to the amount of display data in relationship to the total amount of data including scrollable data For example if there are 54 lines of total data and only 27 lines
77. its lowest position as shown here to align and install the Lock Screw in Hole 2 for MB Conversion _ MB Conversion Lock Screw Hole 2 Installed Location for MB Conversion NOTE Racks may have to be rocked slightly forward or backward in order to align the Lock Screw up with Hole 2 Fig 61 MB Conversion Lock Screw Installation Service Manual 4 7 4 SERVICING BacT ALERT 3D 60 THIS PAGE INTENTIONALLY LEFT BLANK 4 8 Service Manual BacT ALERT 3D 60 4 SERVICING 4 5 DATA BACKUP RESTORE PROCEDURES 4 5 1 BacT ALERT 3D 60 Data Backup Procedure 1 Refer to the BacT ALERT 3D 60 Operator s Manual and NOTE box below 2 Go to Setup screen 3 Enter password numbers lt 4 gt lt 3 gt lt 4 gt lt 3 gt lt 2 gt lt 1 gt lt 2 gt lt 1 gt 4 Click on the BACKUP MANAGEMENT Setup button Refer to Figure 62 Fig 62 Backup Management Button 5 Insert the backup disk into the Zip drive NOTE Only 250 Megabyte zip disks should be used as the backup media 6 Click on the Start Backup button same as the Backup button graphic above but with an exclamation mark to the left of the right arrow symbol 7 Note the flashing backup icon that appears on the screen When this icon disappears backup is complete Total backup time is approximately 20 minutes 8 Click on the Cancel button Refer to Figure 63 X Fig 63 Cancel Button 9 Click on the Previous
78. peripheral devices 6 Power up the 3D 60 instrument Initialization Initialization of the 3D 60 instrument is essentially nothing more than observing that the instrument powers up the system software boots the unit and the Display Monitor displays the Main Screen 3 17 3 INSTALLATION PROCEDURES BacT ALERT 3D 60 BacT ALERT 3D 60 Installation Checklist SITE NAME CITY STATE 1 Site Requirements are met 2 Unpack and Verify Contents Restraint Installation if required 4 Power Configuration 5 External UPS 6 Instrument Placement 7 Configure Instrument 8 Temperature Calibration 9 Modem Function Validation 10 Barcode Reader Validation 11 UPS Function Validation SERIAL SERVICE CALL Pass 12 Record Software Revision and Annotate Logbooks Initials The following table shows items that may be connected to the instrument as shipped or optionally installed parts UPS Domestic or International Monitor Flat Panel or CRT Printer Modem AC Adapter Must be installed with modem Modem Domestic or International Comments External Speaker Set Domestic or International Keyboard Barcode Scanner Mouse Must be installed with the instrument Must be installed with the instrument 3 18 This form may be copied for field use Fig 57 Installation Checklist Service Manual BacT ALERT 3D 60 CHAPTER 4 SERVICING CHAPTER 4
79. position Refer to Figure 99 for screw removal locations 3 Remove 3D 60 Instrument s Right Side Panel and set the panel aside Service Manual 4 143 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 22 Blower Motor Capacitor P N 601 0001 02 Continued Unplug BHP1 i Connector System Power Supply Assembly r LI a A Fig 170 Power Supply Panel BHP1 Connector Fig 171 Power Supply Panel HBJ1 HBP1 Connector 4 Unplug the HBP1 HBJ1 connectors from each other Refer to Figure 171 5 Unplug BHP1 wiring connector coming from the Electronics Compartment to the System Power Supply Assembly Refer to Figure 170 and 171 4 144 Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 22 Blower Motor Capacitor P N 601 0001 02 Continued Remove two 2 Power Supply mounting screws after the Right Side Panel is removed Fig 172 Power Supply Panel Mounting Screw Removal 6 Remove the two 2 screws from the system chassis in the rear of the instrument in order to remove the System Power Supply Assembly Refer to Figure 172 7 Power Supply Assembly up and out of the 3D 60 instrument You may have to push the Top Panel beyond the normal locked position of the Gas Spring Assembly in order to clear the System Power Supply Assembly from the 3D 60 instrument Service Manual 4 145 4 SER
80. screen appears and the display area is scrolled to the first instance of that text The text is highlighted in white iu BacT ALERT 3D SelectLink 14 45 37 04 23 01 1 5 Inc Module 1 Temperature Log ESL IS 19 40 45 1821 40 RCK TEMP s1 36 45 s2 36 46 ofs 8 56 19 44 27 DRH OPEN 19 45 45 DRH CLOS 19 45 45 1 MOD TEMP 37 28 out 36 85 avg 37 86 1B41 60 RCK TEMP 51 36 37 s2 36 28 ofs 8 74 1 1 HOD TEMP in 36 88 out 37 25 37 02 1C801 20 TEMP 51 36 28 52 36 29 ofs 8 78 1 1 MOD TEMP 36 84 out 37 22 avg 37 83 1C21 40 TEMP 515 36 42 52 36 41 ofs 8 62 in 36 84 out 37 28 avg 37 62 1c41 68 51 36 46 52 36 43 ofs 8 58 1n n 20 04 81 20 03 33 1A 28 04 81 20 03 38 1A as 28 04 01 20 04 21 1A 28 04 81 20 84 43 1R Press F3 on your 28 84 81 26 65 45 1 n 26764761 26 65 45 1001 20 H keyboard to search 28 84 81 28 18 45 1 ln i 28 84 81 28 18 45 1021 40 for the next Instance 28784781 28 15 45 1 3 28 84 81 28 15 45 1041 60 RCK TEMP s1 36 21 52 36 22 ofs 8 82 28 84 81 26 26 26 1B DRH OPEN 20 84 81 28 28 24 DRH CLOS 28 84 81 26 26 25 DRH OPEN 26 26 42 DRH CLOS Fig 70 1 5 Inc Module 1 Temperature Log Text String Output To find the additional instances of the search text press the F3 function key on your keyboard When the last instance is reached searching automatically wraps back to the first instance of the text search Save output to ZIP This function save
81. tee dr pug 2 3 2 19 Equipment Characteristics See Operating Reference Data Equipment Description serene 1 3 Error Codes Event Request Signal Excitation BEDS onere n a d at ai Exciter sso onere n EROR External Speaker Port sss Facility Power Rating and Conversion Chart 3 8 e er ie 1 7 4 138 4 139 Fan Assembly ttt tete 1 6 Fast Page See Memory Fault Codes See Quick Reference Card Fax Modem sss 1 19 See Fax Modem a aa ARE International Port Connection Field Eng Password Five phase Stepper Motor sse 2 25 Elag CHECK eese c ii c t ta lu seb 4 30 4 70 Flash eee a da ceea ia ta 1 13 3 17 PUN SEMI pei ea ia ede SERERE a Fuse Holder Fuse Replacement Warning Fuse Types neo coace no oi Gas Spring Assembly sss 4 157 TUS tra TOM seis ettet eee 4 156 General Information eese 1 1 ese fete ee eh xxvi Grounding Strap eee xxvii Hall Effect Sensor nene nenea nene Hazardous Voltages Health Risks Due Service Manual BacT ALERT 3D 60 Image NOTES sn ei espace pa oa do bona ca a az See Typography Incubator Chamber
82. the PCBA before securing the PCBA to the support standoffs with screws Refer to Figure 102 12 Ensure that P7 wire is routed outside the CompactFlash PCBA and perpendicular to the connector before securing the PCBA to the support standoffs with screws Refer to NOTE above Cables do not route underneath the CompactFlash PCBA 13 Align the new CPU PCBA to the support standoffs and install six 6 screws Refer back to Figure 101 Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 2 CPU PCBA Assembly P N 750 0070 01 Continued CPU PCBA Quad Serial PCBA Removed from the CPU PCBA Fig 103 Quad Serial PCBA Removed from CPU PCBA 14 Plug Quad Serial PCBA into the CPU PCBA Ensure the pins on the CPU PCBA are aligned to the female connector on the Quad Serial PCBA as to not bend them or offset them 15 Install the two 2 screws securing the Quad Serial PCBA to the CPU PCBA Refer to Figure 100 16 Plug all cables back in that were unplugged in Step 9 on page 4 82 of this section Go back and refer to Step 9 for identification of each cable Refer to Figure 104 and Figure 105 for the proper cable connections Service Manual 4 85 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 2 CPU PCBA Assembly P N 750 0070 01 Continued NOTE Ensure that you know the location of the connector that each cable plugs in to so that each one can be reconnect
83. the rear of the instrument in order to secure the System Power Supply Assembly Refer to Figure 172 Plug HBP1 HBJ1 connectors back into each other Refer to Figure 171 Plug BHP1 back into BHJ1 Refer to Figure 170 and 171 Service Manual BacT ALERT 3D 60 4 10 22 Service Manual 4 SERVICING REMOVE AND REPLACE PROCEDURES Blower Motor Capacitor P N 601 0001 02 Continued 17 18 19 20 21 22 Reinstall the Left Side Panel on the instrument Prior to installing the panel use cardstock to cover the foam gasket around the door in front of the instrument to prevent damage to the foam Remove the cardstock after the Right Side Panel is reinstalled Close the System Top Panel and secure it with two 2 screws Refer to Figure 99 Refer to Subsection 4 3 3 and perform the 3D 60 Power Up procedure Refer to Subsection 4 11 and perform the Post Service Validation procedure Annotate the appropriate maintenance and lab logbooks Return the system to normal operation 4 147 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 23 Digital Reference Thermometer P N 848 0004 01 Fig 174 Reference Thermometer 1 Open the door on the 3D 60 instrument 2 Note that the digital thermometer is installed on the top left side Refer to Figure 174 NOTE Steps for removal of digital reference thermometer are not available at the time of publication of this manual Service bulletin will
84. to a bottle Bottles with fault are flagged positive and bottle readings are not processed while the fault is present Solution Perform the following procedure 1 Click the Unload Positive Bottlesbutton and unload the affected bottles 2 Subculture the bottle 3 Reload the bottle via the Load Bottle function on the Main screen The original first loaded data and time are maintained 4 If the fault code persists call bioM rieux Service Manual BacT ALERT 3D 60 APPENDIX D ERROR CODES 75 Bottle Data Corrupted Cause The data integrity check has found corrupted bottle data Bottles with fault are flagged positive and bottle readings are not processed while the fault is present Solution Perform the following procedure 1 Click the Unload Positive Bottle button and unload the affected bottle 2 Subculture the bottle 3 Reload the bottle via the Load Bottle function on the Main screen to begin testing of bottle 4 The original first loaded data and time is replaced with the data and time the bottle is reloaded The maximum test time is set to the default associated with the bottle type If desired the bottle s maximum test time may be shortened so that the bottle will complete testing when expected 7 If the fault code persists call bioM rieux 77 Reading Polynomial Change Cause An incorrect bottle type has been previously assigned to a bottle Bottles with fault are flagged positive and
85. 0 respectively when the corresponding end of the rectangle is touched An independent NIST traceable temperature monitoring device A button that becomes active appears to be clicked after the corresponding screen area is clicked and continues to be active until it is clicked again Icon that is used to select a numerical value of 0 to 9 More than one button is available for larger numbers UPS An An acronym for Uninteruptable Power Supply for Uninteruptable Power An acronym for Uninteruptable Power Supply Prepares video signals used on the operator s screen Contains logic for the Backlight Inverter on the Touch Screen Interface between Video Buffer and the Interface between Video Buffer andthe operator s sereen s screen Identifies actions that can result in injury or death to performing procedure or persons that may be nearby From the lab technician s perspective this is another name for a bottle graph For the field engineer it could mean either the same as above or more commonly the picture presentation on an oscilloscope display Disk drive within the Combination Module providing for a means of loading software A 5 APPENDIX A GLOSSARY BacT ALERT 3D 60 THIS PAGE INTENTIONALLY LEFT BLANK A 6 Service Manual BacT ALERT 3D 60 APPENDIX B PARTS LISTING APPENDIX B PARTS LISTING Parts in this list are either spares or shipped separ
86. 0 Connect the Display Monitor s power cord into one of the Surge and Battery Backup Outlets Refer to Figure 207 11 Connect the Printer s power cord into one of the Surge Protection Outlets Refer to Figure 207 4 172 Service Manual BacT ALERT 3D 60 4 10 33 Service Manual 4 SERVICING REMOVE AND REPLACE PROCEDURES APC UPS International Model P N 957 0060 03 Continued 16 17 18 Plug the UPS cable into the Computer Interface Port on the UPS and connect the opposite end cable into the UPS Port on the rear of the 3D 60 Instrument Plug the UPS into a facility AC receptacle rated for 240V and press the UPS power switch to ON The Power ON light will illuminate on the switch Turn on the Printer and Display Monitor Turn the 3D 60 to ON from the PEM s power switch on the rear of the instrument and wait for proper power up initialization and Main Screen to display on the monitor Refer to Subsection 4 11 and perform the Post Service Validation procedure Annotate appropriate maintenance and logbooks Return the system to normal operation 4 173 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 THIS PAGE INTENTIONALLY LEFT BLANK 4 174 Service Manual BacT ALERT 3D 60 4 SERVICING POST SERVICE VALIDATION 4 11 POST SERVICE VALIDATION This chapter describes the equipment quality control procedures to be performed subsequent to maintenance operations 4 11 1 Overview Thi
87. 00 0x4000 0x4000 0x4000 0x4000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x2000 0x2000 0x2000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 Display BACT ALERT FN Display BACT ALERT PF Display BACT ALERT LYM Display BACT ALERT MP Display BACT ALERT MB BacT ALERT 3D 60 Service Manual BacT ALERT 3D 60 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass LES Glass Service Manual 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 0x6000 4 SERVICING SOFTWARE DIAGNOSTICS 4 59 4 SERVICING SOFTWARE DIAGNOSTICS BacT ALERT 3D 60 7 Configuration tables Displays the configuration settings that are used to determine the 3D s operation All configuration settings are shown regardless of whether the value was read from one of the INI file
88. 067 0 3 0 10 5 11 68 068 068 0 3 0 10 5 11 69 069 069 0 3 0 10 5 11 70 070 070 0 3 0 10 5 11 71 071 071 0 3 0 10 5 11 72 072 072 0 3 0 10 5 11 73 Q73 Q73 0 3 0 10 5 11 74 Q74 Q74 0 3 0 10 5 11 75 975 075 0 3 0 10 5 11 76 Q76 Q76 0 3 0 10 5 11 77 Q77 Q77 0 3 0 10 5 11 78 Q78 Q78 0 3 0 10 5 11 79 079 079 0 3 0 10 5 11 Type Name UTT Disp Drw Cnt Disk LES Glass LES Plas 80 080 080 0 3 0 10 5 11 81 081 081 0 3 0 10 5 11 82 082 082 0 3 0 10 5 11 83 083 083 0 3 0 10 5 11 84 084 084 0 3 0 10 5 11 85 085 085 0 3 0 10 5 11 86 Q86 Q86 0 3 O 10 5 11 87 087 087 0 3 0 10 5 11 88 088 088 0 3 0 10 5 11 89 089 089 0 3 0 10 5 11 90 090 090 0 3 0 10 5 11 91 Q91 Q91 0 3 0 10 5 11 92 Q92 Q92 0 3 0 10 5 11 93 093 093 0 3 0 10 5 11 94 Q94 Q94 0 3 0 10 5 11 95 Q95 Q95 0 3 0 10 5 11 96 096 096 0 3 0 10 5 11 97 Q97 Q97 0 3 0 10 5 11 98 Q98 Q98 0 3 0 10 5 11 99 999 099 0 3 0 10 5 11 necs Algorithm Parameter Tables 100 entries 0 ID H2 BltFact 0 1E1 Resv 1320 AdjThres 70 AdjLim 4 StupPts 5 StupSumx 15 StupDenom 50 FastPts 17 FastSumx 153 FastDenom 6936 InitThres 3300 FastStupThres 6 SlopStupThres 0 1E1 FastCntrThres 12 FastBcktThres 0 105E2 FastBcktInc 1 FastRateT
89. 1 4 84 22 4 44 44 44441010 71 1 5 Inc Module 1 Temperature Log Save Output to 21 72 1 5 Inc Module 1 Temperature Log Scroll Anchor Buttons 73 1 5 Inc Module 1 Temperature Log Slide 74 1 1 Inc Module 1 Loopback Test SCreenn sssscsssssssessesesseeesseseesssesseseseeesnseeeasenseseseeneneeenenseeseeeeseneenaneneee 75 1 2 Inc Module 1 Port Stats Test Screen 76 1 3 Inc Module 1 Message Stats Test 77 1 4 Inc Module 1 Message Log Test Screen 78 1 5 Inc Module 1 Temperature Log Test Screen 79 1 6 Inc Module 1 Reading Log Test 80 1 7 Inc Module 1 Flag Check Screen 81 1 7 Inc Module 1 Flag Check Test Screen 82 1 7 Inc Module 1 Flag Check Calibration Screen 83 1 8 Inc Module 1 Heater Screen eee aare roa aa Enn eaaa 84 1 9 Inc Module 1 LED Check eee sensns kK AA AA KAR KARAR AKAR sos ARK AK KAK AK KAK KAK KAR AA KARAR KAK AK KAR RR 85 1 9 Inc Module 1 LED Check Walking 86 7 1 Instrument Cntrl ZIP Drive Test Screen 87 7 2 Instrument Cntrl Barcode Loopback Test 88 7 4 Instrument Cntrl Power Event Log Screen
90. 1 4 2 10 1 4 2 11 1 4 2 12 Service Manual Communications Ports Input Output Continued The communications ports are input output ports that peripheral devices connect to on the rear of the BacT ALERT 3D 60 instrument Refer to Figure 10 COMM Port This port is reserved for future use Printer Port A printer connects to this port via a parallel cable and produces hard copy reports Internal Speaker w external Speaker Jack The system has a remote speaker feature with a 5mm external mini jack to drive two remote stereo speakers from a distance of up to 450 feet see Remote Speakers P N 880 0002 01 and 02 along with 100 ft of speaker wiring P N 957 0004 350 Power Entry Module PEM ON OFF Switch The PEM contains the fuse protection for the unit when connected to main facility AC power The PEM also houses the main power switch for the instrument Modem Port Used to connect the BacT 3D 60 to an external modem LIS Port This port is used for connection to the facility s LIS system Monitor Port This port is used for connection to an external VGA or SVGA monitor UPS Port Used to connect an external UPS to the instrument UPS Serial Port Reserved for future use Mouse Port Used for connecting the mouse to the instrument Keyboard Port A port for connecting the keyboard to the instrument Barcode Scanner Port Port for connecting the barcode scanning wand to the instrument 1 GENERAL INFORMATION B
91. 10 12 18 OxS IMFIt 1 0 99000 1 139813764 07 06 01 10 19 48 OxS IMFIt 1 051000 Service Manual 4 41 4 SERVICING SOFTWARE DIAGNOSTICS BacT ALERT 3D 60 Each line in an event log has the same format as follows 127829789 18 01 01 13 24 00 0 38 82349 seconds dd mm yy hh mm ss event info 4 42 Service Manual BacT ALERT 3D 60 4 SERVICING SOFTWARE DIAGNOSTICS The event info content varies depending on the kind of event and is described below Software exception Exception details Ox1 SWExc LOG TEST MAIN This event occurs if there is a condition for example a hardware problem that the software cannot handle or there is a design flaw in the software that results in a condition that cannot be handled Report this information to the 3D software development team Incubation module fault Module Module Drawer A Drawer B Drawer C Drawer D Number Fault code a code code ateos code Ox3 IMFIt 3 0 This information corresponds to information displayed on TUAE Main ee s incubation pictorial ECTS PSST fault code of 0 means there is no fault in the chamber See Operator s Manual or Quick Reference card for the meaning of non zero fault codes Instrument Controller Fault fault Code OxAICFi This information corresponds to information displayed on the Main Screen s instrument controller pictorial A fault code of 0 means there is no fault See Operator s Manual or Q
92. 140 Text BORES hes eT RR ERES xxi Text Within Quotation Marks esses xxii Thermistor PCBA sese 1 10 1 11 2 7 e RR 2 6 Thermometer See Digital Reference Thermometer time delay Fuse ettet erem 4 137 TimeStamp Faults Recovering 4 67 Tools and Equipment see 4 3 Top Panel Screw Locations sess 4 81 Torque Specs eese RUD Pes 4 154 Transferring SIMM Memory see 4 83 Transformer 1 4 1 5 See Power Supply Transformer RR RR ter ta xxi xxii Service Manual Underlined Text imet ees xxi UPS Battery Backup Outlet 4 167 4 172 Battery Cover Re moval eee 4 170 Battery Terminal Connectioa 4 166 Computer Interface Port Domestic Model Installati n etti International Overload 2 We kise terere Port Connection sd 2 kek Ken Serial Cable Connection Setup and Connections 3 9 Surge 4 167 4 172 UPS Peripheral 4 167 UPS Port 1 8 UPS Serial Cable 1 21 UPS Test 3 13 UPS Test Switch
93. 16C74 source current to turn them on On power up the port pins of the 16C74 initialize inputs with no pull ups This prevents cross conduction between the high and low side MOSFETS In addition as part of firmware initialization the PLD that controls the low side drivers does not enable any outputs until PD7 is driven high Power down protection The configuration bits for the 16F74 will enable the brownout protection that resets the microcontroller if the supply drops below approximately 4V Crossover Protection While running the STEP 5 uses a stepping sequence that never switches a motor phase from high to low or low to high motor phases go through a step where the phase is off neither the high or low side driver is on between high and low transitions If this sequence is changed for instance if the board is ever used to drive a 4 phase stepper then crossover protection will need to be added to the firmware Temperature sensor The printed circuit board and schematic provide for a temperature sensor This part is not installed in the current version of the board Firmware Firmware is developed in Microchip PIC assembly language Firmware performs the following functions e Debounce interlock switches e motor driver transistors on and off to generate motor drive waveform e Ramp motor up and down e Control motor current during ramp up and ramp down using PWM duty cycle e Track position of motor using position s
94. 2 1855 1 72 1A57 1 2 22 1B 3 1 17 1B 7 1 02 1 9 1 1 18154 1 82 1B16 1 22 1B17 1 7 1 0 1B25 1 62 1B27 1 02 1829 2 3 1B3 1B38 2 27 1B39 2 18404 1 72 1B43 1 82 1848 lt 1B56C 1 32 1B58 1 1B59 1 72 1C83C 1 8 1 12 1C25 1 1043 1 12 1C46 1 12 1 56 1 3 32 10176 1 12 Cell location diff 10554 1 22 1R13C 3 12 4 2 12 1 82 1B17 1 1B38 2 22 1B39 2 07 1R13 3 12 1A14 2 12 1B19 2 32 1B29 2 32 4 SERVICING SOFTWARE DIAGNOSTICS 1 7 Inc Hodule 1 Flag Check 1A15 1B19 1840 1952 lt 1825 lt 1848 1 82 1855 1 72 1 62 1B29 2 32 1 74 1B59 1 72 72 N e FER C I N 1B38 2 27 1B39 2 07 1 Diff Z 2 Details C Calibrate Fig 81 1 7 Inc Module 1 Flag Check Test Screen BacT AL 16 41 22 04 23 81 ERT 3D SelectLink 1 7 Inc Module 1 Flag Check 238342 gt 30000 0000000000 0000000000 0000000000 0000000000 0000000000 C Calibrate 1 Diff Z 2 Details Fig 82 1 7 Inc Module 1 Flag Check Calibration Screen To restart the diagnostic and gather new readings press and reenter it Service Manual r the button Or exit the diagnostic 4 31 4 SERVICING SOFTWARE DIAGNOSTICS BacT ALERT 3D 60 1 8 Inc Module 1 Incubation Heater Screen Special equipment None Desc
95. 2 CPU PCBA Assembly P N 750 0070 01 Continued Remove 6 standoff 4 support Screws z kt s Lr 1 WU i 4 RP 4 Remove SIM Memory and install in new CPU PCBA Fig 101 CPU PCBA Screw Removal 9 Remove six 6 screws securing the CPU PCBA to the support standoffs Refer to Figure 101 CAUTION Hold on to the screws as you remove them from the CPU PCBA Screws can fall underneath the ModSig PCBA and may require removal of the ModSig board to recover them 10 Transfer the SIMM memory plugged into the SIM1 connector from the defective CPU board into the new CPU PCBA being installed Service Manual 4 83 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 2 4 84 CPU PCBA Assembly P N 750 0070 01 Continued P27 and P7 Wiring Route cables as shown before installing new CPU PCBA They must be routed under the PCBA Power cable blue black wires routes outside and to the right hand side of the CPU PCBA when installed Fig 102 CPU PCBA J27 and J7 Cable Routing NOTE P27 wire must be routed inside the left standoff before installing the new CPU PCBA Do not overtighten standoff support screws when reinstalling the CPU board WinJ3 cable goes underneath the CPU PCBA before securing the PCBA with screws P7 blue black power cable goes to the right and outside of the CompactFlash Adapter PCBA 11 Ensure that P27 wire is routed inside the left standoff and under
96. 2 avg 35 88 1 35 55 52 35 49 ofs 8 36 in 35 74 out 36 88 avg 35 87 1081 28 RCK 51 35 49 52 35 40 ofs 8 43 1 in 35 74 out 35 96 avg 35 85 ModSig entry shows 1021 40 RCK s1 35 68 s2 35 52 ofs 8 29 16 17 34 1 1 in 35 75 out 36 82 avg 35 88 heater inlet and outlet 16 17 34 1041 68 51 35 27 s2 35 25 ofs 8 62 sensor readings along 16 22 34 1 1 TEHP in 35 74 out 35 97 avg 35 85 Time of event in dd mm yy hh mm ss format Event location 1C41 68 1 with average of those 16 22 34 1981 20 TEMP 51 35 68 52 35 54 ofs 8 28 16 27 34 1 1 TEMP in 35 74 out 35 97 avg 35 85 readings 16 27 34 1921 40 TEMP 51 35 58 52 35 48 ofs 8 32 16 32 34 1 TEMP 35 74 out 36 82 avg 35 88 16 32 34 1941 68 51 35 52 s2 35 53 ofs 8 36 23 84 81 16 35 03 1 1 tmp 37 88 ofs 1 13 This entry indicates that a temperature calibration or temperature setpoint change Rack temperature entry shows readings of the two sensors on a rack occurred Fig 78 1 5 Inc Module 1 Temperature Log Test Screen Door open DOOR OPEN and Close DOOR CLOS events are also displayed but not shown in the example above MOD TEMP events are logged every 5 minutes RCK TEMP events are logged once an hour with a 5 minute interval between racks i e rack1 at time 0 rack 1 at 5 min rack 2 at 10 min and so on DOOR OPEN and DOOR CLOS ev
97. 4 BacT ALERT 3D 22 Service Manual E LE X bioMerieux Inc Box 15969 Durham NC 27704 0969 http www biomerieux com BIOMERIEUX 2002 Manual Part Number 48001 6 Rev A March 2003 BacT ALERT 3D 60 All Rights Reserved Worldwide Printed in the United States of America No part of this publication may be used or reproduced in any form electronic or written via database or retrieval system without the prior written permission of bioM rieux Documenting copies of any part of this publication for any purpose other than for which has been authorized in advance is in strict violation of United States copyright laws BioM rieux Inc PO Box 15969 Durham NC 27704 0969 USA ASTM is a trademark of American Society for Testing and Materials Bac T ALERT BacT LINK BacT VIEW and MB are registered trademarks of bioM rieux in the USA and other countries MS DOS is a registered trademark of Microsoft Corporation Zip is a registered trademark of lomega Corporation The logo is a registered and protected trademark of bioM rieux Inc or one of its subsidiaries Distribution in over 130 countries Service Manual BacT ALERT 3D 60 This document will be updated for each software modification or any other change Information supplied in this document is subject to modification before the products described become available This document may contain information or references concerning certain bioM rieux products
98. 4 TYPOGRAPHY AND GRAPHIC CONVENTIONS eere eren XIX 0 4 1 0 4 2 Text BOXeS e ead ld eid ed 0 4 3 Bracketed lt alicS ord ror ED t ou dade bite a a aa xxi 0 4 4 Lc xxi 0 4 5 Bracketed TOX i taie n tepore b iod xxii 0 4 6 Text Within Quotation xxii 0 4 7 Italicized Whether Bold or Not Hee xxii Service Manual xix TYPOGRAPHY AND GRAPHICS CONVENTIONS BacT ALERT 3D 60 THIS PAGE INTENTIONALLY LEFT BLANK XX Service Manual BacT ALERT 3D 60 0 4 1 0 4 2 TYPOGRAPHY AND GRAPHIC CONVENTIONS Bullets Bullets are used to designate items in a list e or steps in a procedure 1 2 etc Text Boxes Important Steps A text box can be aNOTE CAUTION WARNING or Image Note 0 4 3 0 4 4 Service Manual Fig 1 Text Box Whenever text is contained within a box Reference Figure 1 it identifies things that require special attention There are three different text boxes used within this manual NOTES Used to clarify or explain a particular step These text boxes are identified by the word NOTE bold and all caps centered at the top of the box and normal text following CAUTIONS Used to identify actions that could cause DAMAGE to the instrument or test equipment These text boxes are identified by the word CAUTION bold and all caps centered at the top of the box and bold t
99. 418 1 4 153 Gas Spring Assembly P N 926 0037 01 4 156 Magnetic Door Switches P N 841 0012 01 4 158 Keyboard P N 957 0004 373 sic tote t ia i cee 4 160 Barcode Scanner P N 957 0004 291 4 161 Domestic 56K Fax Modem P N 957 0004 342 4 162 International Fax Modem P N 957 0004 364 4 163 APC Back UPS Model 650 Domestic Model P N 957 0060 02 4 164 APC UPS International Model P N 957 0060 03 4 169 Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 2 CPU PCBA Assembly P N 750 0070 01 1 Perform the following steps a Lookatthe Main Screen on the instrument controller icon and write down the following information e Software version e Bottle counts b Make a backup Refer to Section 4 5 Data Backup Restore Procedures Exit the BTA 3D 60 software by pressing the lt ESC gt key and typing Y E S d Write down the CMOS date and time This can be accomplished by rebooting the instrument While it is powering up press the Delete key to enter the CMOS setup menu e Write down the local time 2 Open the door on the 3D
100. 5 Motor out and to the right as shown in Figure 134 Remove the motor mounting plate from the motor by removing the four 4 nuts and washers that secure it to the plate Install new Step 5 Motor on the motor mounting plate and secure the four 4 mounting nuts with washers Reinstall the motor and align it with the motor mounting screw holes Tighten the mounting screws in an X pattern starting with the upper left screw the lower right screw next then the upper right and finally the lower left Ensure all screws have been tightened Service Manual Fig 135 Step 5 Motor Removal Reinstalling Mounting Screws Push the four 4 motor mounting screws up to the pressed nuts and begin tightening Do not tighten them all the way Begin tightening the mounting screws in an X pattern until all screws are tightened Refer to Figure 135 above Reinstall the Motor Offset Round with proper orientation to Motor Shaft flats Support the opposite end of the Motor when pushing the Round on the Motor Shaft to prevent pushing the isolation grommets from their locations in the chassis holes Reinstall the two 2 Set screws Ensure that they are installed in the proper locations 90 apart and that the Motor Offset Round and Drive Agitation Linkage are in the right position Refer to Figure 132 Replace the instrument s Left Side Panel Place a piece of heavy paper or cardstock over the foam gasket material in the front of the instrume
101. 523 ClusterSector 523 EOCMark gt OxFFF8 BADSectorMark OxFFF7 Cluster 2 sector 523 4 SERVICING SOFTWARE DIAGNOSTICS e e e e kx kx kx ee e He e He He e He He e He e He e e e he He He ke ke ke ke e e e ke e ke e k ke k k k k e k kkk kk ee e e e Fe He He e He He He He He He He e He e He e e ke e ke e ke ke e e k k k k k k k k x SCANDISK C Time 10 12 01 09 14 28 File IO SYS File MSDOS SYS Directory DOS File COMMAND COM File AUTOEXEC BAT File CONFIG SYS File PME16 EXE File BTA3D INI Total Entries 7 Deleted Entries 0 Directories 1 Cluster count 1 Traverse subdirectory DOS Directory Directory File ATTRIB EXE File CHKDSK EXE File COUNTRY SYS Total Entries 5 Deleted Entries 0 Directories 2 Cluster count 1 Check file IO SYS Check file MSDOS SYS Check file COMMAND COM Check file AUTOEXEC BAT Check file CONFIG SYS Check file PME16 EXE Traverse subdirectory DOS Check file ATTRIB EXE Check file CHKDSK EXE Check file COUNTRY SYS Check free space for clusters 2 to 62454 kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk SCANDISK PASSED for drive C Time 10 12 01 09 14 29 ee e e ke e e He Fe He He He He He He He He e He He e He He He He e He e ke e e He ke e ke e ke ke k ke k k k k k k k k k e e e e e He He He e He He He e He e He He He He He He He e He e He He He He He e He He e He ke He ke e ke ke ke ke k k k k k k k k k Service Manual 4 63 4 SE
