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1. A y Q96A BOARD CONNECTORS Fig 73 UPPER BACKPLANE Power Supply J206 287 208 TOMTEC QUADRA 3 Service Manual 73 SECTION VI THE CPU amp ELECTRONICS Q96B BOARD REMOVAL amp INSTALLATION BACKPLANE Q96B CONNECTORS Fig 74 BACKPLANE Q96B BOARD Fig 75 Loosen the four captive screws on top of the board Lift up the board and disconnect the hose from Port B on sensor TOMTEC QUADRA 3 Service Manual 74 SECTION VI THE CPU amp ELECTRONICS Q96B BOARD Fig 76 censor nose connected to PortB FACTORY SETTINGS SERVICE In order to change the factory settings a password needs to be entered when 4 Factory Settings is selected under the System Settings heading Call Tomtec service if changes need to be made Use the up and down arrow keys to move from one field to another Note that the screen below is displayed regardless of which head is installed and the parameters will be disregarded if they are not pertinent to that head NOTE Load tip height shuck tip height backlash factor and steps uL will be unique for each type of head NOTE All Parameter values shown are the default values A parameter sheet is sheet is shipped with each instrument indicating final factory set values for these parameters Fig 77 QUADRA 3 STAGE Stage Run Spd J Stage Run Ramp 3 Stage Init Spd 5 Stage Init Ramp 3 Max S
2. Vacuum Manifold To Bottle Green Precision Pressure Regulator Monitor Port 0 5 PSI From Located on the pneumatic panel opm TOMTEC QUADRA 3 Service Manual 50 SECTION V THE STACKERS SYSTEM PRESSURE GAUGE amp MONITOR PORTS PART OF PNEUMATIC PANEL Fiv 47 Compressor Pressure To System Black Pressure Manifold Return To 5 PSI Green Regulator Pressure Monitor Ports System Pressure Gauge Bottle Pressure Green To Precision Regulator G een e ToSV103 Elevator Red To 25 PSI Regulator Pressure Monitor Plug TOMTEC QUADRA 3 Service Manual 51 SECTION V THE STACKERS ESCAPEMENT LATCHES Fig 48 From System Pressure M Manifold Right Stacker Green Latch Out Red Latch In CV3 Latch In Latch Out 2 Left Stacker Latch Out Green Latch In CV1 Latch In Latch Out Red Cassette Valve Manifold Located on the pneumatic panel TOMTEC QUADRA 3 Service Manual 52 SECTION THE STACKERS STACKER ELEVATORS Fig 49 Stacker Elevators 5 PSI Regulator Elevator Down Located on pneumatic panel To Return Pressure Monitor Port Left Elevator Manifold Green Right Elevator Manifold Green Elevator Elevator Elevator Left Front Left Rear Right Rear Elevator El
3. TOMTEC QUADRA 3 Service Manual 94 SECTION ABOUT QUADRA 3 DECONTAMINATION FORM In order to protect personnel involved in the service and repair of instruments one must ensure that risk factors hazardous to health Biological infectious material or Radioactive isotopes are removed from the equipment in question This form must be signed and accompany the Tomtec instrument when it is returned for service or repair If not the service department may be unable to perform service on the instrument Model Serial number Type of Contamination Biological Radioactive None Method of Decontamination Biological Radioactive Other Please specify Note In all cases equipment must be emptied of all fluids prior to returning to Tomtec I confirm that the instrument listed above has been submitted to an appropriate process of decontamination at this facility before being shipped to Tomtec Inc Name of Institution Institution Address Date Signature Print Name Title TOMTEC INC 1000 Sherman Avenue Hamden CT 06514 USA Phone 203 281 6790 Fax 203 248 5724 TOMTEC QUADRA 3 Service Manual 95 SECTION ABOUT TOMTEC IF YOU NEED HELP If you have any questions regarding this manual or the service and maintenance of any Tomtec equipment please contact the Tomtec Inc Service Department Please have your model number and serial number avai