102. 6 17 MinSkipPts 6 ID G3 BltFact 0 231E1 Resv 1320 MinSkipPts 216 MinAvgPts 24 MinAvgMed 1 SlopProp 0 1E0 SlowSlopProp 0 2E 1 FastDgdr 0 75E0 SlowDgdr 0 9E0 AcelSlopThres 20 SlowSlopThres 10 PosDlyThres 1 DltThres 100 NumAlg3Pts 576 PosSlopDly 720 DltDgdr 0 995E0 Embedded H2 Parms ID H2 BltFact 0 231E1 1320 AdjThres 70 AdjLim 4 StupPts 5 StupSumx 15 StupDenom 50 FastPts 17 FastSumx 153 FastDenom 6936 InitThres 8300 FastStupThres 6 SlopStupThres 0 1E1 FastCntrThres 12 FastBcktThres 0 105E2 FastBcktInc 1 FastRateThres 32 FastRateInc 3 FastDgdr 0 93E0 FastSlopProp 0 825E0 FastMayThres 3 SlowStupThres 12 SlowCntrThres 16 SlowBcktThres 15 SlowBcktInc 1 SlowDgdr 0 98E0 SlowSlopProp 0 9083E0 MinSkipPts 6 ID G3 BltFact 0 231E1 Resv 1320 MinSkipPts 216 MinAvgPts 24 MinAvgMed 1 SlopProp 0 1E0 SlowSlopProp 0 2E 1 FastDgdr 0 75E0 SlowDgdr 0 9E0 AcelSlopThres 20 SlowSlopThres 10 PosDlyThres 1 Dlt Thres 32767 NumAlg3Pts 576 PosSlopDly 720 DltDgdr 1 0E 32 Embedded H2 Parms ID H2 BltFact 0 231E1 Resv 1320 AdjThres 70 AdjLim 4 StupPts 5 StupSumx 15 StupDenom 50 FastPts 17 FastSumx 153 FastDenom 6936 InitThres 8300 FastStupThres 6 SlopStupThres 0 1 1 FastCntrThres 12 FastBcktThres 0 105E2 FastBcktInc 1 FastRateThres 32 FastRateInc 3 FastDgdr 0 93E0 FastSlopProp 0 825E0 FastMayThr
103. 60 2 6 CPU PCBA cI rl III o 5 U1 LITHIUM KEEPER li us ela LTC 3PN Wn nan ella MM a U22 VLLL TT TIT TI TT TT TI U25 U26 Fig 37 CPU PCBA Diagram 2 12 Service Manual BacT ALERT 3D 60 2 BACKGROUND INFORMATION 2 6 CPU PCBA CONTINUED The CPU PCBA Reference Figure 37 is an off the shelf internally mounted WinSystems computer that combines a 586 or higher CPU with Video Floppy IDE Serial and Digital The chipset provides the core logic that makes the board PC AT software compatible It includes the DRAM controller bus interface integrated peripheral controllers 8237 DMA 82C54 timer 82C59 PIC RTC KYBD controller and CMOS memory and an internal PCI bus for high speed operation Up to 32 MB of memory can be populated on board with a 72 pin SIMM The BIOS can detect and automatically support either Fast Page or EDO memory modules Seven DMA channels are supported with Channel 2 dedicated to the floppy disk controller The LPT is jumper selectable for ECP operation The other DMA channels are wired to the PC 104 connector An onboard 256KB x 16 DRAM provides 512KB of video memory Service Manual 2 13 2 BACKGROUND INFORM ATION BacT ALERT 3D 60 2 7 COMPACTFLASH ADAPTER PCBA Fig 38 CompactFlash Adapter P
104. 60 Power Down procedure 2 Remove the two 2 screws securing the Top Panel and secure it into the Up position Refer to Figure 99 for screw removal locations Brown geras Brown Isolation Transformer Terminal Strip das Blue TBI 1B a OS ak w AOO CO ONO Fig 151 Power Supply Simplified Schematic Fig 152 Term Board 1 TB1 3 Remove the instrument s Right Side Panel to access the Power Panel Assembly 4 Remove the bolt that secures the Transformer to the Power Supply Assembly chassis Refer to Figure 149 5 Pull the transformer out of the instrument far enough to easily access the Terminal Board TB1 Disconnection of Transformer wires is not necessary 4 128 Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 15 Service Manual Power Supply MOV Metal Oxide Varistor P N 43116 2 Continued 6 With a short Phillips screwdriver remove the screws from TB1 2B and TB1 3B terminals and remove the MOV 7 Install the new MOV and secure the terminal screws and wires back on to 1 2 and TB1 3B Refer to Figure 151 and Figure 152 8 Align the Transformer back on the chassis and secure it with its mounting bolt Refer to Figure 149 9 Reinstall the Right Side Panel of the 3D 60 instrument 10 Close the Top Panel and install the two 2 screws that secure it Refer to Figure 99 11 Refer to Subsection 4 3 3 and perform the 3D 60 Pow
105. 69 Association Tables Audible Alarm Audio Frequency 2n di12 ye dll n ne ene Eni i Selection Chart esce reete Background Information eene 2 1 BacT 3D 60 Unpacking BacT 3D 60 Instrument Parts Bacteremia eoe eer Barcode Loopback Test sees Service Manual Barcode ARR EE RUNE Barcode Reader Functional Test Barcode Scanner 2 Port Connections nene caen nene cae cae ceea Battery Compartment Battery COVED sc sila e rer a ata cae BIOS CLOCK rtt ceteros Blocks Blower Assembly Blower Motor Capacitor see 4 143 Bracketed Italics seen xxi Bracketed Text Brass Bushing BTA3D Field Utilites 222 22 22 2 4 175 Bullets 1 Bushing Specs teet 4154 Buttons Backup Management Exit Legend Scroll Anchor Cable Clamp ce t e m 4 152 Cable Cover eorum See Rack Assembly Calibrate Temp See See Display Configuration Captive Screws AE EEEE eee See Rack Assembly CAUTION iis eret ette xxv See Typography Gell ene See Incubator Chamber Cell Calibration See Display Configuration Cell Calibration Screen 22020 4 72 Cell Differences 5 2 4 71 Cell Flag eerte See Incubator Chamber Cell Indicator Lamp e See Incubator Chamber Cell Indicator LEDS seen 2 19 Change Passwords
106. 7 1 INSTRUMENT CNTRL ZIP Drive Test Screen Special equipment This verifies that data can be written to and read from the ZIP drive Impact Bottle testing is not affected by this diagnostic Test Procedure Remove ZIP disk from ZIP drive and replace with known good ZIP disk Start diagnostic Let run for at least 2 minutes Verify that no FAIL counts are displayed Exit diagnostic Put the original ZIP disk back into ZIP drive Keyboard functions Press R to reset counts status Run continuously and updates the display continuously The ZIP drive test consist of the following steps a Clear the pass and fail counters b Open a file on the ZIP disk If the file can t be opened increment the open error counter line 2 1 Write garbage to the 7 1 Instrument Cntri Zip drive test file EREMO lt TT d Go back to the start of the file and write AIL count 8 the current date and time If an error is 9 generated while iud eM rre writing increment the write error counter line 2 3 e Go back to the start of the file and read the data If an error is generated while reading the data or the data does not match what was written increment the read error counter eme line 2 2 Fig 86 7 1 Instrument Cntrl Zip Drive Test Screen Close the file Repeat steps b thru f above until the diagnostic is terminated
107. 8 04 37 0x3 139719253 06 06 01 08 04 37 0 3 139719253 06 06 01 08 04 37 0x3 139719253 06 06 01 08 04 37 0x3 139719258 06 06 01 08 04 42 139719258 06 06 01 08 04 42 11 139719535 06 06 01 08 09 19 1 139721277 06 06 01 08 38 21 139721279 06 06 01 08 38 23 139721280 06 06 01 08 38 24 FILE EVENTO LOG 1 139809948 07 06 01 09 16 12 0x38 DTChg 4294948672 139809951 07 06 01 09 16 15 Ox4 ICFIt 0 139809951 07 06 01 09 16 15 Ox3 IMFIt 139809951 07 06 01 09 16 15 Ox3 IMFIt 139809951 07 06 01 09 16 15 0x3 IMFI 139809951 07 06 01 09 16 15 IMF 139809951 07 06 01 09 16 15 139809951 07 06 01 09 16 15 0 3 1 139809956 07 06 01 09 16 20 0x30 IMPwr 11 139809956 07 06 01 09 16 20 1139810161 07 06 01 09 19 45 11 139810363 07 06 01 09 23 07 0 3 2 0 0 74 0 0 139811149 07 06 01 09 36 13 Ox4 ICFIt 0 11 139812682 07 06 01 10 01 46 0x38 DTChg 4294948672 1139812694 07 06 01 10 01 58 139812695 07 06 01 10 01 59 139812695 139812695 07 06 01 10 01 59 0 3 139812695 07 06 01 10 01 59 Ox3 IMFIt 1 139812695 07 06 01 10 01 59 Ox3 IM Fit 139812695 07 06 01 10 01 59 0 3 139812700 07 06 01 10 02 04 0x30 IMPwr 07 06 01 10 01 59 139812700 07 06 01 10 02 04 0x30 IMPwr 139813009 07 06 01 10 07 13 OxS IMFIt 1 0 20000 139813053 07 06 01 10 07 57 0x3 IMFIt 1 00000 139813314 07 06 01
108. 848 0003 01 4 148 4 10 24 Rack Assembly P N 43147 921 922 923 4 149 4 10 25 Step 5 Drive Agitation Linkage Assembly P N 48418 1 4 153 4 10 26 Gas Spring Assembly P N 926 0037 01 4 156 4 10 27 Magnetic Door Switches P N 841 0012 01 4 158 4 10 28 Keyboard P N 957 0004 373 4 160 4 10 29 Barcode Scanner P N 957 0004 291 sse 4 161 4 10 30 Domestic 56K Fax Modem P N 957 0004 342 4 162 4 10 31 International Fax Modem P N 957 0004 364 4 163 4 10 32 APC Back UPS Model 650 Domestic Model P N 957 0060 02 4 164 4 10 33 APC UPS International Model P N 957 0060 03 4 169 POST SERVICE VALIDATION 55 7522 3227 552 v saver na xm noa co RYE kk Ak Ak AA KA KAKA HAAA KK AW AA A 4 175 4 11 1 GTI A 4 175 4 11 2 Required Materials 4 175 4 11 3 4 175 Service Manual vii TABLE OF CONTENTS BacT ALERT 3D 60 THIS PAGE INTENTIONALLY LEFT BLANK viii Service Manual BacT ALERT 3D 60 0 FRONT MATTER 0 1 APPENDICES Appendix A A
109. 957 0060 03 Option Switches N Computer Interface Port 240V Surge and Battery Backup Outlets Duo eo am Fig 201 3D 60 System Rear Communications Ports UPS Cable Connection 1 Refer to Subsection 4 3 2 and perform the 3D 60 Power Down procedure 2 Unplug the UPS cable from the UPS Port on the rear of 60 Instrument and the opposite end of the cable from the Computer Interface Port on the defective UPS Set the UPS aside Refer to Figures 200 and 201 Service Manual 4 169 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 11 33 APC UPS International Model P N 957 0060 03 Continued Set the UPS flat on a work surface International UPS may come shipped with battery already connected The follow ing procedures may be used to check battery connections and to replace defective battery Fig 202 International UPS Battery Connection Preparation 3 Unpack the new UPS from the box Refer to Figure 202 Roll the UPS over on its side and remove two 2 screws that secure the battery compartment cover Remove two 2 Screws Fig 203 International UPS Battery Cover Removal 4 Lay the UPS on its side and remove the two 2 screws from the battery compartment cover Refer to Figure 203 4 170 Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 33 APC UPS International Model P N 957 0060 03 Continued
110. ASSEMBLY CONTINUED Input power for the 3D 60 Refer to Figure 36 is either 115 VAC or 220 VAC The installation technician sets the proper voltage selection at the Power Entry Module PEM The circuitry is protected by one 6 3A time delay 250 VAC fuse 120 VAC version or two 5A time delay 250 VAC fuses 040 VAC version AC voltage is coupled across the isolation transformer thus insulating the instrument from facility power for circuit protection including a 120 120VAC or a 240 120VAC step down voltage ratio Input power is routed to a metal oxide varistor MOV that s mounted between terminals 2B amp 3B of TB1 The varistor provides inline surge protection for the internal circuitry of the system From TB1 power is routed to the fan DC power supply and all power enable relays The DC power supply provides the necessary DC voltages on J2 for various sub units throughout the 3D 60 Instrument There are three separate voltages 12VDC and 5VDC with a common DC return providing a logic ground In addition the DC power supply provides a Power Fail signal that is routed to the ModSig PCBA Service Manual 2 9 2 BACKGROUND INFORM ATION BacT ALERT 3D 60 2 5 DC POWER SUPPLY input Volage Input Surge Current Cold Start 110 VAC 220 VAC 17 A maximum 34A maximum Output Voltage Adjustability 45 1 VDC output Supply Only PIN CHART Ji P6 P8 1206 Ps je eve KEE
111. AdjLim 4 StupPts 5 StupSumx 15 StupDenom 50 FastPts 17 FastSumx 153 FastDenom 6936 InitThres 3300 FastStupThres 6 SlopStupThres 0 1E1 FastCntrThres 12 FastBcktThres 0 105E2 FastBcktInc 1 FastRateThres 32 FastRateInc 3 FastDgdr 0 93E0 FastSlopProp 0 825 0 FastMayThres 3 SlowStupThres 12 SlowCntrThres 16 SlowBcktThres 15 SlowBcktInc 1 SlowDgdr 0 98E0 SlowSlopProp 0 9083E0 MinSkipPts 6 ID H2 BltFact 0 231E1 Resv 1320 AdjThres 70 AdjLim 4 StupPts 5 StupSumx 15 StupDenom 50 FastPts 17 FastSumx 153 FastDenom 6936 InitThres 8300 FastStupThres 6 SlopStupThres 0 1E1 FastCntrThres 12 FastBcktThres 0 105E2 FastBcktInc 1 FastRateThres 32 FastRateInc 3 FastDgdr 0 93E0 FastSlopProp 0 825E0 FastMayThres 3 SlowStupThres 12 SlowCntrThres 16 SlowBcktThres 15 SlowBcktInc 1 SlowDgdr 0 98E0 SlowSlopProp 0 9083 0 MinSkipPts 6 ID H2 BltFact 0 231E1 Resv 1320 AdjThres 70 AdjLim 4 StupPts 5 StupSumx 15 StupDenom 50 FastPts 17 FastSumx 153 FastDenom 6936 InitThres 8800 FastStupThres 6 SlopStupThres 0 1E1 FastCntrThres 12 FastBcktThres 0 105E2 FastBcktInc 1 FastRateThres 32 FastRateInc 3 FastDgdr 0 93E0 FastSlopProp 0 825E0 FastMayThres 3 SlowStupThres 12 SlowCntrThres 16 SlowBcktThres 15 SlowBcktInc 1 SlowDgdr 0 98E0 SlowSlopProp 0 9083 0 Service Manual 4 53 4 SERVICING SOFTWARE DIAGNOSTICS BacT ALERT 3D 60 4 54 13 14 15 1
112. Also check the ModSig Board for connector damage 6 Refer to Subsection 4 11 and perform the Post Service Validation procedure Annotate appropriate maintenance and logbooks 8 Return the system to normal operation N Service Manual 4 161 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 30 Domestic 56K Fax Modem P N 957 0004 342 Modem Port Connection 957 0004 305 25 pin to 9 pin cable 00_0000 International modem has two DIPswitch settings are on the D additional DIPswitch settings 1 1 1 1 rear of the modem 12345678 9 and 10 both set to ON Fig 188 Fax Modem Port Connections Domestic Model Ji 18 gam t zan Lr MELEE PEMTER __ BARCODE pedo dez eum m LP noe Fig 189 Domestic 56K Fax Modem Rear Port Connection 1 Disconnect the fax modem cable from the Modem port on the rear of the 3D 60 Instrument Refer to Figure 189 Disconnect the same cable from the fax modem Refer to Figure 188 Disconnect the AC Adapter 2 Disconnect the Phone cable from the fax modem Refer to Figure 188 3 Disconnect the telephone Line In Telco cable from the fax modem and set the defective fax modem aside 4 Connect the fax modem cable to the Modem port on the rear of the 3D 60 Instrument and connect the other end to the fax modem Refer to Figure 189 and Figure 188 Connect the Phone cable from the fax mode
113. CBA 2 14 Service Manual BacT ALERT 3D 60 2 BACKGROUND INFORMATION 2 7 COMPACTFLASH ADAPTER PCBA CONTINUED A CompactFlash Adapter PCBA with CompactFlash Memory Disk installed is mounted near the WinSystems motherboard It is connected by a flat ribbon cable to the motherboard s IDE port Refer to Figure 38 or Subsection 4 10 4 Figures 108 112 The Flash Memory Disk contains the operating system BacT ALERT 3D 60 s software instrument configurations operator settings layout of the instrument pictorial along with the bottle record data Service Manual 2 15 2 BACKGROUND INFORM ATION 2 8 2 16 QUAD SERIAL INTERFACE PCBA C7 C5 R22 R21 C8 C27 WinSystems Rev B Fig 39 Quad Serial Interface PCBA Diagram BacT ALERT 3D 60 2 o o c o o 8 N D R34 R33 Service Manual 2 8 BacT ALERT 3D 60 2 BACKGROUND INFORMATION QUAD SERIAL INTERFACE PCBA CONTINUED The Quad Serial Interface Com4 board Reference Figure 39 is a daughter board that plugs into the PC 104 bus on the WinSystems motherboard There are four ports on the board Com 1 is configured as a RS 485 port Com 2 3 and 4 are configured as RS 232 ports Com 1 and Com 2 are located on connector J6 while Com 3 and Com 4 are located on connector J3 All communications ports are software supported and operate at a 9 6K Baud data rate The Quad Serial is a four ch
114. CPU NVRAM is unitialized the software is abnormally shutdown without saving the NVRAM SMX error at startup shutdown IS E e e e e n 0x203 SmxErrSD This event is logged any time that the software is shutdown because of an SMX error detected at startup with NVRAM save This event is logged any time that the software is shutdown for an abnormal reason with saving the NVRAM For example if the software is started with the appropriate debug mode for immediate shutdown configuration set the software shuts down abnormally but saves the NVRAM 4 44 Service Manual BacT ALERT 3D 60 4 SERVICING SOFTWARE DIAGNOSTICS Remote User requests shutdown Ox205 RemUserSD 2 This event is logged any time that the software is shutdown because of a request passed by the Remote User software Set the setpoint Module Number New Setpoint temperature oxsoomTset 370 This event is logged any time that the set point has been changed Module temperature Module Number Temperature Offset offset at power up osmos 1 This event is logged any time that the incubation chamber is powered up Module temperature Module Number Temperature Offset offset updated 0x502 IMOfs ______ 0 042 This event is logged any time that the incubation chamber s temperature is updated Module temperature Module Number Current Last Stable Temperature calibrated Temperature Temperature Offset
115. DC Power Supply to the mounting holes and reinstall the four 4 screws Refer to Figure 156 for mounting screw locations Reconnect J1 and J2 connectors to the power supply Refer to Figure 155 Reverse the steps to reinstall the System Power Panel back into the 3D 60 chassis Ensure all wiring connections are made Refer to Section 4 10 13 for System Power Panel Removal and Installation Reinstall the Right Side Panel on the 3D 60 instrument Close the System Top Panel and secure it with two 2 screws Refer to Figure 99 Refer to Subsection 4 3 3 and perform the 3D 60 Power Up procedure Refer to Subsection 4 11 and perform the Post Service Validation procedure Annotate the appropriate maintenance and lab logbooks Return the system to normal operation Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 18 Power Entry Module PEM Fuses P N 870 0008 1 4 17 24 25 Below you will find an installation guide showing specific Facility Power Ratings and the proper fuse installation figure to use from this section Refer to Table 4 10 18 below Facility Power Rating Figure to Use 100 Volts AC 162 0 2 110 Volts AC Figure 162 115 Volts AC Figure 162 120 Volts AC Figure 162 200 Vois AG Figure 163 240 Volts AC 163 Table 4 10 18 Facility Power Rating and Fuse Conversion Chart NOTE The Power Entry Module PEM 805 001 7 02 is loca
116. Data Cause Hardware failure involving the non volatile random access memory Caution Bottles with fault are flagged positive and bottle readings are not processed while the fault is present Solution Determine how long bottle readings have not been processed by going to the Edit Bottle Detail screen and noting the time of the last bottle reading See Viewing Editing Bottle Data on Page 4 2 of the 3D 60 Operator s Manual If the time passed is greater than one hour bottles must be subculture 1 Unload the affected bottle via the Unload Positive Bottle function on the Main screen Subculture the bottle if necessary Reload the bottle via the Load Bottle function on the Main screen The original first loaded date and time is maintained 4 If the fault code persists call bioM rieux 73 Invalid Method Data Cause Important information used for bottle analysis has been corrupted and therefore bottle readings are not being processed Bottles with fault are flagged positive one hour after the fault code first appears Bottle readings are not processed while the fault is present Solution Each bottle type uses the same method data Eventually all bottles of the same type as the one with the fault will also present the same fault code 1 Reboot the system See Instrument Shutdown Startup on Page 6 6 of the 3D 60 Operator s Manual 2 Call bioM rieux 74 Algorithm Change D 6 Cause An incorrect media type has been previously assigned
117. Display values Number of times test was run without any errors Number of times test was run and test file could not be opened Number of times test was run and an error occurred while writing gt Last test data string written to test file on ZIP disk 11 21 22 2 3 Number of times test was run and an error occurred while reading the data or the data did not match what was written 24 31 32 Last data read back from test file on ZIP disk Number of times an error was generated while trying to write the test data Service Manual 4 35 4 SERVICING SOFTWARE DIAGNOSTICS BacT ALERT 3D 60 7 2 INSTRUMENT CNTRL Barcode Loopback Screen Description This diagnostic verifies the operation of the serial hardware that makes up the interface to the bar code scanner It isolates problems to either the barcode scanner or instrument controller Impact Bottle testing is not affected by this diagnostic Test Procedure Access the signal distribution board Replace the barcode scanner connector from the connector on the signal distribution board with loopback connector PN 43012 1 e Start diagnostic e Let run for a period of 2 minutes Verify that FAIL count on 4 2 is 0 Exit diagnostic Remove loopback connector and reattach barcode scanner Keyboard functions Run status Runs continuously and updates the display continuously 7 2 Instrument Cntrl Barcode loopback Interrupt Counts 1 Transmit Buffe
118. IBRATIONS 4 9 1 4 9 2 4 9 3 4 9 4 4 9 5 Service Manual Overview This section provides procedures for verifying calibrations It also provides procedures for adjustments and alignments as necessary System Power Supply Refer to Subsection 4 9 6 to perform System Power Supply Check and Adjustment Adjust only if required The measured voltage shall be 5 2 VDC 05 VDC Temperature The Incubation Chamber temperature should be calibrated if the actual temperature measured with a calibrated thermometer varies by 0 5 C from the instrument s set point temperature Optics Bottle racks are pre calibrated at the factory and while they are designed not to require any re calibration in the field an initial calibration is required for validation purposes Rack Single Cell Calibration Rack cells can be individually calibrated using the Incubation Module Flag Check diagnostic This method of calibration will enable cells that are currently testing to remain operational while concurrently calibrating rack cells that are out of calibration 1 Starting from the Main Screen click on the Next button in the lower right corner of the screen to access the Setup screen 2 Using the numbered buttons at the top of the Setup screen enter the password lt 1 gt lt 2 gt lt 1 gt lt 2 gt lt 3 gt lt 4 gt lt 3 gt lt 4 gt and click the Key Icon button to access the Diagnostic Selection screen Refer to Figur
119. LACE 5 24 1 4 79 4 11 POST SERVICE VALIDAT ION neuen nana ea ase nana na ana na unea nnnm nenne nans KAKA KA AA KA AW WAA 4 175 Service Manual 4 1 4 SERVICING BacT ALERT 3D 60 THIS PAGE INTENTIONALLY LEFT BLANK 4 2 Service Manual BacT ALERT 3D 60 4 SERVICING 4 2 SPECIFIC TOOLS AND REQUIRED The following is a list of the tools required for maintenance of the instrument Calibrated Digital Voltmeter DVM capable of measuring 01 VDC Calibrated Thermometer NIST traceable and accurate to 5 C Lint free cloth Vacuum Cleaner Portable ESD Kit strap and mat Calibrated Reflectance Standards Four 4 each identified by the number of rings around the end of the reflector BTA 3D 60 Field Utilities disk P N 22155 5 Zip Disk Backup copy of the database Standard Field Hand Tools Table 4 2 1 Required Tools and Equipment 4 3 POWER UP DOWN PROCEDURES 4 3 1 Introduction The following procedure is designed to properly bring the BacT 3D 60 system to Power Up and Power Down gracefully 4 3 2 3D 60 Power Down Power Switch d Fig 58 3D 60 Instrument Power Switch Service Manual 4 3 4 SERVICING BacT ALERT 3D 60 4 3 2 3D 60 Power Down Continued 1 Exit from the operating system by pressing Esc Y E lt S gt 2 Ablue screen appears and the following will be displayed e Normal shutd
120. MOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 4 CompactFlash Adapter PCBA P N 957 0004 356 Continued CompacFlash Adapter w CompactFlash Memory Card Installed CompacFlash Adapter PCBA w WinSystems CPU PCBA Fig 109 CompactFlash Adapter amp Zip Drive Installed Fig 110 CompactFlash Adapter w WinSystems Computer 5 Remove the CompactFlash Memory Card by pressing the black release plunger Pull the Memory Card straight out of the CompactFlash Adapter and set it aside Refer to Figure 111 for CompactFlash Memory Card location and black arrow showing disk removal direction 6 Unplug the J7 power cable from the CompactFlash Adapter PCBA Refer to Figure 111 7 Remove the four 4 screws securing the CompactFlash Adapter PCBA to the support standoffs Refer to Figure 112 8 Unplug the J3 cable from the CompactFlash Adapter PCBA Refer to Figure 112 4 92 Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 4 CompactFlash Adapter PCBA P N 957 0004 356 Continued CompactFlash Memory Card J7 Power Cable and Connector Pull Memory Card Out Ui E iuc Fig 111 CompactFlash Card Memory Removal Fig 112 CompactFlash Adapter Removal 9 Reverse the steps to install the new CompactFlash Adapter PCBA NOTE Ensure the J7 Blue Black power cable is routed arount the right side and on top of the CompacFlash PCBA before replacing the mounting screws
121. Manual 4 137 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 19 Fan P N 941 0009 07 Fan wires are connected to TB1 on Terminals 1 2 TB1 4A Two additional wires are also secured to the same terminals Remove nuts and washers from fan Nylon wire clamps and or tie wraps are under washer and nut EI i Fig 164 Fan Inside View Fig 165 Fan Wiring Connections 1 Refer to Subsection 4 3 2 and perform the 3D 60 Power Down procedure 2 Remove the two 2 screws securing the Top Panel and secure it into the Up position Refer to Figure 99 for screw removal locations CAUTION Proper ESD precautions must be observed whenever working on or around any PCBA 3 Remove 3D 60 Instrument s Right Side Panel and set the panel aside 4 Depending on tools available the fan wire disconnection from TB1 may be done using one of the following two methods a or b below a lfaright angle screwdriver is used remove the screws from TB1 2A and TB1 4A and disconnect the two fan wires and the two additional wires from the Terminal Block Mark the wires as appropriate to facilitate proper reinstallation b lfaright angle screwdriver is not available remove the bolt securing the Transformer to the chassis and set the transformer aside with PEM wires still attached Remove the screws from TB1 2A and TB1 4A and disconnect the fan wires and the additional two wires from the Terminal Block
122. N 1 3 14 ASSEMBLY DESCRIPTIONS ciencia desea ien WE ke RAE 1 4 1 5 OPERATOR DISPLAY CONFIGURATION 1 24 1 6 QUICK REFERENCE CARD eter ease KA WEHA RA d da td 1 29 1 GENERAL INFORMATION BacT ALERT 3D 60 1 2 REFERENCE DATA This chart represents the environmental conditions for use including the physical functional and technical characteristics of the BacT ALERT 3D 60 instrument Electrical Power Service Required 100 120 220 240VAC 50 60Hz Power Consumed In Watts 120VAC 480W Max 240VAC 480W Max Heat Dissipated In BTU hr 1639 BTU Hr Max Equipment Characteristics Width 23 1 in 58 7cm Height 23 9 in 60 7cm Depth 19 9 in 60 5 cm Weight 94 Ibs 42 5Kg Environmental Characteristics Operating Temperature Range 10 C 30 C 50 F 86 F Storage Temperature Range 17 57 0 135 F Operating and Storage Humidity Range 10 90 RH non condensing Operating and Storage Altitude No restrictions Table 1 2 1 Combination Module Reference Data 1 2 Service Manual 1 GENERAL INFORMATION BacT ALERT 3D 60 1 3 EQUIPMENT DESCRIPTION The BacT ALERT 3D 60 instrument is a compact and automated microbial detection system capable of incubating agitating and continuously monitoring specimens suspected of contamination from bacteremia fungemia The instrument consists of a W
123. N 48300 901 4 96 Fig 114 ModSig PCBA Cut the ties wraps Refer to Figure 115 and unplug the bundled cables in the following order MS JP30 from connector JP30 Refer to 116 MS JP29 from connector JP29 for Steps 4a thru 4f MS JP18 from connector JP18 MS JP17 from connector JP17 MS JP13 from connector JP13 MS JP15 from connector JP15 MS JP19 from connector JP19 Refer to Figure 117 JP21 Blue Black wires Refer to Figure 118 MS JP11 and MS JP12 Refer to Figure 118 MS JP31 Refer to Figure 118 MS JP1 Blue Black amp Yellow Brown wires Refer to Figure 119 Remove the two 2 screws from the Rear Panel Refer to Figure 120 Remove the eight 8 screws that secure the ModSig PCBA to the support standoffs Refer to Figure 121 4 a b C d e f g h i j k 5 6 7 8 Unplug MCJ4 cable from the J4 connector on the Step 5 PCBA Refer to Figure 122 Remove the ModSig PCBA from the instrument Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 6 ModSig PCBA P N 48300 1 Continued Order Spare P N 48300 901 Fig 115 ModSig PCBA Tie Wrap Removal NOTE JP10 P1 and the ground cables must be pulled up in order to insert the ModSig PCBA Refer to Figure 124 9 With the ModSig PCBA removed from the instrument remove rear bulkhead from the ModSig PCBA Remove two 2 each hex nuts from the left and right sides of the
124. NTERFACE INTERFACE 20210580 WAVEFORM ZIP DRIVE Service Manual APPENDIX A GLOSSARY A text entry field that appears on a display screen The primary purpose for a prompt is for data entry Read only prompts are not selectable and are dimmed User entries into a prompt are checked for validity according to the value range internally assigned for that prompt PCBAs within the Combination Module that provide for the communication between the Incubation Module s and the rest of the system Outlines instructions for system operation and describes specific error codes Found in the Operator s Manual and may be conveniently relocated by the customer Contains 20 cells each of which can hold and monitor an individual culture bottle Racks gently rock to agitate bottles unless they are set up for MB Bracket on the rear of the rack assembly providing for a means of the agitation arm to make contact with the rack Paw acronym for Random Access VAR RAM is volatile memory unless it is the special NVRAM in the BacT ALERT 30 See THERMOMETER A button that allows selection of numerical or symbolic values by clicking arrows above or below a window that shows the selected character While an arrow is being clicked the center portion shows one character from among the available list of choices To choose a screen option with a pointing device A rectangular icon device which moves between ON and OFF symbolized by 1 and
125. ON A member of the set of possible valid entries for the current field PCBA Acronym for Printed Circuit Board Assembly PEM Acronym for Power Entry Module Acronym for Preventive Maintenance POP UP Synonym for display screen dialog POSITIVE Describes a culture bottle that has evidence of microbial activity POWER CONNECTOR A fitting to attach the alternating current AC power cord POWER ENTRY PEM Device on the Instrument that contains the fuse s and facility voltage MODULE Misi It also contains the power connector POWER PANEL Panel within the Instrument containing the DC Power Supply relays and isolation transformer PREVENTIVE PM Routine maintenance procedures that are performed annually by the service MAINTENANCE technician These maintenance procedures ensure proper operation of the instrument and help in reducing major outages PRINTER PORT Printer interface port parallel on the Instrument that s for producing hard copy reports concerning bottle status PRINTED CIRCUIT PCBA A fiberboard containing the necessary electronic components that are BOARD ce via soldered paths in order to create a working circuit assembly A 4 Service Manual BacT ALERT 3D 60 PROMPT QUAD SERIAL PCBA QUICK REFERENCE CARD RACK RACK LEVELING BRACKET THERMOMETER SCROLL BUTTON SELECT SNNT SWITCH THERMOMETER TOGGLE BUTTON UP DOWN SCROLL BUTTON BUFFER VIDEO I
126. P N 750 0075 01 1 Although not required it is advisable that you perform a backup of the records stored on the 3D 60 instrument Refer to Section 4 5 Data Backup Restore Procedures Only 250 Megabyte Zip disks should be used as the backup media 2 Open the door on the 3D 60 to stop the instrument 3 Refer to Subsection 4 3 2 and perform the BacT 3D 60 Power Down procedure 4 Remove the two 2 screws securing the Top Panel and secure it into the Up position Refer to Figure 99 for Top Panel screw removal CAUTION Proper ESD precautions must be observed whenever working on or around any PCBA 5 Disconnect the Ser1 P3 cable from the Quad Serial PCBA Refer to Figure 107 6 Remove the two screws securing the Quad Serial board to the nylon standoffs Refer to Figure 107 7 Carefully unplug the Quad Serial PCBA from the CPU PCBA and hold on to it securely Fig 106 Quad Serial PCBA Service Manual 4 89 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 3 Quad Serial Interface PCBA P N 750 0075 01 Continued Quad Serial PCBA Cable Connections Mounting Screws Remove Fig 107 Quad Serial PCBA Cable Connections 8 Unplug the P6 cable and set the Quad Serial board aside Refer to Figure 107 above 9 Reverse the steps to install a new Quad Serial PCBA Refer to Figure 106 and Figure 107 for proper cable and connector locations 10 Close the Top Panel and repl
127. PCBA to the panel Install the new Inlet Thermistor PCBA and secure with the two 2 mounting screws Plug J3 cable back into the Thermistor at J3 connector To protect the foam door seal use paper cardstock over the wide foam at the top of the door Reinstall the Right Side Panel of the instrument Remove the paper cardstock after completing the Right Side Panel installation 9 Close the System Top Panel and secure it with two 2 screws Refer to Figure 99 10 Refer to Subsection 4 3 3 and perform the 3D 60 Power Up procedure 11 Refer to Subsection 4 11 and perform the Post Service Validation procedure 12 Annotate appropriate maintenance and logbooks 13 Return the system to normal operation TF Service Manual 4 119 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 12 Zip Drive P N 895 0004 38 Refer to Subsection 4 3 2 and perform the 3D 60 Power Down procedure Remove the two 2 screws securing the Top Panel and secure it into the Up position Refer to Figure 99 for screw removal locations 1 2 CAUTION Proper ESD precautions must be observed whenever working on or around any PCBA i 12 1 LE Remove four 4 I screws from o CompactFlash Adapter PCBA M 4 Fig 138 Zip Drive Removal Remove the four 4 screws securing the CompactFlash Adapter PCBA to chassis Refer to Figure 138 4 L
128. Pts 24 MinAvgMed 1 SlopProp 0 1E0 SlowSlopProp 0 2E 1 FastDgdr 0 75E0 SlowDgdr 0 9 0 AcelSlopThres 20 SlowSlopThres 10 PosDlyThres 1 DltThres 32767 NumAlg3Pts 576 Service Manual BacT ALERT 3D 60 4 SERVICING SOFTWARE DIAGNOSTICS PosSlopDly 720 DltDgdr 1 0E 32 Embedded H2 Parms ID H2 BltFact 0 1667E1 Resv 1320 AdjThres 70 AdjLim 4 StupPts 5 StupSumx 15 StupDenom 50 FastPts 17 FastSumx 153 FastDenom 6936 InitThres 6000 FastStupThres 6 SlopStupThres 0 1E1 FastCntrThres 12 FastBcktThres 0 105E2 FastBcktInc 1 FastRateThres 32 FastRateInc 3 FastDgdr 0 93E0 FastSlopProp 0 825E0 FastMayThres 3 SlowStupThres 12 SlowCntrThres 16 SlowBcktThres 15 SlowBcktInc 1 SlowDgdr 0 98E0 SlowSlopProp 0 9083 0 MinSkipPts 6 18 not used 19 not used 20 not used 21 not used 22 not used 23 not used 24 not used 25 not used 26 not used 27 not used 28 not used 29 not used 30 not used 31 not used 32 not used 33 not used 34 not used 35 not used 36 not used 37 not used 38 not used 39 not used 40 not used 41 not used 42 not used 43 not used 44 not used 45 not used 46 not used 47 not used 48 not used 49 not used 50 not used 51 not used 52 not used 53 not used 54 not used 55 not used 56 not used 57 not used 58 not used 59 not used 60 not used 61 not used 62 not used 63 not used 64 not used 65 not used 66 not use
129. RM ATION BacT ALERT 3D 60 2 9 RACK CONTROLLER PCBA CONTINUED Rack Controller Block Diagram Agitation Sensor Cell Sensors OP 68HC11 Microprocessor Amps 1 20 w internal RAM and EPROM Analog Multiplexer Drivers Cell Constant Exciters Rack Current 1 20 Temperature Control Cell 12 Bit Indicators A D 1 20 Converter Reference Voltage Drawer ID RS 485 RCVR XMTR Drawer ID Rack ID Output Event Request To From ModSig or previous Rack Controller 5V IN RS 485 Rack ID Event Request Rack ID OUT Fig 41 Rack Controller PCBA Block Diagram 2 20 To From Next Rack Controller 5 V OUT RS 485 Rack ID Drawer ID Event Request Rack ID OUT Service Manual 2 9 BacT ALERT 3D 60 2 BACKGROUND INFORMATION RACK CONTROLLER PCBA CONTINUED Each cell has an individual external sensor The sensor outputs are multiplexed to cascaded operational amplifiers that drive the analog input of an A D Converter The cell sensor readings are sent on request to the instrument The Rack Controller firmware detects bottle presence from these photodiode sensors as well Circuitry is provided to develop the analog signals to the A D Converter for the two temperature sensors on the Rack PCBA These sensors are part of the calibration factors for the bottle cells The agitation sensor is a Hall Effect sensor The sensor detects bottle rack motion for a change in magnetic flux from a rare earth magn
130. RVICING SOFTWARE DIAGNOSTICS CHECK FIXED SIZED FILES eee ee RR RR RR eee dee e He He de e e e He e SSAA C NCPUNVRAM BIN expected actual size 524288 524288 C NCPUNVR2 BIN expected actual size 524288 524288 C SSDNVRAM BIN expected actual size 2097152 2097152 C SSDNVR2 BIN expected actual size 2097152 2097152 C READDATA READINGS DAT expected actual size 70656512 70656512 FIR IK eee eee ke ee IKI III KIKI IIA II AIH dk e ok I FILE SIZE CHECK PASSED Kee Fe He ke zo ke ee he e e ke kk ee ehe ke ke kk ke e e e ke ke ke ke e e e e ke ke e e He ke e ee ke eee eee dee ee e e ke ee e He e ee e He He He He e He e e He He e ee e e ke ke e e k k ke k k k k kv x DRIVE INFO for D OEMName KBxeIHC Bytes Sec 512 Secs Cluster 8 Rsvd Secs 1 Num of FATS 2 Root Ent Cnt 512 TotSec16 0 Media OxF8 FATSz16 239 Secs Trk 32 Num of Heads 64 Hidden Secs 32 TotSec32 489440 DrvTypeNum 128 Reservedi 0 0 BootSig 0x29 VolID 365958411 Vol Label ZIP250 FileSysType 16 Computed data FAT Type 16 FAT Size 239 Total Secs 489440 Bytes FATEnt 2 RootDirSector 479 RootDirSectrs 32 DataSector 511 ClusterSector 511 EOCMark gt OxFFF8 BADSectorMark OxFFF7 Cluster 2 sector 511 e ke e e e e e e ee e e ee e e e e e e e ee e eee ee e e e de e e e
131. Sig Mounting Screw Locations 8 Install the new Door Switch onto the chassis secure it with two 2 nuts and tighten them 4 158 Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 27 Magnetic Door Switches P N 841 0012 01 Continued Door Switch LEDs lower right corner of ModSig PCBA JP11 E EM Fig 185 Door Switch LEDs ModSig PCBA 9 Slide connector JP11 or JP12 through the circular hole in the chassis Refer to Figure 184 10 Plug in JP11 or JP12 connector into the JP11 or JP12 socket on the ModSig PCBA 11 Close the System Top Panel and secure it with two 2 screws Refer to Figure 99 12 Close the door on the 3D 60 instrument 13 Refer to Subsection 4 3 3 and perform the 3D 60 Power Up procedure 14 Refer to Subsection 4 11 and perform the Post Service Validation procedure 15 Annotate appropriate maintenance and logbooks 16 Return the system to normal operation Service Manual 4 159 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 28 Keyboard P N 957 0004 373 MOUS PRINTER MONITOR Connect keyboard cable into this port j on the rear panel of the instrument x Fig 186 3D 60 Rear Panel Keyboard Port Connection 1 Refer to Subsection 4 3 2 and perform the 3D 60 Power Down procedure 2 Disconnect the keyboard cable connector from the Keyboard port on the rear panel of the 3D 60 Instrume
132. T 3D 60 4 10 8 Step 5 PCBA P N 48301 1 Order Spare P N 48301 901 Step 5 PCBA Fig 128 Step 5 PCBA Location 1 Refer to Subsection 4 3 2 and perform the 3D 60 Power Down procedure 2 Remove the two 2 screws securing the Top Panel and secure it into the Up position Refer to Figure 99 CAUTION Proper ESD precautions must be observed whenever working on or around any PCBA 4 108 Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 8 Step 5 PCBA P N 48301 1 Continued Order Spare P N 48301 901 c x NS a m Ensure MCJ3 wiring goes between D not bend when Vou m 4 rks the standoffs and under the PCBAs removing the Step 5 PCBA TFT Fig 129 Step 5 PCBA Connector and Wiring Locations Unplug MCJ4 cable from J4 connector Refer to Figure 129 above Unplug cable from J3 connector Refer to Figure 129 above Unplug MCJ1 cable from J1 connector Refer to Figure 129 above Remove the six 6 screws securing the Step 5 PCBA to the support standoffs Refer to Figure 129 7 Align the new PCBA over the support standoffs Plug in MCJ4 and MCJ1 Oak Service Manual 4 109 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 8 Step 5 PCBA P N 48301 1 Continued Order Spare P N 48301 901 NOTE Ensure motor wires MCJ3 are routed between the inside standoffs of the ModSig and Step 5 PCBAs Feed motor w
133. VICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 22 4 146 Once Boot is removed disconnect the lugged wires from the terminals Lugged wires are connected to the Capacitor terminals underneath the Boot Blower Motor Capacitor P N 601 0001 02 Continued Capacitor Retaining Clamp w lock nut HBP1 HBJ1 Connector Unplugged at Step 4 Fig 173 Blower Motor Capacitor Boot and Clamp Removal Once the System Power Supply Assembly is removed from the instrument s chassis the Blower Motor Capacitor is exposed as shown in Figure 173 above Remove the Boot from the defective Capacitor Once the Boot is removed lugged wires are exposed Unplug the lugged wires from the terminals on the Capacitor Ensure that you know the proper terminal locations and colors of the wires diagram it or write them down so that they are reinstalled properly on the new capacitor Refer to Figure 173 Remove the lock nut from the Capacitor s Retaining Clamp Slide the capacitor out of the Retaining Clamp and set it aside Refer to Figure 173 Install the new capacitor into the retaining clamp Install the lock washer and tighten it Reconnect the lugged wire connectors to their respective terminals on the Capacitor as noted in Step 9 above Reinstall the System Power Supply Assembly back into the 3D 60 chassis Refer to previous removal steps in this section Reinstall the two 2 screws into the system chassis in
134. able by the user Disabled user interface items are usually displayed in gray DOS Disk Operating System MS DOS is used ELECTROSTATIC ESD Component that is easily damaged by static electricity These components are SENSITIVE DEVICE e associated with PCBAs ENABLED The opposite of disabled See Disabled A 2 Service Manual BacT ALERT 3D 60 APPENDIX A GLOSSARY SPEAKERS external port on the rear of the Instrument FIRMWARE In computer terms firmware is the internal software code that a system uses to operate GENERIC BOTTLE ID A bottle ID that does not indicate one of the pre defined bottle types INTERFACE GUI manipulating graphical screen images INCUBATION The chamber within the Instrument that holds the racks and incubate BacT ALERT 3D 60 CHAMBER bottles INDICATOR LIGHT OR An identifier for an indicated cell that lights up to indicate the location of a particular bottle LAMP or bottle type They are located in the racks adjacent to the cells ISOLATION Isolates and protects the BacT ALERT 3D 60 from facility power TRANSFORMER KEYBOARD Provides for an alternate means of input for bottle IDs accession numbers hospital IDs and names Serves as a backup input device should the mouse or Barcode Reader fail LABORATORY LIS Name for a customer maintained computer system usually a mainframe INFORMATION that collects information from laboratory instruments within the lab SYSTEM LCD MONITOR A
135. acT ALERT 3D 60 1 4 3 Electronic Components CPU Board ModSig Board Fig 11 CPU PCBA Fig 12 ModSig PCBA Quad Serial Board Thermistor Board Fig 13 Quad Serial PCBA Fig 14 Thermistor PCBA 1 10 Service Manual 1 GENERAL INFORMATION BacT ALERT 3D 60 1 4 3 1 4 3 1 1 4 3 2 1 4 3 3 1 4 3 4 Service Manual Electronic Components Continued The Electronics Compartment is situated in the top part of the 3D 60 instrument It contains the internal WinSystems computer CPU PCBA and Quad Serial PCBA CompactFlash Adapter PCBA Zip Drive Step 5 PCBA and the ModSig PCBA CPU PCBA The CPU is a 586 processor with an operating clock speed of 133MHz This is the heart of the system and controls all system operations Reference Figure 11 ModSig PCBA This board provides an interface between the CPU PCBA and the rest of the system It serves as a module controller for the system PCBAs monitors incubation temperature and the external port devices i e modem scanner LIS etc that are attached to the 3D 60 instrument It also monitors several independent system tasks such as DC voltages switches the frequency output of the speaker power reset and other functions Reference Figure 12 Quad Serial PCBA This board provides the communications interface from the WinSystems computer to the rest of the system incubator Reference Figure 13 Thermistor PCBA Input Output There are two Thermis
136. ace the two 2 screws that secure it Refer to Figure 99 11 Close the door on the 3D 60 to allow startup of the instrument 12 Refer to Subsection 4 3 3 and perform 3D 60 Power Up procedure 13 Refer to Subsection 4 11 and perform the Post Service Validation procedure 14 Annotate appropriate maintenance and lab logbooks 15 Return system to normal operation 4 90 Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 4 CompactFlash Adapter PCBA P N 957 0004 356 1 It is recommended that you perform a Backup of the records stored on the BacT ALERT 3D 60 before continuing this Remove and Replace procedure Refer to Subsection 4 5 for BacT ALERT 3D 60 Data Backup procedure 2 Open the door on the 3D 60 to stop the instrument 3 Refer to Subsection 4 3 2 and perform the 3D 60 Power Down procedure 4 Remove the two 2 screws securing the Top Panel and secure it into the Up position Refer to Figure 99 CAUTION Proper ESD precautions must be observed whenever working on or around and PCBA CompactFlash Memory Card CompacFlash Adapter PCBA seva Installed Installed hb a i i D Fig 108 CompacFlash PCBA Note The IDE cable to the CompactFlash Adapter has ferrite bead on it and this should be removed from a defective IDE cable and reinstalled on the new cable as required Service Manual 4 91 4 SERVICING RE
137. affected due to one of the following reasons e Hardware fault with the ModSig Board e Hardware fault with the Solid State Relays that energize the heater e Faulty temperature sensors Contact bioM rieux Service Manual BacT ALERT 3D 60 APPENDIX D ERROR CODES 4 Incubation Chamber Temperature Is Too Low Cause The instrument optimal temperature Set Point has been changed and the Chamber has not yet equilibrated at the new temperature Solution Contact bioM rieux Cause The door has been left open or ajar for an extended period Solution Make sure the door closes tightly and allow the chamber temperature one hour to equilibrate Cause Bottle testing may be adversely affected due to one of the following reasons e Hardware fault with the ModSig Board e Hardware fault with the Solid State Relays that energize the heater e Faulty temperature sensors Solution Call bioM rieux immediately 6 Agitation Stepper Motor Fault Cause Agitation Stepper Motor has reported a fault Solution 1 Ensure AC power source is adequate or connect to an alternate power source 2 instrument runs on UPS power for 1 minute If AC power is not restored during this time the instrument and UPS turn Off When AC power is restored the instrument will automatically reboot 3 If power is not restored within an hour it may be necessary to subculture bottles Caution Do not load or unload bottles until power is restored
138. agram 2 2 Service Manual 2 2 BacT ALERT 3D 60 2 BACKGROUND INFORMATION SYSTEM CONTROL MODSIG PCBA CONTINUED The MODSIG PCBA provides interfaces to the 3D 60 Instrument Controller section the Step 5 board external peripherals and the Rack PCBA s It uses a 68HC11 microprocessor with firmware stored in the EPROM The microprocessor uses an external 16 MHz crystal for its clock 32Kbytes of EPROM and 32Kbytes of static RAM are external with no internal ROM There are 512 bytes of EEPROM and 1024 bytes of RAM both of which are internal A 4 5 volt reference is on the PCBA for A D reference and a 2 5 volt reference for temperature control Power fail circuitry detects if the 5VDC is out of tolerance LED s on the board show E Fan ON Power Enable ON Blower ON Heater ON Agitation ON 5V ON for ModSig 5 ON for Step 5 PCBA 5 ON for Racks Door Switches Closed six status indicators and RS 485 transmit and receive indicators Temperature sensors on the board are used for EFan control and to report electronics over temperature conditions External input and output temperature sensors are used by PID control firmware on the microprocessor for incubation temperature control and are connected to JP1 Heater blower and fan ON OFF time control signals connect through a connector at JP2 A 12 bit amp channel A to D converter integrated circuit does conversion from analog values to digital values for microprocessor use The fr
139. al 184 Magnetic Door Switches 185 Door Switch LEDs ModSig PCBA 186 3D 60 Rear Panel Keyboard Port Connection 187 3D 60 Rear Panel Barcode Scanner Port Connection m 188 Fax Modem Port Connections Domestic 4 189 Domestic 56K Fax Modem Rear Port 190 Modem Port Connections International Model 191 International 56K Fax Modem Rear Port Connection 192 APC UPS Domestic Model BackUPS 650 120V Front and Rear Vie i 4 164 193 3D 60 System Rear Communications Ports UPS Cable Connection 194 UPS Battery Connection Preparation 195 UPS Battery Cover Removall i cssssssssssasssssssasssssssasnsssssasssssnsasesssnsasnsssnsasnsssnsasnsssnsasesssnsasesnensasnsssnsnsnssensasneses 196 Connecting UPS Battery Cable to Terminal s sien eren 197 Domestic UPS with Battery Cables
140. annel serial INS8250 compatible P C 104 module that is based on the 16C554 UART It is ideally suited for applications running DOS programs or languages that require exact register compatible hardware for program execution Each of the channels supports RS 232 with optional RS 485 and RS 422 electrical levels to interface with a wide variety of serial communications devices The Quad Serial PCBA is mapped Each channel requires eight port addresses and each is independently decoded within the I O map The interrupt status register also requires one port The addresses are decoded in the PAL and are jumper selectable with eight different maps The Coma card is a 16 bit stack through card that supports 8 bit data transfers only Service Manual 2 17 BacT ALERT 3D 60 2 BACKGROUND INFORM ATION RACK CONTROLLER PCBA 2 9 Im zi i aa 0 00 0 mo on pide n m a Cu 9c 0 ator o 0 00 0 Co ana Fig 40 Rack Controller PCBA Diagram Service Manual 2 18 2 9 BacT ALERT 3D 60 2 BACKGROUND INFORMATION RACK CONTROLLER PCBA CONTINUED The Rack Controller PCBA Refer to Figure 40 wing EPROM stored software controls the excitation LEDs The LED light illuminates and reflects on the bottle sensors creating emitted measurable values at the photo detectors The Rack Controller digitizes each cell s photo detector output for reading by the ModSig s Control Module and for bottle prese
141. art and stop bit are not correct 4 36 Service Manual BacT ALERT 3D 60 4 SERVICING SOFTWARE DIAGNOSTICS This value can be ignored It is displayed for diagnosis of software activity and indicates whether the software s transmit data FIFO is empty or not 1 or 0 respectively Should remain at 0 0 0 Displayed for purpose of diagnosing software activity and indicates whether there was fault storing data in the software s transmit data FIFO and where in the code that fault occurred Should increment Indicates the number of times data loopback test was run and passed Should remain at 0 Indicates the number of times loopback test was run and failed 41 42 Should remain at 0 Indicates the number of times loopback data was trans mitted but a timeout occurred before all the data was received Should remain at 0 Indicates the number of times loopback data was transmitted and received but the received data did not Red match what was transmitted Should remain at Just before transmitting loopback data the four possible combinations or signal states are asserted on the RTS and DTS lines The state of the CTS line which is connected to the RTS line is monitored and if found inconsistent with the assert RTS DTS signals this count is incremented ul Should remain at 0 Just before transmitting loopback data the four possible combinations or signal states are asserted on the RTS and DTS lines The state of the DSR line wh
142. ated Length A 234 Equipment Int Dem B Thickness of your Mounting Surface Fig 55 Mounting Surface Diagram e Transfer the dimensions from the Mounting Surface Drilling Template to the actual mounting surface and drill four diameter holes Refer to Figure 56 Mounting Surface Drilling Template f Position the instrument Insert the bolts through 1 4 flat washers through the mounting surface and into the threaded inserts of the instrument Refer to Figure 56 Mounting Surface Drilling Template g Lightly tighten the bolts Note Over tightening the bolts may loosen or damage the threaded inserts Service Manual 3 15 3 INSTALLATION PROCEDURES 3 3 2 3 16 Procedure Continued Rear PA Y 5 from hole or 4 from instrument f Note Door will swing 3 1 2 wide 13 Allow 4 left side of hole or 3 V from instrument gt Left side clearance Fig 56 Mounting Surface Drilling Template Drill 1 2 Holes BacT ALERT 3D 60 Service Manual BacT ALERT 3D 60 3 INSTALLATION PROCEDURES 3 4 SOFTWARE INSTALLATION Although software installation is not required during setup of the BacT ALERT 3D 60 instrument there is one instance where the operating software must be reinstalled When the Flash Memory Disk is defective the disk should be replaced and the system software reinstalled See Subsection 4 10 5 Software Installation and Compa
143. ately with the BacT ALERT 3D 60 unit For a list of parts shipped with the unit see Table 3 2 1 3D 60 Instrument Parts on page 3 6 of this manual B 0 Alphabetical Listing of Parts Adapter Power 100 240 VAC 957 0004 384 Shipped for International printer installations only Assy Chassis 3D 60 Bare Instrument Assy Link Agitation Drive Bracket Gas Spring Mounting 73 Bracket Gas Spring Mounting 2 06 Cable Serial Modem Optional Cordset Printer Euro 220V UK 240V 866 0016 02 Euro Only 866 0016 03 UK Only Cover Bottle Holder 1 20 POS Cover Bottle Holder 21 40 POS Cover Bottle Holder 41 60 POS Decontamination Certificate Decontamination Procedure Service Manual B 1 APPENDIX B PARTS LISTING BacT ALERT 3D 60 B 2 Service Manual BacT ALERT 3D 60 APPENDIX B PARTS LISTING Power Cord 100 VAC 110 VAC Service Manual B 3 APPENDIX B PARTS LISTING BacT ALERT 3D 60 THIS PAGE INTENTIONALLY LEFT BLANK B 4 Service Manual BacT ALERT 3D 60 APPENDIX C DISINFECTION PROCEDURES C 0 C 1 C1 1 C1 2 Service Manual APPENDIX C DISINFECTION PROCEDURES Disinfection Introduction This appendix contains detailed instructions on how to disinfect a unit prior to shipment It also instructs on disinfection procedures of assemblies that may be replaced Procedures WARNING HANDLE SPECIMENS AND INOCULATED CULTURE BOTTLES AS THOUGH CAPABLE OF TRANSMITTING INFECTIOUS AGENTS
144. ation and Utilities disk should be labeled as the same software version as the customer was previously using Service Manual 4 87 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 2 4 88 CPU PCBA Assembly P N 750 0070 01 Continued 22 23 24 25 26 27 28 As the instrument is rebooting press the lt Delete gt key to enter the CMOS setup menu a If the CMOS date and time were noted in Step 2d set the CMOS date and time to the time noted in Step 3d plus the elapsed time Specifically you want the local time right now minus the local time noted in Step 2e b Ifthe CMOS date and time were not noted in Step 2d the CMOS date and time should be set to Universal Coordinated Time formerly known as GMT Greenwich Mean Time Reboot the system by pressing lt Cirl gt lt Alt gt lt Delete gt keys simultaneously Look at the Main screen on the instrument controller and verify the correct version of software is displayed Set the display time to the local date and time using the Set Date and Time screen See BacT ALERT 3D 60 Operator s Manual Allow the Power Up screen to complete Verify the bottle counts if notated in Step 2d of this section If the system has been down for more than one hour call bioMerieux for technical support assistance Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 3 Quad Serial Interface PCBA
145. be published for replacement procedures at a later date Remove the defective thermometer from the bracket and replace it with a new one Close the door on the instrument Refer to Subsection 4 11 and perform the Post Service Validation procedure Annotate the appropriate maintenance and lab logbooks Return the system to normal operation w 4 148 Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 24 Rack Assembly P N 43147 921 922 923 Rack Cable Cover Fig 175 Rack Blocks Installed 1 Ensure the rack being replaced is empty and disabled See Rack Enabling and Disabling in the 3D 60 Operator s Manual Relocate the bottles that are in the defective rack if necessary 2 Refer to Subsection 4 3 2 and perform the 3D 60 Power Down procedure 3 Remove the two 2 screws securing the Top Panel and secure it into the Up position Refer to Figure 99 for screw removal locations 4 Remove the two 2 screws securing the Rack Cable Cover to the chassis Refer to Rack Cable Cover removal steps in the 3D 60 Operator s Manual Service Manual 4 149 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 24 Rack Assembly P N 43147 921 922 923 Continued Screw Location approximate Fig 176 Rack Assembly w Cable Cover Removed Fig 177 Rack Cable Clamp Removed 5 Remove the two 2 screws that secure the Rack Cable Clamp of the defective rac
146. beam falls on the reflective label Barcode Scanner does not beep The Barcode Scanner needs to be Scan the barcode label in Fig 64 reprogrammed to the default settings Scanner is defective Replace scanner Barcode Scanner scans but The Barcode Scanner needs to Scan the barcode label in Fig 64 nothing is read reprogrammed to the default NOTE settings Investigate all fault codes reported for this module before making these checks There is are loose connection s Check the connection where the or defective cables scanner connects to the rear for the instrument The Barcode Scanner is defective Replace the Barcode Scanner The CPU PCBA is defective Replace CPU PCBA Blown fuse Check and replace F3 on the ModSig PCBA as required The cables are loose or defective Check the connection to the rear NOTE communications panel bulkhead Secure or replace as required Investigate all fault codes reported for this unit before making checks The keyboard is defective Replace keyboard CPU PCBA is defective Replace CPU PCBA ModSig to CPU PCBA cable is Secure or replace the cable loose or defective Keyboard not responding 4 14 Service Manual BacT ALERT 3D 60 4 SERVICING SOFTWARE DIAGNOSTICS 4 8 SOFTWARE DIAGNOSTICS 4 8 1 Button Legend Set Date Time Button Edit Cell Contents Button Enable Disable Module Drawer Rack or Cell Button Calibrate Cell Button Cali
147. ber matches the bottle Press the Done button to exit the Load Bottle mode UPS Functional Test 3D 60 Only APC UPS 650 1 Perform UPS test a Perform this test only with a properly charged UPS See Subsection 4 11 32 for Domestic or Subsection 4 11 33 for International UPS battery hook up and charging details Set the time to current local time Disable the audible alarms via the system software Remove AC power from the UPS Leave the UPS connected to the 3D 60 instrument and leave the power switches to both the UPS and the 3D 60 to ON Verify that the UPS will emit an audible alarm within 1 minute Observe that the blue Abnormal Shutdown Screen appears on the instrument s monitor screen Observe 3D 60 power off After the instrument powers off restore power to the UPS Verify that the instrument retains correct time and has no visible errors displaced on the monitor screen Complete the Installation Checklist Verify that the Installation Checklist is completed Refer to Figure 57 3 13 3 INSTALLATION PROCEDURES BacT ALERT 3D 60 3 3 3 3 1 3 3 2 3 14 RESTRAINT INSTALLATION Overview The countertop mounting hardware consists of screws and flat washers used to attach the instrument to a countertop or other surface of variable thickness Refer to Table 3 3 3 for required parts ITEM QUANTITY Table 3 3 3 Restraint Hardware Procedure 1 Determine the desired location of the ins
148. bottle ID ASTM Acronym for American Society for Testing and Materials AUDIBLE ALARM The field technician sets the coarse adjustment of volume and frequency with the use of jumpers Fine setting of volume specified by the user to flag positive bottles instrument failure or an operator error BACT ALERT bioM rieux s automated instrumentation to screen test specimens for the presence of microbes BACT LINK BACT LINK BARCODE READER Used to scan accession numbers or bottle barcode labels and identifies bottles when loading or unloading the incubation process BacT ALERT bottle with a specific type of culture medium i e BacT ALERT SA BUTTON BAR The user can freely move to any screen at any time by selecting clicking on and or sliding the appropriate button from the vertical column of buttons that are always visible on the right hand side of the display screen CAUTION A step or action that could easily result in damage to the instrument or create an incorrect result Service Manual A 1 APPENDIX A GLOSSARY BacT ALERT 3D 60 CENTRIFUGATION A technique employing the quantitative application of centrifugal force A centrifuge is a rotating device employing this technique and used for separating liquids of different specific gravities or for separating suspended particles in a liquid solution CALIBRATION Test rod used to calibrate cells There are four separate standards on two rods used to STANDARD calibrate t
149. brate Module Temperature Button View Incubation Module Information Button Set Maximum Test Time Button Backup Management Button Set Audible Alarm Options Button Edit Data Relationships Button Change Password Button Report Label Entry Button Report Configuration Button Disabled Check Button Cancel Button Disabled Cancel Button Next Button mE Exit Screen Button Disabled Select Bottle to Edit Graph Button Check Button Scroll Up Button Scroll Down Button a m _ a Display at Go to Home St Entry Scroll Scroll One Line One Page Anchor Display at Up Down Up Down Last Entry Go to End O Fig 66 Diagnostics Setup Screen Buttons Service Manual 4 15 4 SERVICING SOFTWARE DIAGNOSTICS BacT ALERT 3D 60 4 8 2 Purpose of the Section e This document describes the various diagnostics built into version B 11 of the BacT Alert 3D instrument controller software These diagnostics apply to the standard 3D 60 instrument e This document serves as design specifications for the software implementation e This document is also intended for persons using the diagnostics such as field service personnel persons writing documentation such as the service manuals and those writing software test plans such as the validation test plan 4 8 3 Special Equipment e Several diagnostics are provided to test the various communications ports on the instrument con
150. button to return to the Main Screen 4 5 2 BacT ALERT 3D 60 Data Restore Procedure 1 Insert the Zip disk that has the backup data copied to it and install it into the Zip drive 2 Press Esc and Y E S on the keyboard to exit the 3D 60 program 3 Atthe C3 prompt type RESTORE and press the ENTER key on your keyboard When the program has completed restoration successfully the following message will appear RESTORE COMPLETE 4 Atthe C3 prompt type XBTA3D and press lt ENTER gt on your keyboard to restart the 3D 60 program Service Manual 4 9 4 SERVICING BacT ALERT 3D 60 THIS PAGE INTENTIONALLY LEFT BLANK 4 10 Service Manual BacT ALERT 3D 60 4 SERVICING PREVENTIVE MAINTENANCE 4 6 PREVENTIVE MAINTENANCE This section refers to the descriptions of preventive maintenance operations 4 6 1 4 6 2 4 6 3 4 6 4 4 6 5 4 6 6 4 6 7 4 6 8 Service Manual Overview The Preventive Maintenance PM procedure has been provided for personnel trained by bioM rieux PMs are required to be performed annually unless specified otherwise Perform Data Backup Refer to Section 4 5 Data Backup Restore Procedures Barcode Reader Functional Test 1 On the 3D 60 instrument click on the Load Bottle button from the Main Screen 2 Scan the bottle and verify that the scanned and screen numbers are the same Do not load the bottle but do click on the Done button to