4. TOMTEC QUADRA 3 Service Manual 84 SECTION VI THE CPU amp ELECTRONICS 1 2 3 4 5 6 7 8 9 Enable 24 Volt Relay Fuse Valves 2A LED DS 4 Touch off Driver PWA Fuse Pinch Tube 5A LED DS 3 LED DS 2 Fuse F2 Pump Led DS 1 10 Fuse F1 Y Shuttle 11 SEA Q4 Q11 Q14 E2 Pump 12 PEA Q5 Q8 Q9 Q10 F1 Y Shuttle 13 Communication 14 Dip Switches 15 RAM 16 Air Sensor B Port 5psi Sensor Time Dispense Air Tank Reads Display 17 Board B Firmware Version 0 NOTE Quadra 3 board A or B XU12 9 15 XU12 1 8 XU13 1 8 It does not matter if 9 15 is there or not TOMTEC QUADRA 3 Service Manual 85 SECTION VI THE CPU amp ELECTRONICS 1 2 3 4 5 7 8 9 CIRCUIT BOARD EXAPNSION BOARD UI Do not use unless auto hand is installed It can be swapped with U2 U4 U3 U2 U4 F4 amp DS3 not used amp DSI Y motor enable F2 amp DS2 not used FS amp 054 X motor enable 24VDC 10 014 X stepper Drive 11 U13 Y Stepper Drive 12 Not used unless items are installed TOMTEC QUADRA 3 Service Manual 86 SECTION VI THE CPU amp ELECTRONICS QUADRA 3 BOARD A I O MAP Author Phan Lu 05 15 00 10 24 00 05 21 01 07 30 02 11 08 02 02 13 03 05 12 03 10 19 04 de de e de e de e de e de e e de de ede de de e dee de de de dede de
5. Install the piston block head and covers Replace the tip load safety reed switch Replace the head in accordance with procedure page 13 Replace lower front cover and top cover in accordance with procedure page 34 amp 72 Fig 28 amp 70 TOMTEC QUADRA 3 Service Manual 18 SECTION II THE HEAD 450 1 BACKFILL HEAD 020880 02 FRONT VIEW Fig 7 Air Tubing Pump initialization light switch Lead screw Flag Manifold Assembly Pinch tubes e Clamping rod Assembly E Li T PEEN Pistons Tip block Assembly Stage safety disable reed switch Tip load light switch TOMTEC QUADRA 3 Service Manual 19 SECTION II THE HEAD 450uL BACKFILL HEAD 020880 02 BACK VIEW Fig 8 Clamp Air Tubing Pinch tube motor Cams At D pinch tubes closed Light switch Pinch tubes open shuck plate Tip load light switch Tip pins 96 pin assembly TOMTEC QUADRA 3 Service Manual 20 SECTION II THE HEAD TIP BLOCK ASSEMBLY TOP FRONT VIEW Fig 9 Piston seal plate Piston Body 021021 021019 Tip plate 023360 Bearing 16001 01 Tip shuck plate 023359 BACK BOTTOM VIEW Fig 8 Piston Body 021019 2 Piston seal plate 021021 Tip load light switch 315 001 02 Holes for guide rods Tip plate 023360
6. Tips O rings 020046 01 Quantity 96 Tip shuck plate Light switch pin 023359 assembly plunger 020531 TOMTEC QUADRA 3 Service Manual 21 ___5 965 60uL HEAD 020870 Draw bolts FRONT VIEW Fig 10 Lead screw Interrupter light switch Intialization flag Pistons retracted from Tip and Seal Assembly Tip on snap switch assembly Tips 96 Tip and Seal Assembly 196 101 96SV TIP AND SEAL ASSEMBLY 196 101 Fig 11 TOMTEC QUADRA 3 Service Manual 22 SECTION II THE HEAD 384 60uL HEAD 020869 FRONT VIEWS Fig 12 Draw bolts Initialization flag Interrupter light Tip on snap Tip and Seal Note that pistons switch switch assembly Assembly are inserted into Tip 384 101 and Seal Assembly 965 AND SEAL ASSEMBLY 196 101 Fig 13 NOTE The 384 head also comes as 200uL TOMTEC QUADRA 3 Service Manual 23 SECTION II THE HEAD PISTON BLOCK EXPLODED VIEW Fig 14 Plate Piston Seal Bearings Rings Switch Block Bracket Rings Tip Pins Plate Piston Drive Light Switch Pin Assembly Grid Support aa atm Sy TIE Pad Lubricant Replace tip pins tip pin plate rings and piston plate O rings Tip P