151. can be displayed at a time the raised area would be one half of the total size of the Slide bar Touching a geographical location top middle bottom etc on the Slide bar will scroll the to same relative position in the display area For example if there were 2000 lines of data in the display area and the slide bar is touched in the middle the display area would scroll approximately to line 1000 Fig 73 1 5 Inc Module 1 Temperature Log Slide Bar 4 22 Service Manual BacT ALERT 3D 60 4 SERVICING SOFTWARE DIAGNOSTICS 4 8 5 Diagnostic Screens Overview Continued 1 Inc Module 1 1 1 nc Module 1 Loopback Screen Special equipment Loopback method 1 not applicable to Combo or 3D 60 1 Disconnect the cable between IC and IM at IM end 2 Bring cable out to front and attach 43013 1 Loopback method 2 required for Combo not applicable to 3D 60 1 Attach 43013 1 to 43205 7 2 Access signal distribution board and remove cable from signal distribution board for IM port of interest 3 Connect 43013 1 43205 7 assembly incubation module feet port is being tested with this diagnostic test Test Procedure a First enter the diagnostic test type b Attach loopback hardware using one of the methods described on the Special equipment row above Press R to reset fault counts Let the diagnostic run for 2 minutes and verify that line 4 2 shows a value of 0 Depress the Po
152. card to the back of the new card Affix the card to the BacT 3D 60 Instrument 4 12 Service Manual BacT ALERT 3D 60 4 SERVICING DIAGNOSTICS AND TROUBLESHOOTING 4 7 4 7 1 4 7 2 DIAGNOSTICS AND TROUBLESHOOTING This chapter describes the procedures for detecting the faulty component s depending on the type of failure It also describes the remedial action to be taken to return the instrument to serviceable condition Introduction This section pertains to the symptomatic problems that may appear during normal operation of the BacT ALERT 3D 60 These errors will cause an error code to appear Error Code information can be found in Appendix D of this manual or the BacT ALERT 3D 60 Operator s Manual Symptomatic Errors PROBLEM CAUSE SOLUTION Anonymous Bottle Cell not calibrated Recalibrate the cell using the indicated in empty cell Single Cell Calibration screen and single rod calibration standards If the cell cannot be calibrated or calibration does not fix the problem replace the rack or make the checks listed for Fault 60 starting with the second Cause Solution Cell indicator s never come on NOTE Rack PCBA is defective Replace rack assembly Investigate all fault codes reported If only 1 cell error before making these Rack ModSig or cables defective Replace rack assembly ModSig More than 1 cell or all cells PCBA or defective cables Operator has disabled all audible No a
153. ccurs during storage C1 3 Assembly Shipping Using the same equipment as mentioned in Table C 1 2 perform the following procedures on assemblies before shipping NOTE The assembly decontamination procedure is inclusive of all assemblies returned to bioM rieux St Louis IRC with the exception of printed circuit boards PCBAs e Using 700 PPM free chlorine solution 13 ml of 5 25 bleach to 1 liter of tap water wipe down all external surfaces of the assembly e After the decontamination procedure has been performed on the assembly complete the decontamination certificate noting any areas that were unable to be decontaminated Attach the certificate to the assembly NOTE Printed circuit boards PCBAs are not required to be decontaminated however the decontamination certificate MUST be completed noting on the certificate that decontamination was not performed e Place the assembly in a sealed plastic bag before packaging C 2 Service Manual BacT ALERT 3D 60 APPENDIX D ERROR CODES APPENDIX D ERROR CODES D 1 Error Codes CAUTION Failure to follow the procedures in this Service Manual or failure to attend to the fault conditions reported by the instrument within one hour may lead to invalid test results The following codes are discussed in this appendix 1 43 72 2 44 73 3 45 74 4 46 75 6 47 77 10 51 78 11 52 99 12 53 710 19 54 800 20 55 810 21 56 901 22 5 902 39 60 910 41 62 911 42 71
154. ctFlash Memory Disk Replacement for specific software installation requirements after designated remove and repair procedures are performed on the CompactFlash Adapter PCBA 3 5 SWITCHING ON 3 5 1 Service Manual The following steps offer suggested power up and device power cord connection procedures for the BacT ALERT 3D 60 instrument Proper battery hookup and installation of the UPS is required prior to taking the following steps below Refer to Subsection 4 10 32 APC Back UPS Model 650 Domestic Model or Subsection 4 10 33 APC UPS International Model for UPS installation procedures Plugging peripheral device power cords into the UPS Surge and Backup Battery or Full Time Surge Protection AC outlets is required prior to powering up the instrument 1 Plug the printer s power cord into one of the Surge outlets on the UPS Outlet for the printer will not require Backup Battery protection 2 Plug in the display monitor s power cord into a Surge Protected Battery Backup outlet on the UPS The Display Monitor is required for proper shutdown of the instrument during facility power fail conditions 3 Plug the 3D 60 s main power cord into a Surge Protected Battery Backup receptacle on the UPS UPS battery backup is required to ensure enough time to properly shut down the 3D 60 instrument during facility power fail conditions 4 Power up the UPS and ensure the battery is fully charged 5 Power up the
155. ctFlash Adapter PCBA to the chassis Refer to Figure 138 Close the System Top Panel and secure it with two 2 screws Refer to Figure 99 Refer to Subsection 4 3 3 and perform the 3D 60 Power Up procedure Refer to Subsection 4 11 and perform the Post Service Validation procedure Annotate appropriate maintenance and logbooks Return the system to normal operation 4 123 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 13 System Power Panel 1 Refer to Subsection 4 3 2 and perform the 3D 60 Power Down procedure 2 Remove the two 2 screws securing the Top Panel and secure it into the Up position Refer to Figure 99 for screw removal location 3 Remove the instrument s Right Side Panel to access the Power Panel Assembly CAUTION Proper ESD precautions must be observed whenever working on or around any PCBA AAAA p HAM nu Remove two 2 Power Panel mounting screws Fig 145 Power Panel Assembly Screw Removal 4 124 Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 13 System Power Panel Continued Fig 146 Power Panel Assembly Fig 147 Power Panel Assembly Installed 4 Unplug HBJ1 HBP1 wiring connector coming from the Heater and Blower to TB1 and Relays Refer to Figure 147 5 Unplug BHP1 wiring connector coming from the Electronics Compartment to the Power Supply Refer to Figure 146 and Figure 147 6 Re
156. ction necessary provided alarms Speaker test described in Note 1 works Cable from speaker to the ModSig Secure or replace cable and PCBA is loose or defective speaker External alarm not sounding Speaker is defective Replace speaker See Note 1 Cable from the ModSig PCBA P13 to CPU PCBA J3 is loose r defective Secure or replace cable ModSig PCBA is defective Replace the ModSig PCBA CPU PCBA is defective Replace CPU PCBA Note1 Investigate any fault codes reported for the instrument before making any checks To test the speaker press the Load Bottles button on the Main screen The speaker should beep once Table 4 7 1 Symptomatic Problems Fig 65 Scanner Default Settings Barcode Service Manual 4 13 4 SERVICING DIAGNOSTICS AND TROUBLESHOOTING BacT ALERT 3D 60 4 7 2 Symptomatic Errors Continued PROBLEM CAUSE SOLUTION The Barcode Scanner needs to be Scan the Barcode label in Figure reprogrammed to the default 64 settings Barcode Scanner is defective Replace Barcode Scanner Fuse is blown Check and replace F2 on the ModSig PCBA Spotter beam is not hitting the Observer the reflective label in the reflective label Bar Code Aperture There should be a small red dot produced by the scanners spotter beam Verify Barcode Scanner that this dot falls on the reflective label If not reseat the scanner cradle so that the
157. d 67 not used 68 not used 69 not used 70 not used 71 not used 72 not used 73 not used 74 not used 75 not used 76 not used Service Manual 4 55 4 SERVICING SOFTWARE DIAGNOSTICS 4 56 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 not not not not not not not not not not not not not not not not not not not not not not not used used used used used used used used used used used used used used used used used used used used used used used Default BB 1 41 1 1 1 1 1 1 1 1 1 1 1 1 1 1 O O O O O OC O O O O O OC O O OC O OC O O OC O O O OC O O O O O OC O O O O O O O O O O OC O O O O days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days 604800 604800 604800 604800 604800 604800 604800 604800 3628800 3628800 604800 604800 604800 604800 604800 604800 604800 3628800 3628800 1296000 2592000 1296000 1296000 1296000 1296000 1296000 1296000 1296000 2592000 2592000 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 604800 RRR RRR RRR RRR RRR RRR RRR RRR RR RRR Maximum Test secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs sec
158. des Instrument Status Codes appear in a separate window on the Main screen and are identified by a 98 in the top left corner A description of each Instrument Status Code is provided The following is an example of an Instrument Status Code 710 Fig 208 Instrument Status Code 710 710 Incubation Chamber Temporarily Unavailable While Power Up Initialization Takes Place Cause Turning On the power of an instrument or clicking the Restart Incubation Chamber button invokes the Power Up screen to appear on the monitor It is NOT possible to perform any action when the Power Up screen is present Solution No operator action is necessary The Power Up screen will disappear when the Incubation Chamber is ready Do NOT load bottles while the Power Up screen is present 800 Printer Fault Cause The instrument was unable to print to the printer Solution Check the following e The printer is powered on and connected to the instrument properly e The printer has paper e The paper is not jammed in the printer Service Manual D 9 APPENDIX D ERROR CODES BacT ALERT 3D 60 D 10 810 Backup Failed Cause The instrument was unable to write backup data to the Zip disk because the disk was either missing or defective Solution Perform the following procedure 1 Make certain there is a Zip disk in the drive and attempt a manual backup See Initiating Scheduling System Backups on Page 5 6 of the 3D 60 Operat
159. e 1 MODEM BaudRate 38400 FILE EXTCOMP INI Enabled 0 LIS Enabled 1 BidirectionalLink 1 TestOrderPollPeriod 120 AutoTransmitResults 180 PeriodicallyTestLink 240 Parity NONE BaudRate 2400 BitsPerChar 8 StopBits 1 Example 4 40 Service Manual BacT ALERT 3D 60 4 SERVICING SOFTWARE DIAGNOSTICS Similar to 7 5 1 with the exception that files in the c btlprocs directory with a BID Similar to 7 5 1 with the exception that files in the c btlprocs directory with a BTF Similar to 7 5 1 with the exception that files in the c btlprocs directory with a APF 2 BID files extension are displayed 3 BTF files extension are displayed 4 APF files extension are displayed 5 LOG files Similar to 7 5 1 with the exception that files in the LOG directory specifically EVENT14 LOG EVENT13 LOG and so on to EVENTO LOG are displayed EVENTO LOG contains the most recent data and appears at the bottom of the display EVENT14 LOG contains the oldest data and appears at the top of the displayed If there is more log data than can be displayed the oldest log data is omitted from the display An example is shown below followed by details on what the contents of LOG file mean FILE EVENT1 LOG 11 139719250 06 06 01 08 04 34 0x38 DTChg 4294948672 139719253 06 06 01 08 04 37 Ox4 139719253 06 06 01 08 04 37 0 3 139719253 06 06 01 08 04 37 0x3 139719253 06 06 01 0
160. e 91 Diagnostic Test Selection Screen 4 69 4 SERVICING ALIGNMENTS AND CALIBRATIONS BacT ALERT 3D 60 4 9 5 Rack Single Cell Calibration Continued 1 7 Inc Module 1 Flag Check Collecting data 20 Collecting data from rack 1821 468 Collecting data from rack 1841 68 Fig 91 Diagnostic Test Selection Screen Flag Check 3 Select the Incubation Module 1 0 Inc Module 1 from the Main Selection List then select 1 7 Flag Check 4 Click the Right Arrow button to start the cell flag check diagnostic Allow enough time for the diagnostic to gather flag readings When the diagnostic completes the screen in Figure 91 appears 4 70 Service Manual BacT ALERT 3D 60 4 SERVICING ALIGNMENTS AND CALIBRATIONS 4 9 5 Rack Single Cell Calibration Continued 1 7 Inc Module 1 Flag Check Difference 2 gt 1 8 1882 1 12 1813 3 12 1A14 2 19224 1 62 1A23 19414 1 02 18450 1 12 1849 1 3 difference is greater 1854 1 22 1855 1 72 1857 18034 1 17 1807 lt 1 02 1 09 than or equal to 1B15 1 82 1B16 1 22 1B17 1 7 1 0 1B25 1 62 1B27 1 02 1B29 2 3 22 1B 1 22 1B38 2 22 1B39 2 02 1B48 1 72 1B43 1 82 18480 17721 1B56 1 32 1B58 1 82 1 59 1 72 1 03 1 02 1 12 1 25 lt 1 22 1056 1 32 1 57 1 32 Cell location diff 10170 1 12 1D24 1 12 1028 1 82 1055 1 27 Cells whose Differe
161. e Memory SIMM MEHOE 4 rccte eee 4 83 Software Installation eene eee 3 17 Software Diagnostics Accessing Screens Special Equipment sse Software Exception Log p Software Installation Procedure Solid State Relays Spacing Tool e epe Standard Lab Operating Requirements Standardes See Single Cell Calibration Step 5 Drive Agitation Linkage Assembly 4 153 Service Manual BacT ALERT 3D 60 Step 5 Firmware essere tenente 2 27 Step 5 Motor iste eiie i aa vena 1 7 4 5 Installing eode EU EUER ne 4 115 Mounting Screws 4 114 R moyal 4 112 Windings Diagram essent 4 111 Step 5 Motor Assembly see 1 6 Step 5 PCBA 1 12 2 25 4 5 4 108 Block Diagram et etes 2 28 Dia Sra sete A iE retis 2 24 Wiring and Connectors see 4 109 o Storage Temperature Switching On Symptomatic Errors 4 14 See Diagnostics and Troubleshooting System Power Panel Screw o ener seke reee kk 4 124 Temperature Cal Temperature Log Slide BA ac ye tete ee ts Temperature Verification See Post Servce Validation See Preventive Maintenance Term Board Jie See TBI Terminal Connections loRri dE 4
162. e display continuously 7 4 Instrument Cntrl Pover event log 24784781 24 84 81 1921 49 RACK 24 84 81 14 52 48 1841 G8 RRCK 24 04 01 14 52 41 24 84 81 14 52 41 24 84 81 14 52 42 24 84 81 14 52 42 1601 20 Time of event in 24 84 81 14 52 43 1621 48 POHER 24 84 81 14 52 43 1641 68 POHER dd mm yy hh mm ss 24 84 81 14 52 44 1D81 28 RRCK POWER format 24 84 01 14 52 44 1D21 48 RRCK POWER UP 24 84 81 14 52 45 1D41 6 RACK POWER UP 24 84 81 14 53 56 2 MODULE POWER FAULT 24 84 81 14 54 01 1 MODULE POHER UP 24 84 81 14 54 81 1A81 20 RACK POWER UP 24 84 81 14 54 82 1821 48 RRCK POWER UP 24 84 01 14 54 82 1R41 G8 RRCK POWER UP 24 84 81 14 54 83 1B 1 2 RACK POWER UP 24 84 01 14 54 83 1B21 48 RRCK POWER UP 24 84 01 14 54 84 1B41 6 RACK POWER UP 24 84 81 14 54 84 1C81 28 RRCK POWER UP 24 84 01 14 54 85 1C21 48 RRCK POWER UP 24 84 81 14 54 85 1C41 68 RACK POWER UP 24 84 81 14 54 86 1D81 28 RACK POWER UP 24 84 81 14 54 86 1D21 48 RACK POWER UP 24 84 81 14 54 87 1D41 6 RACK POHER UP Fig 88 7 4 Instrument Cntrl Power Even Log Screen Events that appear in the log but not necessary shown in the example above are INSTR CNTRL AC power fault Note this is logged when AC power fails and returns as reported by the UPS Instrument will do a controlled shutdown INSTR CNTRL UPS battery low Note this is logged when reported by the UPS MODULE POWER FAULT this i
163. e number of times loopback data was transmitted and received but the received data did not match what was transmitted Should match the state of the power fail button on the loopback test cable when that button is depressed the value displayed should be 1 when the button is not depressed the value displayed should be 0 Should match the state of the event request button on the loopback connector when that button is depressed the value displayed should be 1 when the button is not depressed the value displayed should be 0 4 24 Service Manual BacT ALERT 3D 60 4 SERVICING SOFTWARE DIAGNOSTICS 1 2 Inc Module 1 Port Stats Screen Special equipment Description This diagnostic displays statistics for the serial hardware that is used to REN communicate with a given incubation module Impact Bottle testing is not affected by this diagnostic N A Resets counts on lines 1 1 1 5 2 1 2 4 and 3 2 to 0 Run Status Runs continuously and updates the display data continuously 1 8 Interrupt Count 1 1 Transmit Buffer Empty 1086993 1 2 Receive Buffer Full 3731528 1 3 Line Status e 1 4 Nodem Status 8 Disabled 1 5 TOTAL 4818521 2 8 Errors 2 1 Overrun 2 2 Parity 2 3 Framing 2 4 TOTRL 3 8 Transmit FIFO 3 1 Empty 3 2 Put errors 87878 1 2 Inc Module 1 Stats R Reset Fig 75 1 2 Inc Module 1 Port Stats Test Screen Display values Number of transmit b
164. e the two 2 screws from the battery compartment cover Refer to Figure 195 Service Manual 4 165 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 32 APC Back UPS Model 650 Domestic Model P N 957 0060 02 Continued View is looking down on the work surface in this illustration Positive Battery Terminal with Red cable connected Plug Negative Black cable lead onto the Ground Terminal Fig 196 Connecting UPS Battery Cable to Terminal 5 With the UPS case on its side with battery cover open slide the battery out on its side as shown in Figure 196 above 6 Thered positive cable lead should already be connected to the battery s positive ground terminal Refer to Figure 196 Figure 197 shows black negative cable connected to the ground terminal 7 Connect the black negative wire lead to the battery s negative terminal Refer to Figure 196 Fig 197 Domestic UPS with Battery Cables Connected 4 166 Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 32 APC Back UPS Model 650 Domestic Model P N 957 0060 02 Continued Install two 2 Screws Fig 198 Domestic UPS with Battery Cover Secured 8 Secure the battery cover with two 2 screws and place the UPS in its permanent location Refer to Figure 198 Connect 3D 60 Instrument and the Display Monitor to one of the UPS Surge amp Battery Backup Outle
165. eakers The remote speakers control volume Volume jumpers on the board are for future use only See Table 2 2 1 for remote speaker audio frequency selections Service Manual 2 3 2 BACKGROUND INFORM ATION BacT ALERT 3D 60 2 2 SYSTEM CONTROL MODSIG PCBA CONTINUED FREQUENCY JP23 JP24 JP25 JP26 600 Hz 800 Hz 1 5 KHz Table 2 2 1 Audio Frequency Selection JP23 through JP26 2 4 Service Manual BacT ALERT 3D 60 2 2 SYSTEM CONTROL MODSIG PCBA CONTINUED 32KB RAM 32KB RAM 2 Temp Sensors g 68HC11 D A Converter Heater Inlet Outlet Temperature Sensors JP2 Instrument ID Switch Door Interlock Undervoltage JP10 Switches Overvoltage Detector JP16 RS 232 from B N Keyboard IE RS 232 Printer JP15 i Sr Ii Parallel To From CPU JP17 Parallel MN To From CPU JE18 c 8 9 9 9 E L8 8 RS 232 Rs 485 from Quad Serial J2 JP21 RS 232 from Quad Serial PCBA Jen JP31 5VDC Power In Video from CPU JP19 Fig 34 ModSig Block Diagram Service Manual 2 BACKGROUND INFORMATION Step 5 PCBA Door Interlock Switches 5 Power Agitate ON FROM Step 5 PCBA Error Signal Blower ON Heater ON Agitate ON E Fan ON Power En ON To amp From Drawer A 1 Rack PCBA DC Power Rack ID Event Request RS 485 Drawer ID PS2 Keyboard Barcode Port
166. eau d eee es 1 21 1 5 OPERATOR DISPLAY CONFIGURATION 1 24 Instrument Configuration Screen 1 25 1 5 1 1 Accessing the Configuration Screen 1 25 1 5 1 2 Instrument Configuration Screen Initial 1 26 1 5 1 3 Configuration Screen X Box 1 27 1 29 S i a LOT d 2 1 DEEST dai Eu da k duwa dag direka a xa da S au k ka Ku ka w sa 2 1 2 2 SYSTEM CONTROL 2 4 4 2 222 1 2 2 2 3 THERMISTOR PCBA 2 6 2 4 3D 60 POWER SUPPLY ASSE MB L eene enne nnne nnn nnn nnn nnn nnn nnn 2 8 2 10 ETC 2 12 2 7 COMPACTFLASH ADAPTER 2 14 2 8 QUAD SERIAL 2 1 22 1 nnn nennen AA HA A WAR 2 16 TT 2 18 E gt c c c rr rr r r e rrrr rrr rr 2 24 2 10 STEP 5 PCBA Service Manual TABLE OF CONTENTS BacT ALERT 3D 60 3 INSTALLATION PROCEDURES science dna iaca ai aia aa ata 3 1 3 1 INTRODUCTION eerta dalta via belay 3 1 3 2
167. ect a cable that monitors communications between the UPS and the 3D 60 Instrument The port connection is shown as Computer Interface Port in Figure 24 Overload Reset Switch The Overload Switch is a reset switch breaker allowing for UPS reset following a power surge or uncommon UPS shutdown The overload is rated 120VAC 12 Amp Max at 50 60Hz Test Check Battery Alarm Disable Switch By pressing the top of Test toggle switch the UPS battery may be checked The UPS powers the loads from the battery If the UPS emits the battery exhaustion alarm the battery is weak and requires extended charge or replacement 120V Backup Receptacles These 120V AC receptacles are used when devices connected to the UPS require full battery backup to allow proper shutdown of the equipment A device that may require such battery backup might be the Display Monitor since it is required to shut down the 3D 60 instrument in a facility power fail situation Accessory Surge Receptacles These 120V receptacles are used when devices connected to the UPS do not require battery backup but may require voltage surge potection A device that may require surge protection but not battery backup might be a Parallel Printer AC Power Cord The AC Power Cord is a standard three pronged AC grounded cord 1 21 1 GENERAL INFORMATION BacT ALERT 3D 60 1 4 5 Uninterruptible Power Supply UPS Continued Computer Interface On Off Switch
168. ed into its proper place once the new CPU PCBA is installed Move to Step 9 for cable connections and locations to reconnect cables to the new CPU PCBA CompacFlash PCBA VLL 2n Cable bundle secured WEE CPU PCBA pi x 4 with tie wraps W Cable Connection Hidden Fig 104 CPU PCBA Cable Connections 17 Align the bundled cables unplugged in previous Step 9 Secure cable J7 underneath Ser1 P3 cable and WinJ5 cable Refer to Figure 104 18 Add tie wraps around the bundled cables Ensure that cable bundle is reasonably aligned and flat prior to tightening the tie wraps Refer to Figure 104 4 86 Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 2 CPU PCBA Assembly P N 750 0070 01 Continued J2 J3 T T E pum imm e L Ti Fig 105 WinSystems CPU Connector Locations 19 Close the Top Panel and replace the two 2 screws that secure it Ensure that the cables have a forward fold at the ModSig connectors as to not allow the cables to get pinched between the Top Panel and the chassis hinge opening Refer to Figure 99 20 Connect the Main Power cable to the instrument 21 Apply power to the instrument Refer to Subsection 4 3 3 for 3D 60 Power Up procedure CAUTION To ensure proper software settings and compatibility the BacT ALERT 3D 60 Install
169. ee e e e e e e Xo kk IK KK KKK KIKI ek ek KICK IK IKI KIKI KKK KKK e ke k ke SCANDISK D Time 10 12 01 09 14 32 File ZIP250 File 100 1D RKP File 100 1E RKP File 100 1F RKP Directory MTOUCH62 Total Entries 5 Deleted Entries 0 Directories 1 Cluster count 1 Traverse subdirectory MTOUCH62 Directory Directory File MCAL BAT File MCAL OVL Total Entries 4 Deleted Entries 0 Directories 2 4 64 BacT ALERT 3D 60 Service Manual BacT ALERT 3D 60 4 SERVICING SOFTWARE DIAGNOSTICS Cluster count i Check file 100 1D RKP Check file 100 1E RKP Check file 100 1F RKP Traverse subdirectory MTOUCH62 Check file MCAL BAT Check file MCAL OVL Check free space for clusters 2 to 61117 ke e e e e e e e ke e e ee e e e e ce e ee e eee e ce e e e e e e SCANDISK PASSED for drive D Time 10 12 01 09 14 34 ee e e ke e e e He He ee e He e He He e He He e He e He e e se he He He e ke He e ce ke e ke e ke ke k k k ke k k k k kv x Service Manual 4 65 4 SERVICING SOFTWARE DIAGNOSTICS BacT ALERT 3D 60 9 Misc 7 6 Instrument Cntrl Softuare 23 12 3 12 99 92 76 92 6 12 96 82 6 12 8 12 5 42 eap left 15469616 Free blocks 1 Largest block size 15469616 ime of last shutdoun 1 Internal 24 04 81 14 52 52 3 2 Local 24 84 81 14 52 52 Reset Fig 90 7 6 Instrument Cntrl Software Test Screen Misc Display values Percen
170. em connector and the port labeled Modem located on the bulkhead on the rear of the instrument Connect the telephone line designated for modem access into the Jack port of the modem Refer to Figure 52 below for the bulkhead modem connection and Figure 53 for the 56K Fax Modem configuration diagrams Power up the modem if you have not done so already Have bioM rieux Support Services dial into the modem to verify the modem s connection and functionality Note US Robotics computer and jack modem ports are labeled on the bottom of the modem North America only m 3 MOUSE MODEM SERIAL UPS MONITOR KEYBRD f EXT SPKR dajo deb cec OS Fig 52 Communications Panel Connection Diagram Connect and configure the modems as shown below e Set the modem dipswitch as shown Modem Port Connection 957 0004 305 25 pin to 9 pin cable 000000 It International modem has two DIPswitch settings are on the additional DIPswitch settings rear side of the modem gt 12345678 i 9 and 10 both set to ON up Fig 53 Modem Configuration amp Dip Switch Settings Diagram Service Manual BacT ALERT 3D 60 3 2 13 3 2 14 3 2 15 Service Manual 3 INSTALLATION PROCEDURES Barcode Reader Functional Test On the instrument s monitor screen click the Load Bottle button on the Main Menu Scan a bottle and verify that the scanned num
171. emoval Reinstalling Mounting Screws 136 Outlet Thermistor PCBA Removal eere estere rere te tete tete tete teste satt tasa sns se AA ARK AR KAK AA KAK AA KARA 137 Inlet Thermistor PCBA Remowval eere eere ee nene te tenete tete te AA RAKR AR ARK AKAR AR KARAR AKAR AKAR AK KAK HAA KARA 138 Zip Drive 139 Zip Drive Flash Adapter PCBA Removal 140 Zip Drive Screw Remowval 141 Zip Drive Removal Cutout Hole 142 Zip Drive Sled Removal Side Screws 143 Zip Drive Sled Removal Bottom 144 Zip Drive Reconnecting IDE Cable and Power Connector essere 4 122 145 Power Panel Assembly Screw Removal 146 Power Panel Y ke K oi a tii 147 Power Panel Assembly Installed sssscsccecsssesssesssteseseseseeeseeesesseseeneeeasenensseseeeeneeeananenseeseensneneeeanensaeaes 148 Power Supply Transformer Power Supply Panel Removed 149 Power Panel with Transformer Installed eerte terere teneret tette toto ta sese AR KARAR AKAR 150 Tran
172. ensor as home position e Monitor motor current for over current condition e Program microcontroller hardware to generate PWM clock e When door open monitor safety timeout circuit for proper operation e Stop driving motor if 12V motor supply goes off e Generate fault outputs The firmware defines seven states for the stepper motor Stopped Ramping up Holding constant speed Seeking waiting for position count to reach ramp down point Ramping down Fault over current Motor power bad Voltage is applied to the stepper motor using a Microchip PIC16C74 microcontroller and five pairs of MOSFET transistors 5 ea IRL520 and 5 each IRF9530 Service Manual 2 27 2 BACKGROUND INFORM ATION BacT ALERT 3D 60 2 10 STEP 5 PCBA CONTINUED INDEPENDENT SAFETY TIMER INTERLOCKS POSITION STOP RUN DRIVE COMMAND MOSFETS FROM MODULE CONTROLLER HIGH SIDE DC IN PREDRIVERS FAULT OUTPUT Fig 44 Step 5 PCBA Block Diagram 2 28 Service Manual BacT ALERT 3D 60 CHAPTER 3 INSTALLATION PROCEDURES CHAPTER 3 INSTALLATION PROCEDURES Service Manual CHAPTER 3 INSTALLATION PROCEDURES BacT ALERT 3D 60 THIS PAGE INTENTIONALLY LEFT BLANK Service Manual BacT ALERT 3D 60 3 INSTALLATION PROCEDURES 3 INSTALLATION PROCEDURES 3 1 INTRODUCTION This paragraph presents the Installation Procedures chapter contents 3 INSTALLATION PROCEDURES 2225 65 eiae ce a aa AK AK
173. ents are logged when they occur TEMP SET events are logged when they occur 4 28 Service Manual BacT ALERT 3D 60 4 SERVICING SOFTWARE DIAGNOSTICS 1 6 Inc Module 1 Reading Log Screen Special equipment Displays recent history of readings taken Impact Bottle testing is not affected by this diagnostic Test Procedure Keyboard functions status Run continually and adds new readings to end of dsplay as they occur 1 6 Inc Module 1 Reading Log Displays the most recent readings 2 a ta C GN taken on incubation module cells p 1015 Status Reading Poly UNLOAD 5989 Each line of the display identifies each 1016 Status Reading Poly 8CUNLOAD 6228 1017 Status Reading Poly UNLOAD 6858 cell the reading was taken from 1018 Status Reading Poly lt UNLOAD 5877 1019 Status Reading Poly 8 CUNLOAD 6215 followed by 1028 Status Reading Poly 8 UNLORD 6335 1021 Status Reading Poly 8 XUNLORD 6472 1022 Status Reading Poly BCUNLOAD 6272 1023 Status Reading Poly BCUNLOAD 2134 e status of the cell LOAD 1024 Status Reading Poly UNLOAD 6839 1025 Status Reading Poly 8XUNLORD 5927 UNLOAD OUT OF CAL 1026 Status Reading Poly 8XUNLORD 6129 A 1027 Status Reading Poly lt UNLOAD gt 6849 the reading 1028 Status Reading Poly BCUNLOAD 2412 1027 Status Reading Poly lt UNLOAD gt 6849 the number of the polynomial 1030 Status Reading Poly
174. ep 5 Motor Removal MCJ3 Disconnection 4 112 Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 9 Step 5 Motor P N 48104 1 Continued 4 Remove the Left Side Panel by lifting from the top edge of the panel 5 Locate the points on the Motor Offset Round and remove the two 2 set screws Set screws are 90 apart See Figure 132 below Approximate location of Setscrew 2 Move this Setscrew hole 90 clockwise so that it is in the current Rotate 90 clockwise to tar Y position of Set screw 1 remove Setscrew 2 Eb i 4 shown in this diagram Drive Agitation Linkage NOTE Use 7 32 Allen wrench to remove Setscrews jM MEE Fig 132 Step 5 Motor Removal Set Screw Removal 6 Remove the four 4 Motor Mounting Screws from the pressed nuts Refer to Figure 133 Service Manual 4 113 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 Step 5 Motor P N 48104 1 Continued 4 10 9 After removing the two setscrews remove the 4 motor mounting screws With motor mounting screws removed pull the Step 5 Motor out in the direction shown by arrows on the right Fig 134 Step 5 Motor Removal Service Manual 4 114 BacT ALERT 3D 60 4 10 9 4 SERVICING REMOVE AND REPLACE PROCEDURES Step 5 Motor P N 48104 1 Continued Once the motor mounting screws are removed pull the Step
175. er Up procedure 12 Refer to Subsection 4 11 and perform the Post Service Validation procedure 13 Annotate the appropriate maintenance and lab logbooks 14 Return the system to normal operation 4 129 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 16 Power Panel Solid State Relays P N 845 00 18 01 1 Refer to Subsection 4 3 2 and perform the 3D 60 Power Down procedure 2 Remove the two 2 screws securing the Top Panel and secure it into the Up position Refer to Figure 99 for screw removal locations CAUTION Proper ESD precautions must be observed whenever working on or around any PCBA NOTE Individual power supply subassembly components are not repaired or replaced in Domestic 3D 60 s Individual components are spared as parts and replaced in International 3D 60 instruments only K1 Relay K2 Relay There are two threaded studs to align the relays however there is only one lock nut on the top stud to secure the relay to the chassis Relays will appear upside down when installed because the lettering on them is inverted in this diagram Fig 153 Power Panel Solid State Relay Layout 3 Remove the instrument s Right Side Panel to access the Power Panel Assembly Remove the lock nut from the defective relay Refer to NOTE in Figure 153 5 Gently pull the relay out and off of the studs taking care not to damage the wires attached to the terminals 6
176. er chains provides for a wide range of internal timing periods for software use Included is a watchdog timer The Rack Controller PCBA uses 32KB of static RAM in a surface mount package The software for most dynamic storage uses this memory The Rack Controller uses 32KB of EPROM for program storage Jumpers are included to allow the installation of larger memory in the event that the 276256 microprocessor becomes obsolete Memory parts with less than 90ns access are required There are two 20 pin oonnector positions on the board Power 5 volts for each board is supplied through a cable from the ModSig to the JP2 connector The other connector JP1 is cabled to JP2 of the next rack No other power is required A fuse on the ModSig protects the set of three Rack Controllers in the Incubator Chamber The 5 volt input voltage produces two reference voltages A 4 5 reference is provided to the converter A 2 5V reference is provided for the Rack temperature operational amplifiers as well as an accurate current control of the exciter LED s current by an operational amplifier Each cell has one exciter LED Each of these LEDs is driven by an output from a 74ACT374 driver One indicator LED is provided for each bottle holder or cell Each of the LEDs is driven by an output from a 74ACT374 driver In addition there are four status LEDs for general purpose and are explained in the firmware Service Manual 2 19 2 BACKGROUND INFO
177. er to Operator Manual for detailed error description and troubleshooting instructions Code Description Code Description POWER FAULT IN INCUBATION MODULE 60 CELL FAILED QC COMMUNICATION LOST WITH INCUBATION MODULE 62 ERRONEOUS CELL LOAD STATUS REPORTED INCUBATION MODULE TEMPERATURE ISTOOHIGH 71 INVALID TIME STAMP 7 INCUBATION MODULE TEMPERATURE ISTOOLOW 72 INVALID CALCULATION DATA INCORRECT INCUBATION MODULE CONNECTION 73 INVALID METHOD DATA CONTROLLER MODULE POWER FAULT 74 ALGORITHM CHANGE INSUFFIDIENTCHARGEINUPS 75 BOTTLE DATA CORRUPTED LISCOMMUNICATONFAUT 77 READING POLYNOMIAL CHANGE 7 SOFTWAREEXCEPTION 78 NCOMPLETE TEST DATA DRAWEROPENFORTOOLONG gt 79 BOTTLE RELOADED VIA WRONG CONTROLLER DRAWER AGITATION FAILURE 99 BOTTLE LOADED IN A NON OPERATIONAL CELL UNEXPECTED DRAWER AGITATION 710 NCUBATION MODULE TEMPORARILY UNAVAILABLE WHILE POWER UP RACK TEMPERATURE FAULT NITIALIZATION TAKES PLACE RACK S NOT RESPONDING 800 PRINTER FAULT RACK HARDWARE FAILURE 810 BACKUP FAILED SEE REVERSE FOR OPERATOR ERROR CODES Fig 32 Quick Reference Card Rear Side Detailed error descriptions and troubleshooting instructions may also be found in Appendix D of this manual Service Manual 1 31 1 GENERAL INFORMATION BacT ALERT 3D 60 THIS PAGE INTENTIONALLY LEFT BLANK 1 32 Service Manual BacT ALERT 3D 60 CHAPTER 2 BACKGROUND INFORMATION CHAPTER 2 BACKGROUND INFORMATION Service Manual
178. ers are continuously reset as long as both doors are closed If either door interlock opens the timers are allowed to run Either of two outputs from the high order counter may be selected by installing a zero ohm resistor on the board The selected output is applied to the PLD that drives the low side motor transistors When the output goes high the drive transistors are disabled regardless of the state of the microcontroller outputs The redundant timer is included to preclude the possibility that some undefined failure of the microcontroller would leave the motor running after the door is open The timer delay is selected to insure that under normal conditions the microcontroller has time to stop the motor normally before the delay expires Once the delay expires the PLD inhibits the clock to the high order counter to prevent the delay output from cycling Delay values are selected as described below output selected is denoted as IC outputs are labeled on schematic The door timer output is monitored by the microcontroller which generates a fault output after some delay if the door is open and the timer output does not go high 2 26 Service Manual BacT ALERT 3D 60 2 BACKGROUND INFORMATION 2 10 STEP 5 PCBA CONTINUED Motor voltage fault If the motor supply voltage goes off the microcontroller will turn off motor drive until the motor supply is restored Power up protection The high side predriver transistors require that the
179. es 3 SlowStupThres 12 SlowCntrThres 16 SlowBcktThres 15 SlowBcktInc 1 SlowDgdr 0 98E0 SlowSlopProp 0 9083E0 MinSkipPts 6 ID H2 BltFact 0 231E1 Resv 1320 AdjThres 70 AdjLim 4 StupPts 5 StupSumx 15 StupDenom 50 FastPts 17 FastSumx 153 FastDenom 6936 InitThres 8300 FastStupThres 6 SlopStupThres 0 1E5 FastCntrThres 12 FastBcktThres 0 105E2 FastBcktInc 1 FastRateThres 32 FastRateInc 1 FastDgdr 0 93E0 FastSlopProp 0 825E0 FastMayThres 3 SlowStupThres 12 SlowCnt rThres 16 SlowBcktThres 15 SlowBcktInc 0 SlowDgdr 0 98E0 SlowSlopProp 0 9083 0 MinSkipPts 6 ID G3 BltFact 0 1667E1 1320 MinSkipPts 216 MinAvgPts 24 MinAvgMed 1 SlopProp 0 1E0 SlowSlopProp 0 2E 1 FastDgdr 0 75E0 SlowDgdr 0 9E0 AcelSlopThres 20 SlowSlopThres 10 PosDlyThres 1 DltThres 100 NumAlg3Pts 576 PosSlopDly 720 DltDgdr 0 995EO0 Embedded H2 Parms ID H2 BltFact 0 1667E1 Resv 1320 AdjThres 70 AdjLim 4 StupPts 5 StupSumx 15 StupDenom 50 FastPts 17 FastSumx 153 FastDenom 6936 InitThres 6000 FastStupThres 6 SlopStupThres 0 1E1 FastCntrThres 12 FastBcktThres 0 105E2 FastBcktInc 1 FastRateThres 32 FastRateInc 3 FastDgdr 0 93E0 FastSlopProp 0 825E0 FastMayThres 3 SlowStupThres 12 SlowCntrThres 16 SlowBcktThres 15 SlowBcktInc 1 SlowDgdr 0 98E0 SlowSlopProp 0 9083E0 MinSkipPts 6 ID G3 BltFact 0 1667E1 Resv 1320 MinSkipPts 216 MinAvg
180. et as the rack is agitated Each board has a sensor however only one position in each drawer is utilized for monitoring The Event Request signal is a common open drain signal driven by the ModSig PCBA and all Rack Controller PCBAs The ModSig Rack Controller and WinSystems CPU board can also read the signal purpose is similar to an interrupt signal it s to notify the WinSystems CPU board that an event such as a bottle removal has occurred For the ModSig this signal is both an output to the WinSystems CPU board and an input from the Rack Controller When the Event Request is pulled low the Drawer ID low signal used by the Rack Controllers is disabled The Rack Controller drives the Drawer ID lines to indicate which Rack Controller s activated the Event Request line The Rack Control firmware reads the Event Hequest line before and after reconfirming its address to ensure address lines are not in use With only one of four lines low for each drawer the Rack Controllers can determine which drawer they are in for each address identification for WinSystems CPU board commands When the Event Request is low this is disabled allowing the same lines to be used by the Rack Controllers to identify which ones activated the Event Request The driving circuitry and input circuitry is provided on the Rack Controller Firmware on the ModSig aids the WinSystems CPU board in selecting which Rack Controllers read status thus expediting bottle detection sta
181. et the Flash Adapter hang down as shown in Figure 139 Unplug IDE Cable Unplug Power Cable Blue Black wires from the Zip Drive Fig 139 Zip Drive Flash Adapter PCBA Removal 4 120 Service Manual BacT ALERTG 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 12 Zip Drive P N 895 0004 38 Continued 5 Unplug the IDE cable from the Zip drive Refer to Figure 139 6 Unplug the Zip drive s main power connector Blue Black wires Do not pull on the wires to unplug the connector Unplug power connector by pulling on the connector itself Refer to Figure 139 7 Remove the four 4 screws securing the zip drive to the instrument Hold on to the Zip drive as you remove the last mounting screw Refer to Figure 140 CAUTION Slide the Zip drive out Hold on to the Zip Drive when by pushing it up and removing the screws The Zip through the portal hole drive can fall and be damaged when the last screw is removed Remove four 4 screws Remove four 4 screws securing the Zip Drive securing the Zip Drive to the 3D 60 s chassis v to the 3D 60 s chassis Fig 140 Zip Drive Screw Removal 8 Lower the Top Panel about half way From the bottom of the Zip drive push the drive through the cutout hole as shown in Figure 141 Fig 141 Zip Drive Removal Cutout Hole Service Manual 4 121 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 12 Zip Drive P N 895 0004 38
182. exit the load mode Printer Maintenance With the printer powered off clean the print head guide rod of any debris Clean the debris from the interior of the printer Run a printer se f test and install a new ink cartridge if the print quality is poor Reference specific printer operator or service manual for details Temperature Verification Wait for the temperature to stabilize Check the Incubation Chamber temperature using the internal reference thermometer Calibrate the system if the difference between the measured temperature and the BacT 3D 60 s temperature display exceeds 0 5 C Disabled Cell Check Inspect the Incubation Chamber for disabled cells and attempt to re calibrate those cells with Single Slug calibration standards If unable to recalibrate review with the customer and determine what corrective action will be suitable 5 DC Voltage Verification Verify and adjust the power supply voltage only if out of tolerance The 5 VDC Power Supply verification is done on the ModSig PCBA in the Electronics Compartment Refer to Subsection 4 9 6 to perform System Power Supply Check and Adjustments UPS Test 1 Perform UPS test a Setthe time to current local time b Disable the audible alarms via the system software c Remove AC power from the UPS Leave the UPS connected to the 3D 60 instrument and leave the power switches to both the UPS and the 3D 60 to ON d Verify that the UPS will emit an audible alarm with
183. ext following WARNINGS Used to identify actions that could result in INJURY or DEATH to personnel performing the procedure or close by These text boxes are identified by the word WARNING centered at the top of the box and bold capitalized text following IMAGE NOTES Used to explain steps of a process identify component parts suggestions and other steps related to the functionality of the instrument The text boxes are not identified with any special markings Generally they will surround photos and drawings and will explain processes parts or other related information Bracketed Italics Brackets around Italics text Italics Text identifies items to be clicked on the display screen 1 Press On Line to continue Underlined Text Underlined text identifies words groups or characters that are to be typed on the keyboard 1 Type Y E S to continue or Press ALT lt CTRL gt DEL to reboot xxi TYPOGRAPHY AND GRAPHIC CONVENTIONS BacT ALERT 3D 60 0 4 TYPOGRAPHY AND GRAPHIC CONVENTIONS CONTINUED 0 4 5 Bracketed Text Single text within brackets identifies single keys to be pressed on the keyboard 1 Press lt Esc gt to exit the system 0 4 6 Text Within Quotation Marks Whenever text is displayed within auotation marks it usually means that this a displayed message on the screen After previous step is complete the system will display Press Any Key to Continue 0 4
184. ey e ete t v e aes Drilling Template Mouse Port Open Door TEST eese tet eee Operating Reference Data Operating System Exception Log 2 Operation Error Codes eee reke Output ThermiStor rere reee Overload Protection cecene nene ceea cea acne cae cae e Overload Protector essen 1 20 1 22 Over voltage 22 2 11 D 5 PEM xxv 1 9 2 9 4 135 See Power Entry Module FUSES a e cal cacat aa 3 7 3 8 4 135 Replacement PEM Connections Peripheral Devices Phase OUtpUt i ite pete Res PIC16C74 Microcontroller Piezo 77 Port Connection Barcode Scanner eee 4 161 Domestic Modem eene 4 162 International Fax Modem eene 4 163 Keyboard m Port Stats Test eee nea nenea nnne 4 25 Positive Ground Terminal 4 171 Post Service 2 4 175 Power Consumed Power Distribution Block DiaStaim coe tote tete e Power Entry Module Fuse Replacement Power Event Power Fail Circuitry Power Power Panel Assembly Power Supply Check and Adjustments sss 4 74 Power Supply Cal See Alignments and Calibrations Power Supply Data Table 2 10 Power Supply Trans
185. former 4 126 Power Switch eee Power Up Down Power Fail Detection Preventive Maintenance Printer Maintenance Printer Port hre eee eee ekere kek ke nennen Quad Output 5 220 2 11 Quad Serial Interface Cable Connections 4 90 Removals xad auto icant is aes Quad Serial PCBA Diagram ta idrico es x paid aaa Se TRU Quick Reference Card Front Side Rear Side QuickScan 6000 BacT ALERT 3D 60 Cable Clamp see RS less Single Cell Calibration Calibrations Rack Address Concept sse Rack Assembly seen Captive Screw Removal Rack Cable Cover Rack Configuration Rack Controller IP EP E Rack Controller PCBA m Block Diagram aenea Reading SO g5 eerte N k ta Relay Removal Remote Diagnostics cccceseseceseseeceeceseecceseseeceeatseeeeeas Removing Quad Serial PCBA 4 82 Repacking ertet Diagram Web Strapping Diagram Restraint NI WO Serial UPS Cable E Serial UPS Port eR tete aet een e ettet Set Audible Alarm See Display Configuration Set Date and Time See Display Configuration Set Point Temperature sese 2 7 Set Test See Display Configuration SIMM an teet PERPE ES Se
186. gital signals used by the Rack Controller software The same AD Converter is used for converting cell sensor analog signals into digital signals Using the 2 5 reference voltage the resistor voltage dividers an operational amplifier and a MOSFET controls the current for the exciter LEDs Only one exciter LED is activated at any one time Service Manual 2 23 2 BACKGROUND INFORM ATION BacT ALERT 3D 60 2 10 STEP 5 PCBA Fig 43 Step 5 PCBA Diagram 2 24 Service Manual BacT ALERT 3D 60 2 BACKGROUND INFORMATION 2 10 STEP 5 PCBA CONTINUED The Step 5 controller board Reference 43 is designed to drive a five phase stepper motor at the speed of 60 revolutions per minute The board operates with input voltages of 5V and 12V drives the stepper motor directly and provides starting and stopping functions based on inputs received from the ModSig PCBA The STEP 5 controller board drives a Vextra 5phase stepper motor at 1 revolution per second 41096 to provide rack agitation The controller board s inputs outputs and features are listed below 1 Input DC voltages 5V and 12V 2 Input Control e interlocks Two door switches are used The two door switches are mechanical reed switches that are closed when the door is closed The STEP 5 uses optical isolators for these inputs when a switch is closed current flows through the corresponding optical isolator s LED If either switch is open indicating a
187. hart on page 3 8 1 Ensure the instrument is powered down Note the fuse orientation to the rear of the fuse holder Fig 47 Power Entry Module Fig 48 Fuse Holder w Fuse w Fuse Holder Removed Ensure that the main power and interface cables are disconnected Open the PEM cover using a small flat blade screwdriver Slide out the fuse holder Refer to Figure 47 above Remove the fuse s Refer to Figure 49 or Figure 50 on the next page ar wh Service Manual 3 7 3 INSTALLATION PROCEDURES BacT ALERT 3D 60 3 2 5 Set AC Power Continued 6 Install the fuse s for the proper voltage rating 7 Reinstall the fuse holder 8 Close the PEM cover Below you will find Table 3 2 2 an installation guide showing specific Facility Power Ratings and the proper fuse installation figure to use Note Facility power ratings for Japan are 100 Volts AC at 50Hz 10 Refer to Figure 49 for fuse installation Table 3 2 2 Facility Power Rating and Conversion Chart NOTE Refer to Figure 50 for 230 VAC version Steps for replacing fuses in the 230 VAC version are the same as the steps taken with the 115 VAC version with the exception of the fuse size and the 115V Conversion Clip which is not used for 230VAC Remove and dispose of the conversion clip if one is present CAUTION Installation of the 115 V conversion clip Figure 49 into the 230 VAC version Figure 50 COULD RESULT IN DAMAGE to the unit
188. he cells Each standard is identified by the number of rings around the end of the standard CELL Holds and monitors each culture bottle Each cell is numbered from 1 through 60 CELL FLAG Secures bottles in cells Aids in cell diagnostics and with bottle loading and unloading determinations CELL INDICATOR to show the location of positive negative or anonymous bottles as well as to LIGHT show where new bottles should be placed removed An indicator light is adjacent to each cell The Incubation Chamber contains three racks 60 cells in total for a total capacity of 60 culture bottles E zani lt a CURSOR A marker for the active site where input would be directed In BacT VIEW it refers to either the pointer position indicator mouse cursor or the text entry position caret D A CONVERTER A device that transforms digital signals to an analog electrical format DATA SIGNAL Contained within the ModSig PCBA and routes all signals within the Instrument DISTRIBUTION DC POWER SUPPLY Device that produces the required DC voltages used within the Instrument DIMMED BacT ALERT 3D 60 disables dims or grays user interface i e menu items buttons text fields that are unavailable duc to security restrictions or due hs the current context of the software Disabled user interface items are not selectable DISABLED Describes a user interface item i e menu item button text entry field that is not currently select
189. hres 32 FastRateInc 3 FastDgdr 0 93E0 FastSlopProp 0 825E0 FastMayThres 3 SlowStupThres 12 SlowCntrThres 16 SlowBcktThres 15 SlowBcktInc 1 SlowDgdr 0 98E0 SlowSlopProp 0 9083E0 MinSkipPts 6 1 ID E2 BltFact 0 1E1 Resv 1320 AdjThres 70 AdjLim 4 StupPts 5 StupSumx 15 StupDenom 50 FastPts 17 FastSumx 153 FastDenom 6936 InitThres 3300 FastStupThres 6 SlopStupThres 0 1E1 Service Manual 4 51 4 SERVICING SOFTWARE DIAGNOSTICS BacT ALERT 3D 60 4 52 FastCntrThres 12 FastBcktThres 0 105E2 FastBcktInc 1 FastRateThres 32 FastRateInc 3 FastDgdr 0 93E0 FastSlopProp 0 825E0 FastMayThres 3 SlowStupThres 12 SlowCntrThres 16 SlowBcktThres 15 SlowBcktInc 1 SlowDgdr 0 98E0 SlowSlopProp 0 9083E0 ID G2 BltFact 0 1E1 Resv 1320 MinSkipPts 216 MinAvgPts 24 MinAvgMed 1 SlopProp 0 1E0 SlowSlopProp 0 2E 1 FastDgdr 0 75E0 SlowDgdr 0 9E0 AcelslopThres 20 SlowSlopThres 10 PosDlyThres 1 DltThres 100 NumAlg2Pts 576 PosSlopDly 720 DltDgdr 0 995E0 Embedded E2 Parms ID E2 BltFact 0 1E1 Resv 1320 AdjThres 70 AdjLim 4 StupPts 5 StupSumx 15 StupDenom 50 FastPts 17 FastSumx 153 FastDenom 6936 InitThres 3300 FastStupThres 6 SlopStupThres 0 1E1 FastCntrThres 12 FastBcktThres 0 105E2 FastBcktInc 1 FastRateThres 32 FastRatelnc 3 FastDgdr 0 93E0 FastSlopProp 0 825E0 FastMayThres 3 SlowStupThres 12 SlowCntrThres 16 SlowBcktThres 15 Slo
190. ich is connected to the DTR line is monitored and if found inconsistent with the assert RTS DTS signals this count is incremented Service Manual 4 37 4 SERVICING SOFTWARE DIAGNOSTICS BacT ALERT 3D 60 7 3 INSTRUMENT CNTRL Modem Loopback Screen Special equipment P N 43012 1 Description This diagnostic verifies that the operation of the serial hardware that makes up the interface to the external modem It isolates problems to either the external modem or instrument controller Impact Bottle testis not affected by this diagnostic Test Procedure a Replace the modem cable connector at the instrument controller end with the loopback connector P N 43012 1 Start diagnostic Let run for a period of 2 minutes Verify that FAIL count on 4 2 is 0 Exit diagnostic Remove loopback connector and reattach modem cable Keyboard functions status Runs continuously and updates the display continuously NOTE Displayed data is the same shown for the barcode loopback test Refer to Section 7 2 4 38 Service Manual BacT ALERT 3D 60 4 SERVICING SOFTWARE DIAGNOSTICS 7 4 INSTRUMENT CNTRL Power event log screen Special equipment Description Shows recent history of power events including power faults in the instrument controller and incubation module Bottle testing is not affected by this diagnostic EN A 000 _ u Test Procedure N A Keyboard functions Run status Runs continuously and updates th
191. ig Fig Fig Fig Fig 120 ModSig Rear Panel Screw Removal ssc scscssssssssssssesssssessesessesesseseeessessensesseeeeensesasanensseseeneneseseaneneasaes 4 100 121 ModSig PCBA Mounting Screw Locations 4 101 122 ModSig Step 5 MCJ4 Connection 123 ModSig Rear Panel Hex Nut amp Knurled Nut 4 103 124 ModSig PCBA JP10 JP1 and Ground Cable csscscsssesesssesessesessseessenseseeeeeseeeeeeeenseeseeneneeeeeaneneeaes 125 ModSig PCBA Fuse 126 ModSig PCBA Fuse Locations 1 127 ModSig PCBA Installed Fuse Locations 2 128 Step 5 PCBA Location nne 129 Step 5 PCBA Connector and Wiring Locations 130 Step 5 Motor Windings sene 131 Step 5 Motor Removal Disconnection 132 Step 5 Motor Removal Set Screw Remowval 133 Step 5 Motor Removal Mounting Screw Removal 134 Step 5 Motor 135 Step 5 Motor R
192. iguration is required Hash marks exist with or without enable disabled racks or rack configuration Fig 29 Instrument Configuration Screen 1 26 Service Manual 1 GENERAL INFORMATION BacT ALERT 3D 60 1 5 1 3 Service Manual Configuration Screen X Box Buttons Several configuration options are represented by a graphical element called an X Box button As shown in Figure 30 below an X Box button can appear with or without an X in the box The X determines the active selection Clicking inside the box with the mouse switches the box to the opposite state E Fig 30 X Box Selection Checkbox 1 27 1 GENERAL INFORMATION BacT ALERT 3D 60 THIS PAGE INTENTIONALLY LEFT BLANK 1 28 Service Manual 1 GENERAL INFORMATION BacT ALERT 3D 60 1 6 QUICK REFERENCE CARD The Quick Reference Card Figure 31 and Figure 32 on the following pages Front and Rear Sides respectively is simply that a quick reference The card contains references to errors and fault codes that may appear on the BacT ALERT 3D 60 during operation The card s purpose is to aid the operator in determining what have caused a particular problem does not contain corrective action measures For more information refer to Appendix D Error Codes of this manual and the BacT ALERT 3D 60 Operator s Manual for possible solutions Service Manual 1 29 1 GENERAL INFORMATION 1 6 Code 901 902 910 911 912
193. igure 99 for screw removal locations 3 Remove the instrument s Right Side Panel to access the Power Panel Assembly 4 Remove the Power Panel Assembly from the 3D 60 instrument as shown in the removal steps in the previous section Refer to Section 4 10 13 System Power Panel removal Power Supply Transformer Fig 148 Power Supply Transformer Power Supply Panel Removed 4 126 Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 14 Power Supply Transformer P N 851 0015 01 Continued CAUTION Proper ESD precautions must be observed whenever working on or around any PCBA transformer to the panel chassis n Green Brown E TB1 4B Red Blue TB1 1B w Transformer Brown Wire Fig 149 Power Panel with Transformer Installed Fig 150 Transformer PEM Connections 5 Unplug the four 4 Transformer wires that plug into the PEM Brown PWRSWA Orange PWRSWB Red PWRSWC and Yellow PWRSWD Refer to Figure 150 6 Remove the screw securing the transformer to the Power Panel Assembly chassis Refer to Figure 149 7 Remove the screws Terminal Block TB1 1B and TB1 4B Disconnect the Green Brown wires from TB1 4B and the Red Blue wires from TB1 1B Refer to Figure 150 8 Reverse Steps 6 and 7 to mount the new transformer back onto the unit s chassis and reinstall the Red Blue wires onto terminal TB1 1B and the Green Brown
194. ikely to make the instrument dangerous to lab personnel and other users Any adjustment maintenance or repair of the opened instrument while under voltage should be avoided If power to the instrument is necessary repair or maintenance shall be carried out only by a trained and qualified individual who is aware of the hazard s involved with the task In addition a second individual will be nearby to render aid if necessary Make sure that only fuses with the required current rating and of the specified type are used for a replacement The use of makeshift fuses or the short circuiting of any fuse holder is extremely dangerous and prohibited See Subsection 3 2 5 Set AC Power Whenever it is likely that a BacT ALERT 3D 60 has been impaired it will be made inoperative by powering it down and disconnecting the power cord If there is evidence of moisture within the instrument turn the facility power off at the circuit breaker junction box before removing the power cable The instrument is likely to be impaired if it e Shows visible damage e Fails to perform an intended operation e Has been subjected to storage or operation under unfavorable conditions i e above 80 humidity dusty environment prolonged storage Refer to Section 1 2 Table 1 2 1 for tolerances e Has been subjected to severe transport stresses If any of the above conditions occur a qualified service technician must check the instrument out prior to use
195. in 1 minute Observe that the blue Abnormal Shutdown Screen appears on the instrument s monitor screen 4 SERVICING PREVENTIVE MAINTENANCE BacT ALERT 3D 60 4 6 8 UPS Test Continued f Observe 3D 60 power off g After the instrument powers off restore power to the UPS h Verify that the instrument retains correct time and has no visible errors displaced on the monitor screen 4 6 9 Door Open Test With the door of the BacT 3D 60 instrument open there are some functional indicators that will alert the operator that the system is not agitating 1 Open the door on the BacT 3D 60 There should be a red screen on the display monitor with a fault icon 20 that will indicate that the door is open after approximately 2 minutes 2 An audible alarm will also sound when the door is ajar 3 You can visually check LED D55 and 056 on the ModSig PCBA They both should illuminate when the door is closed Both are off when the door is open Refer to Figure 64 for LED D55 and D56 locations 4 Use the Incubation Heater diagnostic screen See Software Diagnostics Subsection 1 8 to verify the door switch settings Ms a fum LEDs D55 amp D56 are in d the bottom right corner of the ModSig PCBA Fig 64 ModSig PCBA LED 55 and 56 location 4 6 10 Completing the Preventive Maintenance Card Complete the Preventive Maintenance Card and transfer any pertinent information from the back of the old
196. inSystems CPU and one 60 bottle chamber consisting of three racks of 20 culture bottles each An externally attached display monitor permits the operator to control and monitor the racks Refer to Figure 4 below BacT ALERT 30 Fig 4 BacT ALERT 3D 60 Instrument Service Manual 1 3 1 GENERAL INFORMATION BacT ALERT 3D 60 1 4 ASSEMBLY DESCRIPTIONS The following paragraphs indicate the composition of the system i e the equipment hardware software and consumables required for it to operate 1 4 1 Electrical Components Fig 7 Blower amp Heater 1 4 Service Manual 1 GENERAL INFORMATION BacT ALERT 3D 60 1 4 1 1 4 1 1 1 4 1 2 1 4 1 3 1 4 1 4 Service Manual Electrical Components Continued Power Panel Assembly The BacT ALERT 3D 60 instrument uses a standard BTA cabinet power supply The Power Panel Assembly provides the AC and DC power supply voltages that are used within the 3D 60 With the use of relays this will also shut down incubation processes when instructed to do so by the ModSig PCBA The power supply provides the four separate DC voltages 5V and 12V used throughout the instrument Refer to Figure 5 Transformer Assembly This is a transformer to isolate the instrument from facility power and is installed on the System Power Panel Refer to Figure 6 Heater The heater provides the necessary heat for the incubation process of bottle cultures Refer to Figure 7
197. ing Link Triangular plate Remove the bottom bushing nut shown Remove the bushing screw from the opposite side l m e e e e e E Fig 180 Step 5 Drive Agitation Linkage Assembly 4 Remove the bottom bushing nut Refer to Figure 180 5 From the reverse side of the Connecting Link the triangular panel remove the bottom bushing screw from the Linkage Assembly with a Phillips screwdriver 6 Remove the two 2 set screws from the Motor Offset Round Refer to Subsection 4 10 9 Step 5 Motor Set Screw Removal Figure 132 Service Manual 4 153 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 25 Step 5 Drive Agitation Linkage Assembly P N 48418 1 Continued 4 154 You should not have to assemble or dissemble the bearing Brass Threaded Insert Ou P M pieces snap together Brass Plate amp Insert bearing assembly into threaded part Torque Screw and nut to 20 in JL end plate Proper tension 25 in lbs for the bearing tightens the brass end plate against the brass insert The plastic material is not compressed Fig 181 Drive Linkage and Bushing Specs Slide the entire Drive Linkage Assembly with Motor Offset Round attached to Drive Linkage up and out of the 3D 60 instrument The bottom part of the Linkage slides through the cutout hole in the support panel See up arrows shown in Figure 180 When removing the entire Dr
198. ing the Configuration Screen Perform the following steps to gain access to the Configuration Screen 1 Atthe Main Screen click on the Next Screen button Refer to Figure 27 below Next Screen button Fig 27 Main Screen 2 Once at the Setup Screen Refer to Figure 28 enter the Field Engineer password lt 4 gt lt 3 gt lt 4 gt lt 3 gt lt 2 gt lt 1 gt lt 2 gt lt 1 gt by clicking on the number buttons at the top of the screen After entering the password click on the Key button See Setup Screen on the next page for Screen Diagnostics Service Manual 1 25 1 GENERAL INFORMATION BacT ALERT 3D 60 1 5 1 1 Accessing the Configuration Screen Continued Password Key buttons System Setup Screen Configure Screen button Previous Screen button Fig 28 Setup Screen w Field Engineer Password Activation Clicking on the Configure Screen button will access the Configuration Screen NOTE To get back to the Main Screen press the Previous Screen button 1 5 1 2 Instrument Configuration Screen Initial Entry Use this screen to configure the instrument Refer to Figure 29 below Determines whether a period or comma this is usedasa decimal point Designates which racks are installed in the 3D 60 instrument When checked this box designates the unit as an MB unit NOTE Checks for enable disabled racks as well as rack conf
199. ip disk into the Zip drive At the CA prompt type Restore and press the Enter key Reboot the system by using the power switch by turning it off and on again Verify the contents of the bottle table and the software version Wait 10 minutes to make sure no errors occur on the display screen such as Fault 19 If Fault 19 occurs call Technical Support Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 6 ModSig PCBA P N 48300 1 Order Spare P N 48300 901 1 Refer to Subsection 4 3 2 and perform the 3D 60 Power Down Unplug all peripherals 2 Remove the two 2 screws securing the Top Panel and secure it into the Up position Refer to Figure 99 for screw removal locations CAUTION Proper ESD precautions must be observed whenever working on or around any PCBA 3 Starting at the upper left section of the PCBA perform the following steps a Unplug MSJ2 This connector is keyed with a tab lock Refer to Figure 113 b Unplug MSJP2 Refer to Figure 113 Unplug JP10 P1 Refer to Figure 113 NOTE JP4 and JP28 connectors have no cables connected to them 3 i Unplug MSJ2 Unplug MSJP2 1 Har i Unplug JP10 P1 EL Fig 113 ModSig PCBA Connector Location Service Manual 4 95 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 6 ModSig PCBA P N 48300 1 Continued Order Spare P