7. Using F2 move from one position to the next After each movement raise and lower the stage The nest should lift off the shuttle table with the locator pins on the stage going smoothly into the hole on the nest The nest should seat back on the shuttle with the locator pins going into the holes without hitting the shoulder If the nest is not flat on the TOMTEC QUADRA 3 Service Manual 41 SECTION IV THE SHUTTLE shuttle or if the pins hang up on the shoulder before seating then adjustment is necessary Use the arrow keys to adjust the shuttle Raise and lower the stage to check it after each adjustment In each station position over the stage raise and lower each stacker elevator that the shuttle is over and check the smoothness of raising and lowering he nest in the same manner Press F2 and repeat this procedure for the next position Continue testing and adjusting all six positions of the shuttle in the same manner until all six positions are satisfactory Front to back adjustments will affect all stations in that row Le adjusting station 1 back will also adjust stations 2 and 3 back Left to right adjustments affects both stations in the same column Le adjusting station 1 left will also cause station 6 to shift left Other column pairs are 2 amp 5 and 3 amp 4 ANNUAL SHUTTLE PREVENTIVE MAINTENANCE ON THE QUADRA 3 BY FIELD SERVICE ENGINEER Clean guide rods with alcohol based solvent Refer to Fig 38 amp 41
8. QUADRA 3 Service Manual TOMTEC D 1000 Sherman Ave Hamden CT 06514 203 281 6790 FAX 203 248 5724 www tomtec com TABLE OF CONTENTS SECTION I GENERAL INFORMATION Warnings Cautions Notes amp Symbols Specifications Quadra 3 Pictorials Operational Functionality Bar Code Installation Kit 330 10 SECTION II THE HEAD Head Removal amp Installation Head Alignment 450uL Backfill Theory of Operation Tip Pin and O Ring Replacement 450uL Backfill Head Pictorials Tip Block Assembly 96SV 60uL Head Pictorials 384 60uL Head Pictorials Piston Block Annual Head Preventive Maintenance SECTION THE STAGE Stage Removal amp Installation Annual Stage Preventive Maintenance SECTION IV THE SHUTTLE Removal amp Installation of Shuttle Cover amp Bottom Covers Installing Side Covers Removal of Shuttle Table Shuttle to Stage Alignment Shuttle Calibration Text Screen Annual Shuttle Preventative Maintenance Shuttle Pictorials SECTION V THE STACKERS Quadra 3 Air System General Theory of Operation Elevator Air Pressure Control Setup Compressor Removal amp Installation Elevator Removal amp Installation Stacker Elevator Alignment Stacker Escapement Test amp Adjustment Plate Present Sensor Adjustment Annual Stacker Preventative Maintenance 28 31 32 35 36 40 40 42 43 45 45 47 55 57 59 62 64 66 SECTION VI THE CP
9. 0 2300 XY Safe Height The maximum height that the stage will go to in which it can index with a plate on it without interference from the pipetting tips 0950 1250 LOAD AND SHUCK TIPS Load Tip Speed 1 6 Six is the fastest speed 7 amp 8 are for future use Speed at which the stage moves up and down when loading tips Load Tip Ramp 1 3 Relative time it takes for the stage to go from stop to its load tip speed or to accelerate Load Tip Light Switch 0 Disable 1 Enable When enabled the light switch senses that the tips have been loaded at the required height and signals that the stage can be lowered This pertains to the 450u1 head only Load Tip Height 0 2200 This is the height the stage should be set to in order to load the tips which are seated in a tip jig Shuck Tip Height 0 1770 This is the height the stage should be set to in order to shuck the tips into the appropriate tip jig PUMP Pump Shuck Speed 1 4 Four being the fastest 5 to 8 are for future use Pump Shuck Ramp 1 4 Relative time for pump to go from stop to its shuck speed or to accelerate Pump Shuck Step 0 5000 Number of steps it takes for the pump to move the tip shuck plate to remove the tips Pump Asp Ramp 1 4 Relative time for the pump to go from stop to its aspirate speed Pump Disp Amp 1 4 Relative time for the pump to go from stop to its aspirate speed Backlash Factor 0 256 Number of steps set to compensate for the