200. ires underneath the Step 5 PCBA and plug it in before installing the support screws 8 Plug in MCJ3 Motor wiring to connector J3 and route the cables underneath the Step 5 and ModSig PCBA s Ensure that all of the wires are routed between the inner support standoffs on both PCBA s Refer to Figure 129 9 Install the support screws and check the cable and wiring routes as you reinstall them See NOTE above 10 Close the System Top Panel and secure it with two 2 screws Refer to Figure 99 11 Refer to Subsection 4 3 3 and perform the 3D 60 Power Up procedure 12 Refer to Subsection 4 11 and perform the Post Service Validation procedure 13 Annotate appropriate maintenance and logbooks 14 Return the system to normal operation 4 110 Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 9 Step 5 Motor P N 48104 1 Black Orange Red Resistance Table NOTE Readings may vary 0 2 o There is no measurable conductivity between the windings and frame Fig 130 Step 5 Motor Windings Service Manual 4 111 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 9 Step 5 Motor P N 48104 1 Continued 1 Refer to Subsection 4 3 2 and perform the 3D 60 Power Down procedure 2 Remove the two 2 screws securing the Top Panel and secure it into the Up position Refer to Figure 99 3 Unplug MCJ3 from connector J3 Refer to Figure 131 Fig 131 St
201. ive Linkage Offset Round assembly you will have to pull the Motor Offset Round slightly towards you to slide the Offset Round off of the Step 5 Motor s drive shaft Separate remove the Drive Linkage Assembly from the Motor Offset Round by removing the bushing nut on the reverse side of the Offset Round Remove the bushing screw from the Drive Linkage Assmbly shown in Figure 180 Set the Drive Linkage Assembly aside Install the new Drive Linkage Assembly onto the Motor Offset Round by inserting the top bushing screw through Linkage Assembly and the Motor Offset Round Torque the bushing screw to 20 in lbs Install the top bushing nut located on the reverse side of the Offset Round onto the bushing screw Torque the bushing nut to 20 in Ibs Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 25 Service Manual Step 5 Drive Agitation Linkage Assembly P N 48418 1 Continued 15 16 17 19 20 21 NOTE An Offset Round Spacing tool part number to be determined is required to properly space the system chassis from the Motor Offset Round prior to installing the Offset Round onto the Drive Motor shaft The tool is insterted between the system s chassis and the Motor Offset Round prior to reinstalling the set screws into the Offset Round Reinstall the combined Motor Offset Round Drive Linkage Assembly by sliding the bottom part of the Linkage Bar through the cutout hole in the
202. k being replaced Refer to Figure 177 Rack Controller PCBA cable connections Li Fig 178 Rack Cable Disconnection 6 Disconnect the cable s from the Rack Controller PCBA Refer to Figure 178 4 150 Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 24 Rack Assembly P N 43147 921 922 923 Continued T Captive screw locations Fig 179 Rack Assembly Captive Screw Removal 7 Loosen the two 2 Captive Screws located at either end of the defective Rack Assembly Refer to Figure 179 8 Slide the Rack Assembly out of the instrument Disinfect the rack if necessary 9 Remove the two 2 screws securing the Rack Cable Clamp of the new Rack Assembly Remove the ground cable from the old Rack Cable Clamp Retain the old parts and return them with the defective Rack Assembly 10 Disconnect the daisy chained cables from the Rack Interface PCBA connectors 11 Install ground cables on the new Rack Cable Clamp 12 f replacing a rack with cells 1 through 20 or 21 through 40 remove the plug from P1 on the Rack Interface PCBA Retain these parts and return them with the defective Rack Assembly 13 Slide the new rack into the instrument and tighten the two 2 Captive Screws Refer to Figure 179 for screw locations 14 Plug the rack cable connectors daisy chained cables of the Rack Assembly into the appropriate sockets on the Rack Interface PCBA
203. k ideo eee ete eet ee aee ieee 1 15 1 4 3 8 2 gt Cell cre deter tip pt ae 1 15 1 43 8 3 ette iz 1 15 1 4 3 8 4 Indicator Lamp sse 1 15 Service Manual BacT ALERT 3D 60 1 4 4 1 4 5 1 5 1 1 6 QUICK REFERENCE CARD 2 BACKGROUND INFORMATION 2 1 INTRODUCTION 2 5 DC POWER SUPPLY 2 6 PCBA 2 9 RACK CONTROLLER PCBA TABLE OF CONTENTS Input Output Devices K RR RAA k kl s k kun y ke 1 16 1 4 4 1 Operator Display Monitor ceea KK KA 1 17 1 4 4 2 Barcode Scanner es Qele Pr ROSE pu e wad QE deu einen 1 17 1 4 4 3 oet x em tea e eh eee 1 17 1 4 4 4 Zip DOVE vee 1 17 1 4 4 5 56K FAX Modem 1 19 1 4 4 6 56K Fax Modem 1 19 Uninterruptible Power Supply 1 20 1 4 5 1 On Off ud m 1 21 1 4 5 2 UPS Comm Port Computer Interface 1 21 1 4 5 3 Overload Reset 0 1 21 1 4 5 4 Test Check Battery Alarm Disable Switch 1 21 1 4 5 5 120V Backup Receptacles 1 21 1 4 5 6 Accessory Surge 1 21 1 4 5 7 Powel indie tit tea ede pub
204. ld remain at 0 Number of modem status interrupts generated by serial hardware note this interrupt is disabled as indicated on the screen Total of lines 1 1 through 1 4 Should remain at 0 Number of overruns reported by serial hardware An overrun occurs if received data is not removed from the serial hardware faster than it comes in This value should remain at 0 Should remain at 0 Number of parity errors reported by serial hardware Parity error checking is turned off so no errors should be reported _1 1 12 kA Should remain at 0 Number of framing errors reported by serial hardware A framing error occurs if the number of serial bits between the start and stop bit are not correct This value can be ignored It is displayed for diagnosis of software activity and indicates whether the software s transmit data FIFO is empty or not 1 or 0 respectively Should remain at 0 0 0 Displayed for purpose of diagnosing software activity and indicateswhether there was fault storing 41 pee data in the software s transmit data FIFO and where in the code that fault occurred Should increment Indicates the number of times data loopback test was run and passed Should remain at 0 Indicates the number of times loopback test was run and failed Should remain at 0 Indicates the number of times loopback data was transmitted but a timeout occurred before all the data was received Should remain at 0 Indicates th
205. lopStupThres 0 1E1 FastCntrThres 12 FastBcktThres 0 105E2 FastBcktInc 1 FastRateThres 32 FastRateInc 3 FastDgdr 0 93E0 FastSlopProp 0 825E0 FastMayThres 3 SlowStupThres 12 SlowCntrThres 16 SlowBcktThres 15 SlowBcktInc 1 SlowDgdr 0 98E0 SlowSlopProp 0 9083E0 MinSkipPts 6 ID H2 BltFact 0 1667E1 Resv 1320 AdjThres 70 AdjLim 4 StupPts 5 StupSumx 15 StupDenom 50 FastPts 17 FastSumx 153 FastDenom 6936 InitThres 6500 FastStupThres 6 SlopStupThres 0 1E1 FastCntrThres 12 FastBcktThres 0 105E2 FastBcktInc 1 FastRateThres 32 FastRateInc 3 FastDgdr 0 93E0 FastSlopProp 0 825E0 FastMayThres 3 SlowStupThres 12 SlowCntrThres 16 SlowBcktThres 15 SlowBcktInc 1 SlowDgdr 0 98E0 SlowSlopProp 0 9083E0 MinSkipPts 6 ID G2 BltFact 0 1667E1 Resv 1320 MinSkipPts 216 MinAvgPts 24 MinAvgMed 1 Service Manual BacT ALERT 3D 60 4 SERVICING SOFTWARE DIAGNOSTICS 10 11 12 SlopProp 0 1E0 SlowSlopProp 0 2E 1 FastDgdr 0 75E0 SlowDgdr 0 9E0 AcelSlopThres 20 SlowSlopThres 10 PosDlyThres 1 DltThres 100 NumAlg2Pts 576 PosSlopDly 720 DltDgdr 0 995E0 Embedded E2 Parms ID E2 BltFact 0 1667E1 Resv 1320 AdjThres 70 AdjLim 4 StupPts 5 StupSumx 15 StupDenom 50 FastPts 17 FastSumx 153 FastDenom 6936 InitThres 6000 FastStupThres 6 SlopStupThres 0 1E1 FastCntrThres 12 FastBcktThres 0 105E2 FastBcktInc 1 FastRateThres 32 FastRateInc 3
206. m Refer to Figure 188 Connect the telephone Line In Telco cable to the fax modem Refer to Figure 188 Ensure modem DIP switch setting are as shown in Figure 188 Connect the AC Adapter to the modem and return the system to normal operation 4 162 Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 31 International Fax Modem P N 957 0004 364 Modem Port Connection 957 0004 305 25 pin to 9 pin cable 0000 Imm International modem has two DIPswitch settings are on the UU additional DIPswitch settings rear of the modem 12345678719 10 9 and 10 both set to ON Fig 190 Modem Port Connections International Model L DH Ar z BARCODE KETERD as us Fig 191 International 56K Fax Modem Rear Port Connection 1 Disconnect the fax modem cable from the Modem port on the rear of the 3D 60 Instrument Refer to Figure 191 Disconnect the same cable from the fax modem Refer to Figure 190 2 Disconnect the Phone cable from the fax modem Refer to Figure 190 3 Disconnect the telephone Line In Telco cable from the fax modem and set the defective fax modem aside Refer to Figure 190 4 Connect the fax modem cable to the Modem port on the rear of the 3D 60 Instrument and connect the other end to the fax modem Refer to Figure 191 and Figure 190 Connect the Phone cable to the fax modem Refer to Figure 190 Connect the telephone Line
207. manual contains WARNINGS CAUTIONS and NOTES specific instructions and other information that must be followed and observed at all times This will help ensure the safe handling and operation of the instrument NOTE Clarifies or explainsa particular step or procedure A note box is identified with the word NOTE in bold text and the explanatory body text is not bolded CAUTION Warns of a risk of DAMAGING equipment or components A caution may be identified with the word CAUTION and its explanatory body text is bolded WARNING Identifies a process step that may cause injury or DEATH to personnel warning may be identified with the word WARNING and its explanatory body text is bolded in all caps 0 5 2 Electrical Warnings The BacT ALERT 3D 60 has been designed and tested IAW IEC Publication 61010 1 Safety Requirements for Electrical Equipment for Measurement Control and Laboratory Use UL 3101 1 CAN CSA C22 2 No 1010 1 92 and has been supplied in safe condition A CB Certificate and Construction File have been established for the instrument 1 Service Manual Before applying power ensure that the Power Entry Module PEM is properly configured for the specific facility power voltage Also ensure that the fuse s is are installed and of proper rating value See Subsection 3 2 5 Set AC Power Any interruption of the protective conductor inside or outside of the instrument or disconnection of the protective earth terminal is l
208. move the two 2 screws from the system chassis in the rear of the instrument as shown in order to remove the Power Panel Assembly Refer to Figure 145 7 Lift the defective Power Supply Assembly up and out of the 3D 60 instrument You may have to push the Top Panel beyond the normal locked position of the Gas Spring Assembly in order to clear the Power Supply Panel from the 3D 60 instrument 8 Reverse the previous steps to install the new Power Supply Assembly 9 Ensure that all wiring connectors are reconnected prior to power up 10 Close the System Top Panel and secure it with two 2 screws 11 Use cardstock to protect the door seal when installing Reinstall Right Side Panel 12 Refer to Subsection 4 3 3 and perform the 3D 60 Power Up procedure 13 Refer to Subsection 4 11 and perform the Post Service Validation procedure 14 Annotate appropriate maintenance and logbooks 15 Return the system to normal operation Service Manual 4 125 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 14 Power Supply Transformer P N 851 0015 01 NOTE Individual power supply subassembly components are not repaired or replaced in Domestic 3D 60 s Individual components are spared as parts and replaced in International 3D 60 instruments only 1 Refer to Subsection 4 3 2 and perform the 3D 60 Power Down procedure 2 Remove the two 2 screws securing the Top Panel and secure it into the Up position Refer to F
209. moving parts Care must be taken to avoid exposure of clothing hands fingers arms etc Prior to performing maintenance procedures around moving parts it is advised that loose clothing i e ties long sleeves etc be secured Heating Element The instrument contains a heater to perform the incubation process The heater may remain hot for a period of time after the unit is first shut down for maintenance To prevent burns avoid contact with the heater until it is known that it is cool enough to touch xxvii SAFETY SUMMARY BacT ALERT 3D 60 THIS PAGE INTENTIONALLY LEFT BLANK xxviii Service Manual BacT ALERT 3D 60 CHAPTER 1 GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION BacT ALERT 3D 60 THIS PAGE INTENTIONALLY LEFT BLANK Service Manual BacT ALERT 3D 60 1 GENERAL INFORMATION 1 GENERAL INFORMATION This chapter describes the theory of operation and the general characteristics of the equipment 1 1 INTRODUCTION The following is a comprehensive list of the general descriptions of instrument components operational reference data subassemblies and operator display configurations 1 GENERAL INFORMATION 5 aaa ia iai aa ian aa AK AK AK aaa KK KK KK a ii 1 1 1 1 ele lak ka ya kaka l eu a kr kd ak ku k Kak ER s da aS ai a 1 1 1 2 REFERENCE DAT A HEB ve EK EV sce dioe eV Ee A 1 2 1 3 EQUIPMENT DESCRIPTIO
210. n This prompts the user to verify the cell is empty and the instrument s door is closed Close the door before going to Step 8 8 Click the Check button NOTE The rack and cell scroll buttons will be grayed out and inactive until calibration of the cell is complete 9 If instrument fault code 20 appears on the top of the Calibrate Staircase icon the door is not closed Close the door to clear error code 20 and click on the Check button again Note If door is left open more than 2 minutes error 20 will reappear 10 Insert the Standard Number One into the selected cell A single ring around the end of the reflectance standard identifies Standard 1 11 Click the Check button 2 will appear above the second step of the Calibration Staircase icon 12 Insert Standard Number Two into the selected cell Two rings around the end of the reflectance standard identify Standard 2 4 72 Service Manual BacT ALERT 3D 60 4 SERVICING ALIGNMENTS AND CALIBRATIONS 4 9 5 Rack Single Cell Calibration Continued 13 Click the Check button 3 will appear above the third step of the Calibration Staircase icon 14 Insert the Standard Number Three into the selected cell Three rings around the end of the reflectance standard identifies Standard 3 15 Click the Check button 4 will appear above the fourth step of the Calibration Staircase icon 16 Insert Standard Number Four into
211. n on the Locking Tab too hard The Locking Tab can be damaged losing its ability to lock the heater in place Locking Tab 1 Pull down gently to release heater Fig 167 Heater Removal Gently pull down on the Locking Tab and remove the Heater by pulling outward from the bottom of both ends Refer to Figure 167 Steps 1 and 2 Install the new heater by aligning the Support Tabs with the top holes in the Heater Push the bottom of both ends of the Heater inward until the Locking Tab locks the Heater in place Refer to Figure 167 Reinstall the HTR 1 and HTR2 wires on the terminals and secure with lock nuts Refer to Figure 166 Reinstall the Left Side Panel Use cardstock to cover the foam gasket around the door in front to prevent damage to the foam Remove cardstock after panel is reinstalled Close the System Top Panel and secure it with two 2 screws Refer to Figure 99 Refer to Subsection 4 3 3 and perform the 3D 60 Power Up procedure Refer to Subsection 4 11 and perform the Post Service Validation procedure Annotate the appropriate maintenance and lab logbooks Return the system to normal operation 4 141 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 21 4 142 Blower Assembly P N 4841 1 1 po oR Unplug BLP1 BLJ1 Connector for Power Cable Mounting Screws T and Lock Nuts s P Blower Power Cable Fig 168 Blower M
212. nce 2 gt 1 5 1813 3 12 4 2 12 1815 1 57 1852 1 82 1A55 1 72 1B15C 1 82 1B17 1 77 1 19 2 3 1B25 1 67 1B29 2 37 1B38 2 22 1B39 2 07 1B48 1 77 1B48 1 72 1B59 1 72 Difference 2 gt 2 8 1813 3 12 1R14C 2 12 1B19 2 32 1B29 2 32 1B38 2 22 1B39 2 82 1 Diff 7 2 Details C Calibrate Fig 92 Incubator Flag Check Cell Differences Screen 5 Observe cells displayed in the Differences gt 1 5 section on the screen use the Scroll Up Down buttons to find this section if necessary Write down the cell numbers or if printer is available print out the list of cell numbers by clicking the Print button 6 Enter lt C gt from the keyboard to go to the Calibrate screen Refer to Figure 93 Flag Check Cell Calibration Screen Service Manual 4 71 4 SERVICING ALIGNMENTS AND CALIBRATIONS BacT ALERT 3D 60 4 9 5 Rack Single Cell Calibration Continued BacT ALERT 3D SelectLink 16 41 22 04 23 01 1 7 Inc Module 1 Flag Check 0000000000 0000000000 0000000000 0000000000 0000000000 1 Diff Z 2 Details C Calibrate Fig 93 Flag Check Cell Calibration Screen 7 Input select the menu buttons Rack and Cell that require calibration by choosing the appropriate cell 1 60 with the cell scroll buttons The first screen displays an X at the bottom of the staircase ico
213. nce detection Cell indicator LEDs are controlled for operator information Status and data are communicated through an RS 485 cable from the Rack Controller to the ModSig board The microprocessor software also monitors the bottle rack rocking motion with a Hall Effect sensor In addition the software normalizes illumination readings with cell and temperature calibration factors Address lines from the ModSig are used to confirm that the 3D 60 s WinSystems CPU board is addressing the correct Rack Controller thus eliminating the need for switches on each Rack Controller Calibration values are stored onboard the Rack Controller PCBA in a non volatile RAM NVRAM The Rack Controller PCBA is located in the rear portion of the rack channel of the Incubation Chamber fully implemented Incubation Chamber will have three Rack Controller PCBAs The microprocessor is the Motorola 68HC11 and the same used on the ModSig PCBA This microprocessor has separate 16 bit address and amp bit data lines defined This eliminates the need of having external address and data multiplexing for the external 32KB of RAM and 32KB of EPROM included on the PCBA The clock speed of the 68HC11 is set at 16 MHz by an external crystal Internally the microprocessor contains 512 bytes of EPROM 1024 bytes of RAM and no ROM External memory for the microprocessor is on the Rack Controller PCBA A 16 bit free running counter driven by a programmable prescaler and other divid
214. ne which fuse s are defective and replace it them with a new fuse that has the proper amperage and voltage ratings 4 136 Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 18 Power Entry Module Fuses P N 870 0008 14 17 24 25 Continued NOTE Refer to Figure 163 for 230 VAC version Steps for replacing fuses in the 230 VAC version are the same as the steps taken with the 115 VAC version with the exception of the fuse size and the 115V Conversion Clip which is not used for the 230VAC Remove and dispose of the conversion clip if one is present CAUTION Installation of the 115 V conversion clip shown in Figure 162 into the 230 VAC version Figure 163 COULD RESULT IN DAMAGE to the unit Conversion Clip 4 orientation V Aa 54 pits i n e 2103245 s 1 ud li E l bej d imn 1 pL p 6 3A 250V time delay F ct TA P 6 ime delay Fuse l A i time delay amp 22129 S Y m 2 em Fig 162 w 115 VAC Version Fig 163 PEM w 230 VAC Version 5 Reinstall the fuse holder Refer to Figure 160 and Figure 161 6 Close the PEM cover Refer to Figure 160 7 Refer to Subsection 4 3 3 and perform the 3D 60 Power Up procedure 8 Refer to Subsection 4 11 and perform the Post Service Validation procedure 9 Annotate the appropriate maintenance and lab logbooks 10 Return the system to normal operation Service
215. nt Refer to Figure 186 3 Connect the new keyboard to the PS2 port connector labeled Keyboard on the rear panel of the instrument 4 Refer to Subsection 4 3 3 and perform the 3D 60 Power Up procedure 5 If the keyboard is still not working refer to Subsection 4 7 2 Table 4 7 1 Diagnostics and Troubleshooting for the Keyboard Also check PS2 connector on the ModSig Board for damage 6 Refer to Subsection 4 11 and perform the Post Service Validation procedure Annotate appropriate maintenance and logbooks 8 Return the system to normal operation N 4 160 Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 29 Barcode Scanner P N 957 0004 291 PRINTER _ em a WONIOR wm m Connection the Barcode Scanner cable into this port on the rear im panel of the 3D 60 instrument Fig 187 3D 60 Rear Panel Barcode Scanner Port Connection 1 Refer to Subsection 4 3 2 and perform the 3D 60 Power Down procedure 2 Unplug the Barcode Scanner s cable connector from the port on the rear panel of the 3D 60 Instrument labeled Barcode Reference Figure 187 3 Plug in the connector on the new Barcode Scanner into the port labeled Barcode 4 Refer to Subsection 4 3 3 and perform the 3D 60 Power Up procedure 5 If the barcode wand is still not working refer to Subsection 4 7 2 Table 4 7 1 Diagnostics and Troubleshooting for the Barcode Scanner
216. nt to prevent damaging the foam when reinstalling the side panel Ensure alignment is proper before pushing the side panel down fully into its secured position 4 115 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 9 4 116 Step 5 Motor P N 48104 1 Continued 15 16 17 18 19 Close the System Top Panel and secure it with two 2 screws Refer to Figure 99 Refer to Subsection 4 3 3 and perform the 3D 60 Power Up procedure Refer to Subsection 4 11 and perform the Post Service Validation procedure Annotate appropriate maintenance and logbooks Return the system to normal operation Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 10 Outlet Thermistor PCBA P N 32300 1 1 Refer to Subsection 4 3 2 and perform the 3D 60 Power Down procedure 2 Remove the two 2 screws securing the Top Panel and secure it into the Up position Refer to Figure 99 for screw removal locations CAUTION Proper ESD precautions must be observed whenever working on or around any PCBA 3 Remove the instrument s Left Side Panel to access the Outlet Thermistor PCBA Outlet Thermistor PCBA Pr Unplug J3 lm Connector i 1 AL Fig 136 Outlet Thermistor Removal Unplug cable from J3 connector on the Outlet Thermistor PCBA Refer to Figure 136 Remove the two 2 screws securing the Outlet Thermistor PCBA to the panel Install
217. o facilitate maintenance Fig 94 System Power Panel and DC Supply 1 It is recommended that you perform a Backup of the records stored on the BacT ALERT 3D 60 before continuing this procedure Refer to Subsection 4 5 for BacT ALERT 3D 60 Data Backup Restore Procedure 2 Go to the Ci DOS prompt and do not turn the instrument off 3 Open the door on the 3D 60 to stop the instrument 4 Remove the two screws securing the Top Panel and secure it into the Up position Refer to Figure 99 for Top Panel Screw locations On the ModSig connect both of the DC voltmeter s POS RED lead and the NEG BLACK lead to respective VCC Orange Wire and Ground White Wire on JP31 located in the bottom right corner Refer to Figure 96 for 5VDC Test Points WARNING ENERGIZED CIRCUITS AND COMPONENTS POSE AN ELECTRICAL SHOCK HAZARD DO NOT SHORT THE VOLTMET ER S TEST LEADS TOGETHER WHEN TAKING VOLTAGE MEASUREMENTS AT JP31 CAUTION Proper ESD precautions must be observed whenever working on or around any PCBA 4 74 Service Manual BacT ALERT 3D 60 4 SERVICING ALIGNMENTS AND CALIBRATIONS 4 9 6 System Power Supply Check and Adjustments Continued Ground Wire at J4 Black 5V Test Point at JP31 Orange Fig 95 Step 5 PCBA at Connector J4 Fig 96 ModSig PCBA with 5 VDC Test Points 6 measured voltage shall be 5 2 05 VDC Refer to Figure 96 7 If the voltage reading is out of tole
218. ock Diagram CHAPTER 3 INSTALLATION PROCEDURES 45 3D 60 Instrument Repacking Sequence 3 4 46 3D 60 Instrument Repack Web Strapping Diagramas 3 5 47 Power Entry Module w Fuse Holder 3 7 48 Fuse Holder w Fuse 49 PEM RUBRDATUCTTI LIME 50 RURAL M 51 Installation and Setup Diagran 52 Communications Panel Connection Diagram 53 Modem Configuration amp Dip Switch Settings Diagram 54 Countertop Surface Mounting Diagram 55 Mounting Surface Diagram 56 Mounting Surface Drilling Template a 57 Installation CHAPTER 4 SERVICING 58 3D 60 Instrument Power Switch s xi
219. on Number of event requests generated by the rack controller 1 Number of messages exchanged between instrument controller and rack controller 1 Number of messages exchanged with rack controller 1 with any problem 33 34 Number of messages sent to rack controller 1 where the expected response did not occur in the required time 3 5 Number of responses from the rack controller 1 that had a checksum error 3 6 Number of message exchanges with the rack controller 1 that fail for some reason other than timeouts or corruption p r3 Remaining sections duplicate the information in 3 1 thru 3 7 but appl 4 26 Service Manual BacT ALERT 3D 60 4 SERVICING SOFTWARE DIAGNOSTICS 1 4 Inc Module 1 Message Log Screen Special equipment Description Displays the recent history of commands and responses exchanged between the instrument controller and incubation module Impact Bottle testing is not affected by this diagnostic Test Procedure Keyboard functions status Runs continually and adds new messages to the end of the display as they occur 1 4 Inc Module 1 Hessage Log 1 1CE3823265889RFF CR lt LF gt T Timestamp 1CE32EB28888888888888888888888888888888888888888888884884BF7 shown for reference not actually part of the message data 1 1 31RES823164 1RES7CB188 module 88811888FR188088C1 ur21688471888BF18911 IN Data received from incubation module
220. on 4 5 Data Backup Restore Procedures Backup is not completed until the Backup Now button changes from gray to blue NOTE if errors appear call the Support Center for assistance To exit the software press the lt Esc gt key and type in Y E S Shut down the power on the 3D 60 instrument from the Power Entry Module PEM on the rear of the instrument If the 3D 60 s Top Panel is not open remove the two 2 screws that secure the Top Panel and open it Refer to Figure 99 Top Panel Screw Locations Removal Eject the old CompactFlash Memory Card Refer to Subsection 4 10 4 CompactFlash Card Figure 111 Insert the new CompactFlash Memory Card Restore power Remove the backup Zip disk Install the software using the BTASD Installation and Utilities Disk NOTE Check the software version identified on the Utilities Disk label is the same version as noted in Step 1 above Reboot the system by powering down recycle the instrument however when rebooting press the left Shift key as the instrument powers up This keeps the system in DOS At the C prompt type ZIP and press the Enter key NOTE The following step will restore previous patient record data and may only be a useful step if the system has been turned off for an hour or less You should call for technical assistance if the system has been down for more than one hour 14 15 16 17 18 4 94 Insert the Backup Z
221. on procedure 10 Annotate appropriate maintenance and logbooks 11 Return the system to normal operation Service Manual 4 157 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 27 Magnetic Door Switches P N 841 0012 01 Door Magnets With JP12 Connector With JP11 Connector Door Switches a Slide JP11 or JP12 connector j through this hole in the chassis Fig 184 Magnetic Door Switches 1 Refer to Subsection 4 3 2 and perform the 3D 60 Power Down procedure 2 Remove the two 2 screws securing the Top Panel and secure it into the Up position Refer to Figure 99 for screw removal locations 3 Open the door of the instrument slightly to view the door magnets Refer to Figure 184 4 Determine which door switch is defective The door switch LEDs are located on the ModSig PCBA at D55 and D56 Refer to Figure 185 on the next page 5 Remove the two 2 nuts that secure the defective Door Switch to the instrument chassis 6 Unplug the door switch connector at JP11 or JP12 on the ModSig PCBA depending on which door switch is defective 7 Slide JP11 or JP12 connector through the circular cut out hole in the chassis The connector must go through vertically to fit through the hole NOTE The front mounting screws of the ModSig PCBA may have to be loosened in order to facilitate sliding the JP11 or JP12 switch connectors through the hole in the chassis Refer to Figure 121 Mod
222. onnector Locations 106 Quad Serial 22222222 4 1 107 Quad Serial PCBA Cable Connections 108 EMC CompactFlash 109 CompactFlash Adapter amp ZIP Drive Installed eere terere ener 110 CompactFlash Adapter w WinSystems 111 CompactFlash Card Memory Remova 112 CompactFlash Adapter Remowval 113 ModSig PCBA Connector Location 114 ModSig PCBA ccessssssssssssssssssssssssesesssssssssess 115 ModSig PCBA Tie Wrap Remowval 116 ModSig PCBA Bundled Cable Disconnection 117 ModSig PCBA JP19 Cable 118 ModSig PCBA JP21 MS JP11 JP12 amp JP31 Cable Removal 119 ModSig PCBA MS JP1 Cable Removal Service Manual XV TABLE OF CONTENTS BacT ALERT 3D 60 Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig F
223. ont door has two separate interlock switches These connect to the MODSIG PCBA through JP11 and JP12 One switch which the firmware cannot override functions as a safety interlock that disables the heater and blower if the door should open The second switch is for logic functions and redundancy Both switches are monitored by the firmware and by the Step 5 agitation motor control firmware An instrument ID thumbwheel switch normally set to 1 is available if there should be a need to separately identify a 3D 60 at a customer s site A Piezo buzzer is provided as an audible alarm A remote speaker system may be used by connecting to J1 The keyboard connects to JP16 A barcode reader connects to P1 and a mouse connects to P2 A parallel port printer connects to P4 A LIS system is interfaces via P8 and a modem via P9 JP13 JP15 JP17 JP18 and JP19 connect to the Instrument Controller CPU in the 3D 60 JP29 and JP30 are used for transferring serial data signals from the Quad Serial PCBA The Serial UPS connector at P7 is for future use The UPS is controlled through the connector at P5 and must be connected for proper system operation The VGA display monitor is connected at P6 Five volt power is connected to the board at JP31 and is supplied to the Zip Drive and the CompactFlash PCBA through JP21 Control and data signals for the racks are supplied through JP10 Jumpers on the ModSig PCBA control the audio frequencies supplied to the remote sp
224. or s Manual If this backup fails insert a new Zip disk and attempt and manual backup If this backup fails call bioM rieux Service Manual BacT ALERT 3D 60 APPENDIX E DIAGRAMS E 0 Diagrams This section includes drawings or diagrams used for field service SCHEMATIC DIAGRAMS 1 System Wiring Schematic 2 System Interconnect Schematic Service Manual APPENDIX E DIAGRAMS E 1 APPENDIX E DIAGRAMS BacT ALERT 3D 60 E 2 Service Manual BacT ALERT 3D 60 INDEX INDEX Cover Sheet Service Manual INDEX 1 INDEX BacT ALERT 3D 60 Service Manual BacT ALERT 3D 60 INDEX INDEX 16C554 UART 3 lt nce ER 2 17 5 VDC See Preventive Maintenance 56K Fax Modem DOMES Consin e GT OE 4 162 International teer CER 4 163 SA time delay See Fuses 5 phase Stepper Motor 1 13 2 25 6 3A time delay See Fuses 68HC11 2 2 3 AC Backup Receptacles 22 2222 222111 1 21 Accessing Configuration Screens 1 25 Accessory Surge Receptacles Converter Adjustment AgItatlODS sec ERE wna Agitation Arm x Agitation Drive Arm Alignments and Calibratione APC UPS Battery Connection Domestic Model Illustration eerte tete ete International Model sss 4 1
225. ormerly Greenwich Mean Time in a 24 hour format The BIOS time is set in manufacturing and should not require readjustment in the field The current UTC may be obtained from the National Technical Information Services WWV radio station by calling 1 303 499 7111 or from the Internet USNO Master Clock Contact Instrument Service for assistance in setting the BIOS time 5 Verify that each component is enabled by viewing the Main Screen Any disabled component will be displayed by gray Hash Marks denoting the disabled rack or individual cells within the rack Use the Enable Disable Rack and Cell screen to enable each accordingly Hash marks are visible whether racks are enabled or disabled or whether the unit s racks are configured or not Check the rack status for Enabled Disabled status first 3 2 10 Temperature Set the instrument s operating temperature Once the temperature has stabilized 4 hours calibrate the actual instrument temperature Refer to 3D 60 Operator s Manual 3 2 11 Error Check Ensure that no error codes are displayed on the Main Screen Error Codes may be found in Appendix D Error Codes of this manual Service Manual 3 11 3 INSTALLATION PROCEDURES BacT ALERT 3D 60 3 2 12 Modem Functional Test Set the modem s DIPswitches Refer to Figure 53 for DIP Switch settings When modem and telephone connections are available connect the Modem Interface cable between the mod
226. otor Refer to Subsection 4 3 2 and perform the 3D 60 Power Down procedure Remove the two 2 screws securing the Top Panel and secure it into the Up position Refer to Figure 99 for screw removal locations Remove 3D 60 Instrument s Left Side Panel and set the panel aside Disconnect the Blower s power cable at BLP1 BLJ1 Refer to Figure 168 Remove the four 4 mounting nuts from the screws as shown in Figure 168 Remove the defective Blower from the instrument Install and align the new Blower in the system and install the nuts Tighten the nuts in a X pattern to ensure alignment Reconnect the power cable BLP1 BLJ1 Reinstall the Left Side Panel Use cardstock to cover the foam gasket around the door in front to prevent damage to the foam Remove cardstock after panel is reinstalled Close the System Top Panel and secure it with two 2 screws Refer to Figure 99 Refer to Subsection 4 3 3 and perform the 3D 60 Power Up procedure Refer to Subsection 4 11 and perform the Post Service Validation procedure Annotate the appropriate maintenance and lab logbooks Return the system to normal operation Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 22 Blower Motor Capacitor P N 601 0001 02 Fig 169 Blower Motor Capacitor 1 Refer to Subsection 4 3 2 and perform the 3D 60 Power Down procedure 2 Remove the two 2 screws securing the Top Panel and secure it into the Up
227. oubleshooting of the instrument The modem interfaces the instrument through a connection to the Modem port on the rear of the unit Digital signals are converted to tones by the modem for sending to the telephone system through the telephone jack connection and to a remote modem at on the receiving end Conversely tones from the remote modem are converted to digital signals and sent to the instrument through the Modem port Power for the modem is supplied by a wall mounted power supply that supplies low voltage required by the modem The wall mounted power supply plugs directly into a standard electrical outlet 1 GENERAL INFORMATION BacT ALERT 3D 60 1 4 5 Uninterruptible Power Supply UPS Computer Interface Port Telephone Surge Protection IPS Overload Protector On Off Switch Test Switch Accessory Surge Receptacles Fig 24 Uninterruptible Power Supply UPS Domestic Model Front and Rear Views 1 20 Service Manual 1 GENERAL INFORMATION BacT ALERT 3D 60 1 4 5 1 4 5 1 1 4 5 2 1 4 5 3 1 4 5 4 1 4 5 5 1 4 5 6 1 4 5 7 Service Manual Uninterruptible Power Supply UPS Continued Refer to Figure 24 for the following component descriptions of the domestic UPS On Off Switch Turns the UPS and BacT ALERT 3D 60 unit ON and OFF from the UPS UPS Comm Port Computer Interface Port The UPS Computer Interface Port is a standard 9 pin port used to conn
228. own in progress e Shutdown complete 3 After the DOS prompt appears power can be removed by accessing the PEM s Main Power Switch on the rear of the BacT ALERT 3D 60 instrument 4 Turn the Main Power Switch located on the Power Entry Module PEM to OFF Refer to Figure 58 5 If performing work on the interior of the chassis disconnect the Main Power Cord from the PEM 4 3 3 3D 60 Power Up 1 If the main power cord has been disconnected from the PEM reconnect it 2 Turn Main Power Switch on the PEM to ON to provide AC power to the 3D 60 instrument Wait for the system to initialize and come up to the Main Setup screen Refer to Figure 58 for Main Power Switch location 4 4 Service Manual BacT ALERT 3D 60 4 SERVICING 4 4 MB CONVERSION PROCEDURE 4 4 1 Overview By removing power from the agitation Step 5 motor and anchoring the linkage assembly that rocks the racks the incubation chamber can be converted to a stationary MB configuration 4 4 2 Procedure 1 Refer to Subsection 4 3 2 and perform the 3D 60 Power Down procedure 2 Remove the two screws securing the Top Panel and secure it into the Up position CAUTION Proper ESD precautions must be observed whenever working on or around any PCBA 3 Unplug connector at J4 on the Step 5 PCBA This removes 12 power to the Step 5 PCBA and Motor Refer to Figure 59 4 Unplug the connector at J1 on the Step 5 PCBA This removes communication
229. pact Bottle testing is not affected by this diagnostic Test Procedure a Enter the diagnostic b Open the door and verify that all cell LEDS are ON c Press the 2 key d Open the door and verify from the Walking pattern that only one cell LED turns on at a time for the top rack Verify the same for the middle rack and then the lower rack Keyboard functions 1 Turns on all LEDS 2 Initiates the Walking LED pattern Run status Diagnostic runs continuously and updates the display continuously 1 9 Inc Module 1 LED Check Upon initial entry to diagnostic all LEDs are turned on ES TER mms and the display appears as shown in the adjacent picture pun i 015 1 ALL LEDs ON 2 Halking LEDs Fig 84 1 9 Inc Module 1 LED Check Pressing 2 initiates the Walking LED test and the display appears as shown in the adjacent picture a 1907 Ce 1827 Cel LED The displayed data indicates which LED should be on Liner LEJ err eei LEB 1C47 Cel LED 1007 Cel LED 1027 Cel LED 1047 Cel LED 1 ALL LEDs ON 2 Walking LEDs Fig 85 1 9 Inc Module 1 LED Check Walking Service Manual 4 33 4 SERVICING SOFTWARE DIAGNOSTICS BacT ALERT 3D 60 THIS PAGE INTENTIONALLY LEFT BLANK 4 34 Service Manual BacT ALERT 3D 60 4 SERVICING SOFTWARE DIAGNOSTICS INSTRUMENT CNTRL
230. ppendix B Appendix C Appendix D Appendix E INDEX Service Manual TABLE OF CONTENTS GLOSSARY ataca Panica a unica He e a REN L kak HARE NO huku atita a DONE La eu a A 1 PARTS LIST c B 1 Alphabetical 2 222 2 2222 11 2 kana kd Wek s d k k xwa kn wak n ue dU AE W S t ia c 1 Hare C 1 e n C 1 e ana C 1 lnstrument SHIPPING oci C 1 Assembly ShippIng due te dulcia C 1 ERROR CODES 2 aaa isa dea cual LER MER RA E REK MER RR EAREKE D 1 DIAGR nic dak Ea Index 1 ix TABLE OF CONTENTS BacT ALERT 3D 60 THIS PAGE INTENTIONALLY LEFT BLANK x Service Manual BacT ALERT 3D 60 TABLE OF CONTENTS 0 2 LIST OF TABLES Section 1 Table 1 2 1 Reference Data ec aa ul d pdt ca cie subdi ud ka 1 2 Section 2 Table 2 2 1 Audio Frequency Selection JP 23 through JP26 2 4 Table 2 5 1 Power Supply i d Dae bl i i 2 1 Section 3 Table 3 2 1 30 60 instrument Paris EISE ito tee daia eue v pa 3 6 Table 3 2 2 Facility Power Rating and Conversion
231. procedure 1 Check the temperature in the Incubation Chamber 2 If the temperature is high there is a system failure Leave the door open so the bottles will not overheat and call bioM rieux 3 If the temperature is low make sure the door is completely closed and wait 30 minutes to see if the fault goes away If the fault does not go away call bioM rieux 41 47 Rack s X Not Responding Cause Faulty rack controller or rack interface cable s Solution Call bioM rieux 51 57 Rack Hardware Failure Cause Faulty Rack printed circuit board Solution Call bioM rieux D 4 Service Manual BacT ALERT 3D 60 APPENDIX D ERROR CODES 60 Cell Failed QC Cause A cell failed the automatic internal diagnostic check Solution Perform the following procedure 1 Identify the cell that failed the QC using the View Cell Status screen 2 Inspect the cell for debris and remove or clean if necessary 3 Calibrate See Calibrating an Instrument Cell on Page 6 13 of the 3D 60 Operator s Manual Get corrected Calibration Report if necessary 4 If calibration cannot be performed at this time or if a cell fails to calibrate disable cell and insert an orange cell plug in the disabled cell Call bioM rieux if cell calibration is unsuccessful 62 Erroneous Cell Load Status Reported Cause A cell is out of calibration Solution Use the View Cell Status screen See Viewing Faults on Page 3 4 of the 3D 60 Opera
232. programs and services not available in certain countries this however shall not mean that bioM rieux intends to commercialize such products programs or services in said countries To request copies of publications or for any technical request contact bioM rieux or your local distributor Liability disclaimer bioM rieux disclaims all warranties guarantees or liabilities express or implied arising by law or otherwise with respect to this manual its quality accuracy or performance including without limitation any obligation of bioM rieux with respect to MERCHANTABILITY AND FITNESS FOR A PARTICULAR USE non infringement and consequential or incidental damages IN NO EVENT SHALL bioM rieux s LIABILITY TO CUSTOMER UNDER ANY CLAIM EXCEED A REFUND OF THE AMOUNT PAID TO bioM rieux FOR THE PRODUCT OR SERVICE WHICH IS THE SUBJECT OF THE CLAIM In no event shall bioM rieux be bound by the manual bioM rieux shall have the right to modify the manual without notice bioM rieux Copyright This manual s content and graphics are copyrighted by bioM rieux In no event does bioM rieux concede to the manual s users any right for reproduction adaptation or translation by any process and in any country whatsoever All editorial content and graphics including without limitations all articles text images logos compilations designs are protected by United States Copyright Law French Copyright Law and international treaties and ma
233. r Empty 131 2 Receive Buffer Full 8 3 Line Status 4 Hodem Status n 8Oisabled 5 TOTAL 126 Errors 1 verrun 2 Parity s Framing 4 TOTAL Transmit FIFO 1 Empty 1 2 Put errors 87878 Loopback status PRSS count 8 FRIL count 24 3 1 Timeout 24 3 2 Mismatch 8 3 3 RTS CTS 24 3 4 DTR DSR 24 D PROWWOENNNNOK KR Re O A A N LL Fig 87 7 2 Instrument Cntrl Barcode Loopback Test Screen Display values 1 1 Should increment Number of transmit buffer empty interrupts seen by serial hardware 1 2 Should increment Number of receive buffer full interrupts generated by serial hardware 1 3 Should remain at 0 Number of line status interrupts generated by serial hardware RAN Should remain at 0 Number of modem status interrupts generated by serial hardware note this interrupt is disabled as 15 R Reset indicated on the screen Total of lines 1 1 through 1 4 Should remain at 0 Number of overruns reported by serial hardware An overrun occurs if received data is not removed from the serial hardware faster than it comes in This value should remain at 0 Should remain at 0 Number of parity errors reported by serial hardware Parity error checking is turned off so no errors should be reported Should remain at 0 Number of framing errors reported by serial hardware A framing error occurs if the number of serial bits between the st
234. rance insert a plastic wand into the POT access hole Reference Figure 97 below While observing the voltage reading adjust the POT until it meets the voltage specification in Step 6 above 8 Although adjustments are not required there should be 12V at J4 on the Step 5 PCBA The measured voltage tolerance should be within 1 DC NOTE Do not make any adjustments if the voltage meets specifications Fig 97 DC Power Supply Service Manual 4 75 4 SERVICING ALIGNMENTS AND CALIBRATIONS BacT ALERT 3D 60 4 9 6 4 76 System Power Supply Check and Adjustments Continued Remove the voltmeter s test leads from JP31 on the ModSig PCBA Close the Top Panel and replace the two screws that secure it Refer to Figure 99 Close the door on the instrument Refer to Subsection 4 3 3 and perform the 3D 60 Power Up procedure Refer to Subsection 4 11 and perform the Post Service Validation procedure Annotate appropriate maintenance and logbooks Return the system to normal operation Service Manual BacT ALERT 3D 60 4 SERVICING ALIGNMENTS AND CALIBRATIONS 4 9 7 Door Micro Switch 1 amp 2 Checks 1 Go to the Ci DOS prompt but do not turn the unit off 2 Open the door on the 3D 60 to stop the instrument 3 Remove the two 2 screws securing the Top Panel and secure it into the Up position Refer to Figure 99 for Top Panel Screw locations Door Magnets Door Micro Sw itches Micro Switch
235. ransformer was removed in Step 4b reinstall it and secure the mounting bolt to the chassis 14 Reinstall the Right Side Panel on the instrument 15 Close the System Top Panel and secure it with two 2 screws Refer to Figure 99 16 Refer to Subsection 4 3 3 and perform the 3D 60 Power Up procedure 17 Refer to Subsection 4 11 and perform the Post Service Validation procedure 18 Annotate the appropriate maintenance and lab logbooks 19 Return the system to normal operation Service Manual 4 139 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 20 Heater P N 847 0009 01 amp Disconnect HTR 2 Threaded an iE Terminal Connection White Terminal Remove nut w Lock Nut gt Disconnect 1 Terminal Connection Orange Remove nut Fig 166 Heater Terminal Connectors 1 Refer to Subsection 4 3 2 and perform the 3D 60 Power Down procedure 2 Remove the two 2 screws securing the Top Panel and secure it into the Up position Refer to Figure 99 for screw removal locations 3 Remove 3D 60 Instrument s Left Side Panel and set the panel aside 4 Disconnection HTR 1 and HTR 2 terminal wires by removing the nut on each terminal Refer to Figure 166 4 140 Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 20 Service Manual Heater P N 847 0009 01 Continued 10 11 13 14 CAUTION Do not pull dow
236. re 99 for screw removal locations 4 156 Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 26 Gas Spring Assembly P N 926 0037 01 Continued Support Bracket Separate the assembly from the support bracket 2 Support the bracket here Protective Cap 4 4 m the slot and pry the protective cap off 1 sw support bracket here a i 4 Repeat above steps the bottom support bracket and spring assembly Fig 183 Gas Spring Assembly Removal 3 Remove the protective cap with a small flat blade screwdriver Refer to Figure 183 4 While holding the support bracket at dot 2 in the diagram above pull and separate the Spring Assembly from the support bracket The spring assembly socket and the support bracket ball joint essentially serve as a ball joint and socket assembly It does require a bit of force to separate the two from each other 5 Repeat Steps 3 and 4 to remove the Bottom Support Bracket and separate the spring assembly socket from the bottom bracket ball joint 6 Install the new Gas Spring Assemby by reversing the above steps Ensure that the protective caps are securely replaced on both the top and bottom 7 Close the System Top Panel and secure it with two 2 screws Refer to Figure 99 8 Refer to Subsection 4 3 3 and perform the 3D 60 Power Up procedure 9 Refer to Subsection 4 11 and perform the Post Service Validati
237. rent They do not pose any immediate hazard to technicians There is however facility power of either 115 VAC or 230 VAC within or near the power supply assembly which could pose an electrical hazard if proper precautions are not observed Note All voltages are potentially hazardous under the proper circumstances Cleaning Agents Follow manufactures instructions and MSDS Material Safety Data Sheets information to prevent any possible hazards that may be present when using cleaning agents or other chemicals Service Manual BacT ALERT 3D 60 SAFETY SUMMARY 0 5 SAFETY SUMMARY CONTINUED 0 5 7 0 5 8 0 5 9 0 5 10 Service Manual Health Risks Specimens and inoculated culture bottles are to be assumed as though they are capable of transmitting infectious agents Handling of any bottles or specimens must be done with the utmost care Spills must be cleaned as soon as possible using the disinfection procedures outlined in the BacT ALERT 3D 60 Operator s Manual and Appendix C of this manual ESD Precautions The BacT ALERT 3D 60 contains several electrostatic sensitive devices within the modules Proper ESD precautions in addition to the use of a grounding strap are imperative whenever working on or near any ESD components Moving Parts There are moving parts within the left side of the instrument s chassis At times personnel may be exposed to the Agitation Drive Arm Motor Offset Round and other internal
238. ription This diagnostic displays the state of the drawer switch and heater function in an incubation module Impact 7 testing is not affected by this diagnostic Test Procedure N A Keyboard functions None Run status Runs continuously and updates the display continuously 1 8 Inc Hodule 1 Draver Heater Incubation module 1 Right 1 8 Temperature Control Average of heater inlet 1 1 Calibrated temperature and outlet sensor plus 1 2 Calibration offset 1 3 Heater Power calibration offset 2 6 Drv A 1 1 Upper Heater Closed 1 2 Lower Drawer Closed Offset determined EU ERIS when temperature 2 1 Upper Heater Closed was last calibrated 2 2 Lower Drawer Closed 4 8 Dru 3 1 Upper Heater Closed 3 2 Lower Drawer Closed Amount of heater power currently being 5 0 Drv D applied to maintain 4 1 Upper Heater Closed 4 2 Lower Drawer Closed temperature Note goes to 0 if door is opened Value is updated once every 30 seconds Switch position Switch function Current state Fig 83 1 8 Inc Module 1 Heater Screen 4 32 Service Manual BacT ALERT 3D 60 4 SERVICING SOFTWARE DIAGNOSTICS 1 9 nc Module 1 LED Check Screen Special equipment None None ooo SOS Description This diagnostic provides a way to turn all the LEDs both drawer and cells ON and also to blink them in a pattern to verify that they all work and that no LEDs are shorted together Im
239. s secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs secs 2 KIRI c SD SSD SD KIRI SD SR a Type Type Type Type Type Type Type Type Type Type Type Type Type Type Type Type Type Type Type Type Type Type Type Type Type Type Type Type Type Type Type Type Type Type Type Type Type Type Type Type Type Type Type Type Type Type Times FAN FAN PZA PZA Q30 Q31 032 033 034 035 036 037 038 039 040 041 042 043 044 045 0 UNKNOWN 1 2 3 4 5 PEDI BACT 6 LYM BACT 7 MB BACT 8 MB BACT BLOOD 9 BACT ALERT SV BACT ALERT SA BACT ALERT SN BACT ALERT FA BACT ALERT FN BACT ALERT PF BACT ALERT LYM 16 BACT ALERT MP 17 BACT ALERT MB 18 GENERIC DRUG 19 PYRAZINAMIDE 20 RIFAMPIN 21 ISONIAZID 22 ISONIAZID HI 23 STREPTOMYCIN 24 ETHAMBUTOL 25 DIRECT CONTROL 26 PROP CONTROL 27 10 11 12 13 14 15 DIRECT CONTROL 28 PROP CONTROL 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 BacT ALERT 3D 60 Service Manual BacT ALERT 3D 60 1 1 1 1 1 1 1 1 1 1 1 1 1 1
240. s This line displays the key and the corresponding function that key invokes Operation buttons These buttons invoke operations that are common to all the diagnostics See the table below for details Functionality of Diagnostics System Buttons Description Run continuously When pressed diagnostic runs continuously and data in the display area is updated continuously Pause Run Once If pressed while the diagnostic is running continuously the diagnostic is allowed to run one more time and then it is paused Once paused the data in the display area represents the data generated the last time the diagnostic was run If pressed while the diagnostic is already paused the diagnostic is allowed to run one time and updates the display data This function is used to find a text string in the display data When pressed the following screen appears BacT ALERT 3D SelectLink 1 5 Inc Module 1 Temperature Log Enter text here that you want to search for Press to Exit Press to without search Start search 23 04 81 14 37 34 1801 20 23 04 01 14 42 34 1 1 MOD TEHP in 35 74 out 36 88 avg 35 87 23 04 01 14 42 34 1821 40 RCK TEMP s1 35 33 52 35 36 ofs 8 53 Fig 69 1 5 Inc Module 1 Temperature Log Find Text String Service Manual 4 19 4 SERVICING SOFTWARE DIAGNOSTICS BacT ALERT 3D 60 For example if the search text entered is 1B21 and the Check button is clicked the original diagnostic
241. s because of one of the following faults 51 52 54 60 or 62 Bottle readings are not processed in faulty cells Solution Use the Edit Bottle Detail screen to determine when the last bottle reading was successfully processed See Viewing Editing Bottle Data on Page 4 2 of the 3D 60 Operator s Manual If less than one hour has passed it is only necessary to relocate the bottles using the following procedure 1 From the Main screen press lt CTRL gt F1 This mode identifies cells containing bottles with 99 51 52 54 60 or 62 fault codes with a lit indicator 2 Remove bottles from these cells one at a time and move them to cells whose indicators are unlit Note If not bottle s are present in the indicated cell call bioM rieux If more than an hour has passed unload and subculture the bottle s in the faulty cells using the following procedure 3 From the Main screen press lt CTRL gt lt F10 gt 4 Remove a bottle to subculture and scan the bottle ID Repeat this step for the remaining bottles needing subcultures 5 Click the Check button when done 6 After sub culturing bottles reload them via the Load Bottle function on the Main screen Affected bottles that do not need to be sub cultured should be relocated Relocate bottles Note If no bottle s are present in the indicated cell call bioM rieux Service Manual BacT ALERT 3D 60 APPENDIX D ERROR CODES D 1 2 Instrument Status Co
242. s diagnostic output to a text file on the Zip disk To use this function Place a ZIP disk in the instrument s ZIP drive Press the Save button In response the following screen will appear Destination filename entry box DIAGDUMPN1 5 txt Fig 71 1 5 Inc Module 1 Temperature Log Save Output to ZIP 4 20 Service Manual BacT ALERT 3D 60 4 SERVICING SOFTWARE DIAGNOSTICS A default file name is automatically entered for you By default the data is saved on the ZIP disk in a subdirectory named DIAGDUMP The file name corresponds to the number of the diagnostic that is currently selected If you wish to use another filename touch the destination filename entry box press the SPACE bar to clear the box and then type in the desired name NOTE You cannot change the destination drive It will always be the ZIP drive NOTE Use Only 250 M ZIP Disk To initiate the Save press the Check button To Cancel the save press the X button Operation will return to the currently selected diagnostic screen The data is written to the file in text and 50 this file can be viewed using any text editing program For example Windows Notepad Print all output Send all lines of diagnostic output to the printer Print current page Send just diagnostic output lines currently displayed to the printer Cancel print Button is normally disabled yet enabled while printing is in progress Pressing this button cancels printing
243. s logged when incubation chamber asserts its power fault signal MODULE POWER UP this is logged when incubation chamber negates its power fault signal or whenever the instrument software is started RACK POWER UP this is logged when rack reports a power up event or whenever the instrument software is started Service Manual 4 39 4 SERVICING SOFTWARE DIAGNOSTICS BacT ALERT 3D 60 7 5 INSTRUMENT CNTRL View files screen Impact Bottle testing is not affected by this diagnostic Y Keyboard functions Selects the file that is to be viewed 1 All the INI files 2 All the BID files 3 All the BTF files 4 All the APF files 5 All the event log files LOG EVT 6 the preload data file PLDSTORE DAT Run status 1 Runs once and stops 1 INI files For each file on the c drive of the Flash card withan INI extension the file name is displayed followed by a row of dashes followed by the contents of the file kBlue 120 nhibitCommHoldoffTime 120 Userlntf FaultReminderPeriod 300 DrawerOpenFaultPeriod 300 Printer Type HP PaperSize LTR BottlelD FirstCharAlpha 1 FirstCharNumeric 0 FirstCharOther 1 AlertlfGeneric 1 AccessionNum MinLength 0 MaxLength 0 FirstCharAlpha 0 FirstCharNumeric 1 FirstCharOther 0 Lifetime 30 ForceUppercase 0 HOSPITALID ForceUppercase 1 PATIENTNAME ForceUppercas
244. s or whether the value is a default value An example is shown below Configuration Data Log DEBUG LockNeverUsedList 0 SpecialKeys 1 ShowBottleProcState 0 ExtCellStatusScreen 1 MODEM Init8 Init7 Init6 Init5 Init4 Init3 Init2 Initl RIToDCDTimeout 30 BaudRate 3 PATIENTNAME Available 1 FNameRequired 0 LNameRequired 0 ForceUppercase 1 HOSPITALID Available 1 Required 0 ForceUppercase 0 ACCESSIONNUM Available 1 Required 0 ForceUppercase 0 Lifetime 0 FirstCharOther 1 FirstCharNumeric 1 FirstCharAlpha 1 MaxLength 0 MinLength 0 BOTTLEID Required 0 AlertIfGeneric 1 FirstCharOther 1 FirstCharNumeric 1 FirstCharAlpha 1 USERINTF PositiveReminderPeriod 60 DrawerOpenFaultPeriod 120 FaultReminderPeriod 300 PRINTER PaperSize 0 Type 0 InstrCntrl RackTempStableThres 10 RackTempDeltaThres 300 RackTempWrongWayThres 2 InhibitCommHoldoffTime 620 DeskBlue 0 DeskGreen 0 DeskRed 0 Type 0 LIS PeriodicallyTestLink 0 TestOrderPollPeriod 0 4 60 Service Manual BacT ALERT 3D 60 4 SERVICING SOFTWARE DIAGNOSTICS FlagResultOnUnload 0 FlagResultOnPositive 1 FlagResultOnNegative 1 FlagResultOnLoad 0 AutoTransmitResults 0 Bidirectional 1 BitsPerChar 8 StopBits 1 Parity 0 BaudRate 48 Enabled 0 DBMS Enabled 1 Service Manual 4 61 4 SERVICING SOFTWARE DIAGNOSTICS BacT ALERT 3D 60 8 Scandisk Output 7 6 Instrument Cntr i Softvare m E x ditt
245. s section provides the procedures for verifying the proper functioning of the BacT ALERT 3D 60 after a service call repairs alignments They are not used after PMs or installations as they are covered separately 4 11 2 Required Materials The following items are needed as a minimum to complete the validation BacT ALERT 3D 60 Instrument BTA3D Field Utilities ZIP Disk 4 11 3 Procedures 1 Verify that the internal temperature of the Incubation Chamber has stabilized and then verify that the displayed temperature on the display monitor is within 0 5 C of the calibrated reference thermometer Refer to Subsection 4 6 5 2 Verify that the Barcode Scanner will load a bottle by using the Load Bottles function 3 Unplug the UPS from the AC wall outlet and verify the audible alarm emergence of the red triangle icon and the UPS alarm Immediately plug the UPS back in NOTE Try not to keep AC power off for too long If the AC is allowed to remain off more than 1 minute the 3D 60 Instrument will begin an orderly shutdown If this occurs the system will require rebooting 4 Press Esc key and Y E and S followed by the Enter key 5 Install the BTA3D Field Utilities Disk and execute CAL1 Select DIAGNOSTICS and verify that the door switches are functioning correctly 6 Select the TEMP settings to look at the Rack PCBA temperature sensors Verify that they are reporting within tolerance
246. sformer PEM Connections eere eerte eere re nere te tete AA KARAR AA AA AA AA KARAR HAA AR KAR HAK KAK AA KARA 151 Power Supply Simplified Schematic 152 Term Board 1 TB1 sene 153 Power Panel Solid State Relay Layout 154 Power Supply Assembly w DC Power Supply 155 DC Power Supply J1 and J2 Disconnection 156 Power Panel Assembly DC Supply Screw Removal 157 Power Entry Module w Fuse Holder Removed 158 Fuse Holder Fuse Installation 159 PEM Fuse Removal w Screwdriver eere eren re eere te tenete tete tete tetas sete sese sesso sesso sonus 160 PEM Fuse Holder Removal 161 PEM Fuse Holder Pulled Out 162 w 115 VAC Version 163 w 230 VAC Version 164 Fan Inside View 165 Fan Wiring Connections 166 Heater Terminal Connectors 167 Heater 168 Blower Motor eee 169 Blower Motor Capacitor
247. sh table index result code 1 2 neg 3 ntd 4 near pos s status P prelim I incomplete F final x significant test result if non zero 1 0 unloaded 1 loaded loc if ld 1 cell where bottle is loaded if ld 0 cell where bottle was last loaded bid bottle id acc accession number hid hospital id pn last first parts of patient relates a base accession to accessions with same base hash table index base accession accession with suffix relates a base accession to all record numbers in the preload file that have that accession ash table index accession preload file rec relates a bottle ID to the one record number in the preload file that has that bottle ID hash table index bottle ID preload file rec num 4 47 4 SERVICING SOFTWARE DIAGNOSTICS BacT ALERT 3D 60 PRELOAD to RecNum Dictionary release an accession to the one record number in the preload file that has that accession 191 AH4ACC 1 2 ash table index accession preload file rec 275 AH3ACC 8895AFA 1 4 48 Service Manual BacT ALERT 3D 60 4 SERVICING SOFTWARE DIAGNOSTICS 6 Bottle processing tables Displayed the current content of the tables that drive the way the 3D processes bottles An example is shown below Bottle Processing Tables Log TIEDE AENT Bottle IDs Table 76 entries Prefix Min Max BottleType Container Type ZINHI 5 15 23 2 ZBLYM 5 8
248. size of a matchbook and weighs about one half ounce Since it is a solid state device utilizing flash memory it contains no moving parts and requires no battery for data retention The CompactFlash Disk is compatible with IDE ATAPI standards and serves as the C drive in the BacT ALERT 3D 60 application where it holds the operating program bottle records system configurations event log files and miscellaneous other information needed for BacT ALERT operation Refer to Figure 15 CompactFlash Adapter PCBA The PCM CFLASH PCBA Reference Figure 16 is a PC 104 compatible adapter module designed specifically to adapt CompactFlash memory disks for use in embedded systems such as the BacT ALERT 3D 60 The adapter provides for master slave selection and a visual drive status indicator The CompactFlash Adapter PCBA is installed on the top cover of BacT ALERT 3D 60 system Step 5 PCBA The Step 5 controller board Reference Figure 17 is designed to drive a five phase stepper motor at the speed of 60 revolutions per minute The board operates with input voltages of 5V and 12V drives the stepper motor directly and provides starting and stopping functions based on inputs received from the ModSig PCBA 1 GENERAL INFORMATION BacT ALERT 3D 60 1 4 3 Electronic Components Continued Te 256000 Fig 18 BacT 3D 60 Incubator Chamber Fig 19 Rack Assembly 1 14 Service Manual 1 GENERAL INFORMATION BacT ALERT
249. stic b When the diff Delta data appears scroll up to find the cells in the Difference gt 1 5 group c For each of the cells listed in this group perform a single cell calibration NOTE you can enter the calibration screen by pressing C from the diagnostic screen Output Keyboard functions 1 Display the percentage difference screen 2 Display the details screen C Enter the calibration screen The diagnostic automatically stops running once it has gathered all the required readings and the run button will be in the unpressed state Pressing the run button restarts the diagnostic It will gather new readings and then display the diff data 1 7 Inc Hodule 1 Flag Check When first entered or whenever the Eo le tina data diagnostic is restarted RUN button pi Ea pie e pressed the diagnostic gathers readings from the racks in the incubation module It takes several seconds to gather all of the data So the rack that is being processed is indicated as shown in the adjacent picture If a rack is not installed or a drawer is not installed they are skipped and do not appear in the display During the gathering phase keyboard input is ignored uae Fig 80 1 7 Inc Module 1 Flag Check Screen 4 30 Service Manual BacT ALERT 3D 60 Once all of the required data is gathered the diff data is displayed as shown on the adjacent screen
250. support plate Slide the Motor Offset Round onto the Motor s Drive Shaft Leave enough room between the Offset Round and the system chassis to slide the spacing tool in between With spacing tool properly inserted between the Motor Offset Round and the system chassis reinstall the Motor Offset Round s set screws Refer to Subsection 4 10 9 Step 5 Motor Set Screw Removal Figure 132 for reinstallation of the set screws Align the Drive Linkage Assembly s bottom bushing screw hole with the hole in the Connecting Link Insert the bushing screw through the reverse side of the Linkage Assembly s brass bushing and torque the screw to 20 in lb Install the bushing nut onto the bottom bushing screw and torque to 20 in lbs Reinstall the Left Side Panel on the instrument Close the System Top Panel and secure it with two 2 screws Refer to Figure 99 Refer to Subsection 4 3 3 and perform the 3D 60 Power Up procedure Refer to Subsection 4 11 and perform the Post Service Validation procedure Annotate appropriate maintenance and logbooks Return the system to normal operation 4 155 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 26 Gas Spring Assembly P N 926 0037 01 Gas Spring Assembly Fig 182 Gas Spring Assembly 1 Refer to Subsection 4 3 2 and perform the 3D 60 Power Down procedure 2 Remove the two 2 screws securing the Top Panel and secure it into the Up position Refer to Figu
251. t not Serial UPS on the Communications panel Connect the 3D 60 s main power cord into a UPS AC Receptacle labeled as Surge with Battery Backup Plug the UPS main power cable into the properly rated AC wall outlet Connect the external speaker cable if external speakers are installed into the Ext Spkr jack on the Communications panel Not supplied optional Plug the external speaker s AC power cord into the properly rated AC wall outlet Not supplied optional Plug in the monitors 15 pin cable into the Monitor port on the Communications panel Not supplied optional Plug in the monitor s main power cable into the proper UPS AC Receptacle labeled as Surge with Battery Backup Connect the keyboard cable into the Keybrd port on the Communications panel Connect the printer s parallel cable into the Printer port on the Communications panel Plug in the printers main power cord into the UPS AC Receptacle for Surge Only no Battery Backup Connect the modem s communications interface cable into the Modem port on the Communications panel If supplied and installed Connect the modem s telephone cable into the Jack port on the modem If supplied and installed Plug in the modem s power adapter into the modem Plug in the main power cord from the adapter into the properly rated AC wall outlet If supplied and installed Connect the barcode scanner s communications cable into the Barcode port on the Communications panel
252. tage of time the processor is idle Percentage of time processor is executing task code Percentage of time processor is executing interrupts of operating system code Amount of bytes left in heap Number of free blocks in heap Largest block left on heap in bytes Approximate CMOS clock value the last time the instrument controller software was terminated Approximate local time the instrument controller software was terminated RECOVERING FROM TIMESTAMP FAULTS When replacing a CPU board it is crucial to transfer the CMOS date time from the old board to the new board however of course this is not possible if the old board is not functioning Consequently when the instrument is powered up it is possible that timestamp faults 71 are reported This diagnostic screen provides the best chance of fixing the CMOS time as follows 1 71 faults appear turn off the instrument 2 Goto this diagnostic screen and note the date and time on line 3 1 4 66 Service Manual BacT ALERT 3D 60 4 SERVICING SOFTWARE DIAGNOSTICS Determine the amount of time that the instrument was down and add that to date time from step 2 Exit the 3D software Enter the time from step 3 into the CMOS clock Restart the 3D software Service Manual 4 67 4 SERVICING SOFTWARE DIAGNOSTICS BacT ALERT 3D 60 THIS PAGE INTENTIONALLY LEFT BLANK 4 68 Service Manual BacT ALERT 3D 60 4 SERVICING ALIGNMENTS AND CALIBRATIONS 4 9 ALIGNMENTS AND CAL
253. tandoffs Ensure no cables are underneath the ModSig PCBA Loosely install the two 2 Rear Bulkhead screws to allow for proper alignment of the ModSig PCBA Do not tighten yet Refer to Figure 120 Loosely install all eight 8 mounting screws to assist in proper alignment Refer to Figure 121 for mounting screw locations Tighten the eight 8 ModSig PCBA mounting screws Tighten the two 2 Rear Bulkhead mounting screws Refer to Figure 120 Reconnect the cables to the PCBA according to the previous cable removal steps Reverse Steps 2 3 and 4 4 3 and 2 Close the Top Panel and replace the two 2 screws that secure it Refer to Figure 99 Close the door on the 3D 60 to allow startup of the instrument Refer to Subsection 4 3 3 and perform the 3D 60 Power Up procedure Refer to Subsection 4 11 and perform the Post Service Validation procedure Annotate appropriate maintenance and logbooks Return the system to normal operation Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 7 ModSig PCBA Fuses P N 870 0008 14 17 22 Fig 125 ModSig PCBA Fuse Locations 1 Refer to Subsection 4 3 2 and perform the 3D 60 Power Down procedure 2 Remove the two 2 screws securing the Top Panel and secure it into the Up position Refer to Figure 99 for Top Panel screw removal locations Service Manual 4 105 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4
254. te changes The ModSig makes only one of the three Rack ID lines low for each rack and then polling this line within the Rack PCBAs the Rack Controllers determine their address without having individual address switches Refer to Figure 42 on the next page Four outputs from one of the 74ACT374 exciter LED drivers serve as the output drivers for the Rack ID Out signals through open drain inverters The communication between the modules is over RS 485 full duplex circuitry The necessary conversion between RS 485 differential signals and single ended CMOS compatible serial signals for use by the software is contained on the Rack Controller The actual RS 485 signals connect to all Rack Controllers through a connector on the ModSig PCBA Service Manual 2 21 2 BACKGROUND INFORM ATION BacT ALERT 3D 60 2 9 RACK CONTROLLER PCBA CONTINUED Rack Address Concept JP10 ModSig PCBA 5 O Polling line connects via JP2 on each Rack PCBA RACK 1 RACK 2 RACK 3 JP2 JP1 JP2 JP1 JP2 1 16 16 16 Rack 1 Address Code Rack 2 Address Code Rack 3 Address Code Input pins 18 17 16 Input pins 18 17 16 Input pins 18 17 16 Binary 1 1 0 Binary 1 0 1 Binary 0 1 1 Fig 42 Rack Address Concept 2 22 Service Manual BacT ALERT 3D 60 2 BACKGROUND INFORMATION 2 9 RACK CONTROLLER PCBA CONTINUED A 12 bit A D Converter is provided to convert the rack temperature sensor s analog signals to the di
255. ted in the rear and lower left corner of the instrument See Figure 159 When configured for 115VAC the has one 6 3 Amp 250V time delay fuse 870 0008 25 In addition a conversion clip is located across the neutral line in the fuse holder Refer to Figure 162 When configured for 230VAC each has two 5 0 Amp 250V time delay fuses 870 0008 24 Refer to Figure 163 CAUTION This instrument comes configured for 240V operation For other voltage settings replace fuse s as instructed in this section and according to Table 4 10 18 Facility Power Rating and Conversion Chart Note the fuse orientation to the rear of the fuse holder PEM shown as removed from the 3D 60 instrument Fig 157 Power Entry Module w Fuse Holder Removed Fig 158 Fuse Holder Fuse Installation 1 Refer to Subsection 4 3 2 and perform the 3D 60 Power Down procedure Service Manual 4 135 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 18 Power Entry Module Fuses P N 870 0008 14 17 24 25 Continued Mr ouem tar i an Fig 159 PEM Fuse Removal w Screwdriver 2 With a flat tip screwdriver open the PEM cover to access the fuses Refer to Figure 159 PEM Fuse Holder Pulled Out Fig 160 PEM Fuse Holder Removal Fig 161 PEM Fuse Holder Pulled Out 3 Slide out the fuse holder Refer to Figure 160 and Figure 161 4 Determi
256. the new Outlet Thermistor PCBA and secure with two 2 mounting screws Plug J3 cable back into the Outlet Thermistor PCBA at J3 NP Or de Service Manual 4 117 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 10 4 118 Outlet Thermistor PCBA P N 32300 1 Continued 8 Reinstall the Left Side Panel To protect the foam door seal from damage place a piece of thick paper or cardstock over the wide foam at the top of the door Remove the paper cardstock after completing the Left Side Panel installation Close the System Top Panel and secure it with two 2 screws Refer to Figure 99 Refer to Subsection 4 3 3 and perform the 3D 60 Power Up procedure Refer to Subsection 4 11 and perform the Post Service Validation procedure Annotate appropriate maintenance and logbooks Return the system to normal operation Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 11 Inlet Thermistor PCBA P N 32300 1 Fig 137 Inlet Thermistor PCBA Removal Refer to Subsection 4 3 2 and perform the 3D 60 Power Down procedure Remove the two 2 screws securing the Top Panel and secure it into the Up position Refer to Figure 99 for screw removal locations Remove the instrument s Right Side Panel to access the Inlet Thermistor PCBA Unplug cable from J3 connector on the Inlet Thermistor PCBA Refer to Figure 137 Remove the two 2 screws securing the Inlet Thermistor
257. the selected cell Four rings around the end of the reflectance standard identifies Standard 4 17 Click the Check button 18 If a check mark appears at the top of the Calibration Staircase icon then the calibration of the cell was successful Remove the Standard Four and click the Check button to save the new calibration values If instrument fault code 60 appears at the top of the Calibration Staircase icon then the calibration of the cell was unsuccessful Press the Cancel button and follow Steps 7 18 to recalibrate the cell If a fault code 420 appears at the top of the screen the door has been open too long Close the door click Cancel and follow Steps 7 18 again within two 2 minutes NOTE The calibration process can be canceled and any new calibration values discarded by pressing the Cancel button at any time during the calibration process 19 Click the Previous Screen button to return to the Flag Check Diagnostic screen Service Manual 4 73 4 SERVICING ALIGNMENTS AND CALIBRATIONS BacT ALERT 3D 60 4 9 6 System Power Supply Check and Adjustments The DC Power Supply is mounted on the System Power Panel located on the right hand side of the 3D 60 s chassis Refer to Figure 93 A metal housing encloses the DC Power Supply Since the adjustment POT Refer to Figure 97 is only accessible through a hole in the metal housing the instrument s top and right side panels must be removed t
258. tor PCBAs One is the Input Thermistor and the other is the Output Thermistor The Input Sensor measures the air temperature from the warmer air circulated by the heater fan and the Output Sensor the temperature of the cooler air measured after Incubator Chamber circulation A reading is taken from each sensor and the average temperature reading of the two comprise the Incubator Chamber s temperature used by the temperature control logic Refer to Figure 14 Note The Input and Output Thermistors are not components of the Electronics Compartment yet they are described as integrated PCBAs of the electronic system The thermistors boards are installed in the lower compartment of the left and right inside chassis respectively 1 GENERAL INFORMATION BacT ALERT 3D 60 1 4 3 Electronic Components Continued COMPACTFLASH ETAIT Besos Ph 217 1 OB BLUMER LEU pueHan mc 27704 Fig 15 CompactFlash Memory Disk Fig 16 CompactFlash Adapter PCBA NOTE Flash memory disk above may not necessarily reflect the actual memory disk or size being used in the 3D 60 instrument Fig 17 Step 5 PCBA 1 12 Service Manual 1 GENERAL INFORMATION BacT ALERT 3D 60 1 4 3 1 4 3 5 1 4 3 6 1 4 3 7 Service Manual Electronic Components Continued CompactFlash Memory Disk This CompactFlash disk is a removable mass storage device installed on the CompactFlash Adapter PCBA It is a device about the
259. tor s Manual to locate affected cells Relocate bottle in affected cells using the following procedure 1 Press lt CTRL gt lt F10 gt to enter a special Bottle Relocation mode that allows bottles to be relocated The cell indicator lights will illuminate in the following pattern e Cells with bottles are lit continuously e Cells available for reloading are unlit Pull bottles out one at a time and reload one at a time into any available cell If the bottle is anonymous the Bottle ID field is blank then enter the bottle ID See Text Data Entry Page 3 6 in the 3D 60 Operator s Manual When all bottles are unloaded click the Check button on the Main Screen 4 Attempt to calibrate the cell See Calibrating an Instrument Cell on Page 6 13 of the 3D 60 Operator s Manual Get corrected Calibration Report if necessary 5 If the calibration fails then disable the cell See Enabling and Disabling Racks and Cells on Page 6 10 of the 3D 60 Operator s Manual e Insert an orange cell plug into the disabled cell e bioM rieux Note Call bioM rieux if error occurs with numerous cells It could be a faulty Rack Controller 71 Invalid Time Stamp Cause Hardware failure involving the real time clock Caution Bottle readings are not processed while the fault is present Solution Call bioM rieux Service Manual D 5 APPENDIX D ERROR CODES BacT ALERT 3D 60 72 Invalid Calculation
260. troller The tests require special cables connectors as described below Part Number TOOL RS485 LOOPBACK 3D Loopback diagnostics for incubation module ports There are several options for using this part 1 It can be plugged directly into any Incubation Module ports on the back of the Combination Module or it can be plugged into the end of the cable going to the incubation module by using 43014 1 or it can be plugged into the signal distribution board using 43205 7 43014 1 TOOL CA ASSY RS485 LOOPBACK Loopback diagnostics for incubation module ports Allows 43013 1 to PERLE ed su er be connected to end of incubation module cable be connected to signal distribution board 43012 1 TOOL RS232 LOOPBACK 3D Loopback diagnostics for LIS BARCODE and MODEM ports 43005 19 KIT CALIBRATION TOOL 3D amp This kit includes the part above 43013 1 43014 1 43205 7 and 43012 1 COMBO along with parts used for calibrating cells 4 16 Service Manual BacT ALERT 3D 60 4 SERVICING SOFTWARE DIAGNOSTICS 4 8 4 Accessing the Diagnostics Screens e Starting from the Main screen click on the Next button in the lower right corner of the screen to access the Setup screen e Using the numbered buttons at the top of the Setup screen enter ihe password lt 1 gt lt 2 gt lt 1 gt lt 2 gt lt 3 gt lt 4 gt lt 3 gt lt 4 gt and click on the button with the key icon to access the Diagnostic Selection screen e NOTE Any reference to Dra
261. truments on the countertop or mounting surface 2 Four bolts fasten the 3D 60 to any mounting surface with four properly positioned 4 holes The instrument s 4 rubber feet must be removed a You must A determine the length of the bolts needed for your unique mounting Refer to Figure 55 b Properly locate B and drill four Y nch diameter holes in the mounting surface Refer to Figure 55 X Position C the equipment and secure it with four inch bolts Refer to Figure 55 CAUTION Care should be taken to avoid braces or bulkheads within the counter which could interfere with hardware installation and mounting Drilling into these may also reduce the integrity of the counter s strength Threaded holes are accessible once the four rubber feet are Fig 54 Countertop Surface Mounting Diagram Service Manual BacT ALERT 3D 60 3 INSTALLATION PROCEDURES 3 3 2 Procedure Continued d For mounting surfaces up to 2 W4 thick you can use the 5 inch bolts supplied with the instrument For mounting surfaces or surfaces requiring longer bolts you can use the Table of Equivalent Dimensions and Figure 54 Mounting Surface Diagram to determine the required bolt length Equivalent Dimensions 4 10 2 cm 2 6 4cm 5 212 7 cm 13 33 cm 3 Ye 8 9 cm 21 53 Table 3 3 4 Table of Equivalent Dimensions Inches to Centimeters Drill holes in surface Stationary Mounting Surface A B Calcul
262. ts Connect Printer to one of the Surge Protection Outlets Fig 199 Domestic UPS Peripheral Connections 9 Connect the 3D 60 Instrument s power cord into one of the Surge and Battery Backup Outlets Refer to Figure 199 10 Connect the Display Monitor s power cord into one of the Surge and Battery Backup Outlets Refer to Figure 199 11 Connect the Printer s power cord into one of the Surge Protection Outlets Refer to Figure 199 Service Manual 4 167 4 SERVICING REMOVE AND REPLACE PROCEDURES BacT ALERT 3D 60 4 10 32 APC Back UPS Model 650 Domestic Model P N 957 0060 02 Continued 12 Plug the serial UPS cable into the Computer Interface Port on the UPS and connect the opposite end cable into the UPS Port on the rear of the 3D 60 Instrument 13 Plug the UPS into a facility AC receptacle rated for 120V and press the UPS power switch to ON The Power ON light will illuminate on the switch 14 Turn on the Printer and Display Monitor 15 Turn the 3D 60 to ON from the PEM s power switch on the rear of the instrument and wait for proper power up initialization and Main Screen to display on the monitor 16 Refer to Subsection 4 11 and perform the Post Service Validation procedure 17 Annotate appropriate maintenance and logbooks 18 Return the system to normal operation 4 168 Service Manual BacT ALERT 3D 60 4 SERVICING REMOVE AND REPLACE PROCEDURES 4 10 33 APC UPS International Model P N
263. uffer empty interrupts seen by serial hardware Number of receive buffer full interrupts generated by serial hardware Number of line status interrupts generated by serial hardware Number of modem status interrupts generated by serial hardware note this interrupt is disabled as indicated on the screen Total of lines 1 1 through 1 4 Number of overruns reported by serial hardware An overrun occurs if received data is not removed from the serial hardware faster than it comes in This value should remain at 0 Number of parity errors reported by serial hardware Parity error checking is turned off so no errors should be reported Number of framing errors reported by serial hardware A framing error occurs if the number of serial bits between the start and stop bit are not correct Indicates whether the software s transmit data FIFO is empty or not 1 or 0 respectively 2 Indicates whether there was fault storing data in the software s trans mit data FIFO and where in the code that fault occurred Service Manual 4 25 4 SERVICING SOFTWARE DIAGNOSTICS BacT ALERT 3D 60 1 3 Inc Module 1 Message Stats Screen Special equipment Description Displays statistics related to messages exchanged between the instrument controller and incubation module Also displays statistics related to incubation module power faults and event requests Bottle testing is not affected by this diagnostic impact Keyboard Resets co
264. uick Reference card for the meaning of non zero fault codes Module power up Module Number 0x30 IMPwr This event indicates that the incubation chamber has just powered up Display time offset Offset in seconds a n mm 2 2 Internally the 3D software maintains time in GMT time When the operator uses the Set Date Time screen to enter the local time the difference between local time and GMT is calculated and this event is logged to record that difference This event is an indication that the operator has changed the date or time Cell QC fault Module Drawer Rack Cell Fault present Number Number Number Number 0x39 GCFIt RA J H255 ee e e 11422 252 224 This event is logged anytime a cell goes out of calibration or back into calibration presumably because the operator has calibrated the cell The Drawer Number value range 1 and corresponds with drawer A only The Rack Number ranges from 1 to 3 and corresponds with the top rack middle rack and bottom rack respectively The Cell Number ranges from 1 to 20 and identifies the affected cell The cell number that the operator sees depends on Rack Number For example if Rack Number is 2 and Cell Number is 5 the operator would see this as cell 25 If the Rack Number is 3 and the Cell Number is 10 the operator would see this as cell 50 If the Fault present value is 1 the cell is out of calibration 0 then the cell has been calibrated Service Manual
265. unts on all lines functions Status Runs and updates display values continuously 1 3 Inc Module 1 Hessage Stats 1 8 Incubation module 1 1 Power fails 1 2 Event requests 2 8 Module Controller Event requests Total messages Failed messages Receive timeouts Corrupted msgs Other faults w 1 ack Controller 1991 28 Event requests Total messages 486 AMAUNET 0Y QI J N ED 0N QIR O N Fai led messages Receive timeouts Corrupted 595 Other faults gt ack Controller 1921 40 Event requests Total messages Failed messages Receive timeouts Corrupted msgs Other faults 8 2 2 2 2 2 2 3 8 4 4 4 4 4 4 1 1 4 8 8 8 R Reset Fig 76 1 3 Inc Module 1 Message Stats Test Screen Display values Number of times incubation module reported a power fail condition Number of event requests received from the incubation module Number of event requests generated by the module controller should be the same as 1 2 Number of messages exchanged between instrument controller and module controller Number of messages exchanged with module controller with any problem Number of messages sent to module controller where the expected response did not occur in the required time Number of responses from the module controller that had a checksum error Number of message exchanges with the module controller that fail for some reason other than timeouts or corrupti
266. vered by the following e Tools the tools required for the assembly and disassembly of the component in question e System Power Down Procedure follow procedure in Section 4 3 2 for BacT 3D 60 Power Down e Disassembly step by step component disassembly procedure e Assembly step by step component assembly procedure e Assembly and disassembly diagram diagram s identifying the parts indicated in the assembly and or disassembly paragraphs e System Power Up Procedure follow procedure in Section 4 3 3 for BacT 3D 60 Power Up 4 10 REMOVE AND REPLACE PROCEDURES nenea oana one nennen nennen nn nnne 4 79 4 10 1 Introduction te 4 79 4 10 2 CPU PCBA Assembly P N 750 0070 01 0777777 777 7 4 81 4 10 3 Quad Serial Interface PCBA P N 750 0075 01 4 89 4 10 4 CompactFlash Adapter PCBA P N 957 0004 356 4 91 4 10 5 Software Installation and CompactFlash Memory Card Replacement 4 94 4 10 6 ModSig PCBA P N 48300 1 Order Spare P N 48300 901 4 95 4 10 7 ModSig PCBA Fuses P N 870 0008 14 17 22 4 105 4 10 8 Step 5 PCBA P N 48301 1 Order Spare P N 48301 901 4 108 4 10 9 Step 5 Motor P N 48104 1 eee 4 111 4 10 10 Outlet Thermistor PCBA P N 32300 1
267. vice Manual 2 25 2 BACKGROUND INFORM ATION BacT ALERT 3D 60 2 10 STEP 5 PCBA CONTINUED Motor Output The PM589 motor is a 5 phase stepper wired in a pentagon configuration 500 steps per revolution in full step mode Step sequence example for the 5 phases is PHASE1 J LS PHASE 2 WLU T LE PHASE4 L IT Lj PHASE5 L L If an over current occurs the motor will be stopped The fault signal is generated by the open collector of Q16 and goes LOW to indicate a fault By design a disconnected power cable will also result in a fault indication 4 internal indicators e LED 1 Output Codes 1 flash Motor stopped OK 2 flashes Motor running OK 3 flashes Motor over current 4 flashes Door switch one switch open the other closed 5 flashes Position sensor not changing state 6 flashes Safety timer not functioning doesn t go high after door opened 7 flashes Motor power bad 12VDC Note LED 1 on the Step 5 PCBA constantly outputs one of the above codes To interpret the code count the number of longer flashes LED on periods after the short start flash e Redundant door timer The Step 5 includes a timer independent of the microcontroller It disables the stepper motor after the door is opened and some delay has elapsed The redundant door timer consists of an oscillator clocking a pair of 14 bit counters which are wired to result in a 28 bit binary divider The count
268. wBcktInc 1 SlowDgdr 0 98E0 SlowSlopProp 0 9083E0 ID G2 BltFact 0 1E1 Resv 1320 MinSkipPts 216 MinAvgPts 24 MinAvgMed 1 SlopProp 0 1E0 SlowSlopProp 0 2E 1 FastDgdr 0 75E0 SlowDgdr 0 9 0 AcelSlopThres 20 SlowSlopThres 10 PosDlyThres 1 DltThres 32767 NumAlg2Pts 576 PosSlopDly 720 DltDgdr 1 0E 32 Embedded E2 Parms ID E2 BltFact 0 1E1 Resv 1320 AdjThres 70 AdjLim 4 StupPts 5 StupSumx 15 StupDenom 50 FastPts 17 FastSumx 153 FastDenom 6936 InitThres 3300 FastStupThres 6 SlopStupThres 0 1E1 FastCntrThres 12 FastBcktThres 0 105E2 FastBcktInc 1 FastRateThres 32 FastRateInc 3 FastDgdr 0 93E0 FastSlopProp 0 825E0 FastMayThres 3 SlowStupThres 12 SlowCntrThres 16 SlowBcktThres 15 SlowBcktInc 1 SlowDgdr 0 98E0 SlowSlopProp 0 9083E0 ID H2 BltFact 0 1E1 Resv 1320 AdjThres 70 AdjLim 4 StupPts 5 StupSumx 15 StupDenom 50 FastPts 17 FastSumx 153 FastDenom 6936 InitThres 3300 FastStupThres 6 SlopStupThres 0 1E5 FastCntrThres 12 FastBcktThres 0 105 2 FastBcktInc 1 FastRateThres 32 FastRateInc 1 FastDgdr 0 93E0 FastSlopProp 0 825E0 FastMayThres 3 SlowStupThres 12 SlowCntrThres 16 SlowBcktThres 15 SlowBcktInc 0 SlowDgdr 0 98E0 SlowSlopProp 0 9083E0 MinSkipPts 6 ID H2 BltFact 0 1667E1 Resv 1320 AdjThres 70 AdjLim 4 StupPts 5 StupSumx 15 StupDenom 50 FastPts 17 FastSumx 153 FastDenom 6936 InitThres 6000 FastStupThres 6 S
269. ware exception log Displays software exceptions messages intended for the 3D software development team Access this screen if a 19 fault code is being displayed on the main screen The format and content messages put in this log are left up the software implementer and no design specifications are imposed When a software exception is detected a fault code 19 is displayed on the main Screen While the software exception log is being displayed pressing CTRL R clears the fault 19 and a short beep will sound on the speaker Note Clearing the fault does not fix the problem Contact Global Customer Service as soon as possible 3 Operating system exception log Displayed exceptions reported by the 3D operating system SMX The format and content messages put in this log are determined by the operating system vendor Micro Digital and no design specifications are imposed 4 Modem activity log Displays software debug messages intended for development activity and is intended for the 3D software development team The format and content messages put in this log are left up to the software implementer and no design specifications are imposed 4 46 Service Manual BacT ALERT 3D 60 4 SERVICING SOFTWARE DIAGNOSTICS 5 Association tables Displays current content of various dictionaries and association tables used to keep track of bottle and pre load data An example of the Association screen content is shown below Explanatory
270. wer Fail button on the loopback test cable Verify line 5 1 shows 1 Release the button and verify line 5 1 shows 0 Repeat a few times Depress the Event Request button on the loopback test cable Verify line 5 2 shows 1 Release the button and verify line 5 2 shows 0 Repeat a few times Remove loopback hardware and reattach original hardware Exit diagnostic NOTE the 710 screen will appear momentarily This is normal Keyboard functions R Resets counts on lines 1 1 1 5 2 1 2 4 3 2 4 1 4 2 4 2 1 4 2 2 to 0 Once started the diagnostic runs continuously and updates the display data continuously Service Manual 4 23 4 SERVICING SOFTWARE DIAGNOSTICS BacT ALERT 3D 60 1 1 Inc Hodule 1 Loopback nterrupt Counts Transmit Buffer Empty 1084649 Receive Buffer Full 3726412 Line Status Status 8 Disabled 4811056 verrun 2 Parity 3 Framing 3 8 Transmit FIFO 3 1 Empty 1 3 2 Put errors 8 8 8 4 8 Loopback status 4 1 PRSS count 8 4 2 FRIL count 25 4 2 1 Timeout 25 4 2 2 Hismatch 8 5 8 Signal status 5 1 Power fail 8 5 2 Event request 8 R Reset Fig 74 1 1 Inc Module 1 Loopback Test Screen Display values Should increment Number of transmit buffer empty interrupts seen by serial hardware Should increment Number of receive buffer full interrupts generated by serial hardware Should remain at 0 Number of line status interrupts generated by serial hardware Shou
271. wer s and or additional Incubation Modules in the following text or within any of the software screen capture images is actually referring to the single Incubation Chamber of the 3D 60 instrument Additional incubation modules cannot be added to the 3D 60 instrument Fig 67 Diagnostic Test Selection Setup Screen e Select the diagnostic by clicking on the corresponding lines in the two selection boxes on the screen and press the right arrow button to start the diagnostic e If necessary use the scroll buttons on the selection list box to locate the diagnostic then touch that line Service Manual 4 17 4 SERVICING SOFTWARE DIAGNOSTICS BacT ALERT 3D 60 4 8 5 Diagnostic Screens Overview e All diagnostics screens have the same general form An example screen is shown below Operation Buttons Run continuously Pause Run once Find text Save output to ZIP Print all output Print current page Cancel print Diagnostic Name BacT ALERT 3D SELECT LINK 1 7 Inc Hodule 1 Flag Check 1825 lt 1854 lt 1807 1B19 1B34 1848 1 25 1 17 1D15 53 72 1033 1 62 n 3c 2 325 1 15 lt 1 525 1B38 1 725 1D15 53 725 1A13 2 32 2 32 1R14 22 1f48 1 1 1 62 1 17 lt 1 42 1B28 1 92 1B38 1 12 1B59 1 1 825 122 1D28 52 1ASS 62 1B19 1B29 Diagnostic output Helpline display area 1 Diff Z
272. y not be copied without the express permission of bioM rieux Any representation or reproduction whether partial or integral by any process whatsoever would therefore be considered fraudulent and sentenced by the applicable law Service Manual BacT ALERT 3D 60 THIS PAGE INTENTIONALLY LEFT BLANK Service Manual BacT ALERT 3D 60 TABLE OF CONTENTS TABLE OF CONTENTS 0 FRONT MO KEKO SK D Be Ku i ta IX 0 1 APPENDICES tete M IX 0 2 XI 0 3 EISTOFIEEUSTBHATIONS adde eta a dei KA AA l KA WARA KA HA KA HW WA A XIII 0 4 TYPOGRAPHY AND GRAPHIC XIX 0 4 1 met ET WER ARA R oat Re al k S aaa xxi 0 4 2 ext DONO TEE xxi 0 4 3 Bracketed o tet Ee 0 4 4 Underlined Text iioi cot et io eit ue tet N O n y ber iic eei xxi 0 4 5 Bracketed ext ci c itd bmrm xxii 0 4 6 Text Within Quotation xxii 0 4 7 Italicized Whether Bold or Not Text ll mH xxii 05 SAFETY SUMMARY iioi avi ie Don tv cea e vacua se vmi k cR vid ev Ir vu E XXIII 0 5 1 General Information to 0 5 2 Electrical Warnings 30 5 iul EE XXV 0 5 3 Electrical Gro nding cri ete eee 232 ER xxvi 0 5 4 Fuse Replacement

BacT-3D 60 Service Manual Rev A

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