10. 3 96 384 X Offst 144 Run Ramp 3 96 384 Offst 144 SHUTTLE CALIBRATION 2 Stackers Left Rear 71 8 Right Rear 11 21 3 Shuttle 61 51 4 Stackers Left Front 81 91 Right Front Stage PGUP Run Up EPGDN1 Run Down c t 41 Calibrate Shuttle 11 5 21 POS F31 85 STEP PER ESC 1 CRNCEL Max firm Height 4288 Backlash Factr 816 firm Safe Hght 88808 Half Steps uL 816 Tray UP Delay 83 F1 SAVE F2 SHUTTLE CALIBRATION 1 TO FLOPPY ESCI CANCEL i Ramp 3 1 SHUTTLE CALIBRATION TEXT SCREEN Stackers Pressing the buttons on the front panel with numbers 7 8 9 and 0 will raise the corresponding stacker elevator when pressed the first time and lower it when pressed again Shuttle Pressing numbers 1 to 6 will cause the shuttle to move so that the corresponding station is over the stage Stage Pressing Page Up will cause the stage to rise and pressing Page Down will cause it to lower TOMTEC QUADRA 3 Service Manual 40 SECTION IV THE SHUTTLE Calibrate Shuttle pressing the right left up or down arrows in the front panel will cause the shuttle to move in the corresponding direction the number of steps selected using F3 Pressing the right arrow will cause the shuttle to move right X direction Pressing the left arrow will cause the shuttle to move left X direction Pressing the up arrow will cause the shuttle t
11. Procedure On the main menu select System Functions 4 and press enter Press F2 Select Light Switch Status 0 and press enter Notice that in the left column the presence of the right front and rear and left front and rear light switches Plate Present is abbreviated Prsent 0 true indicate the presence of a plate A 1 false indicates no plate Place stacker nest on the shuttle station under the stacker associated with the sensor to be adjusted Remove the two screws holding the sensor to the cassette mounting plate The sensor will hang freely On the sensor the dark light mode designated D and L switch should be in the light position fully CW Hold the light switch so that the red beam shines through the hole in center of the nest Turn the sensitivity adjustment to the fully CW position which is maximum sensitivity Back off the adjustment until a 1 is displayed Place a black plate on the nest The status should switch to 0 This may have to be repeated until it is just right Install the sensor Test again and repeat procedure if necessary TOMTEC QUADRA 3 Service Manual 64 SECTION V THE STACKERS An installed sensor which sees a plate when one is not present requires a decrease in sensitivity CCW A sensor which does not see a plate when one is present requires an increase in sensitivity CW PLATE SENSOR INSTALLED
12. SECTION V THE STACKERS 4 Elevator Pressure monitors elevator up pressure and is adjustable by the elevator pressure regulator on the pneumatic panel Two stacker override momentary toggle switches are used to release a plate in any one of the four stackers Two elevator override toggle switches with two positions each provide manual control for four elevators The load override switches are for future use Also mounted on the pneumatic panel are the Compressor fuse holder e Stacker cylinder valves CV1 4 e System pressure manifold Compressor control relay Cassette Based Plate Handling Cassette release solenoids are controlled by the three way valves that send system pressure to return and release stacker solenoids ELEVATOR AIR PRESSURE CONTROL SETUP Tool required 1 4 inch flat blade screwdriver The section of the pneumatic system that controls the operation of the four elevators has two regulators for elevator up and down The AC compressor is controlled by a solid state relay energized by the system 24VDC If the panel is opened while power is on an interlock on the front panel shuts off the 24VDC which shuts off the compressor 1 Move the pressure gauge to the Elevator Pressure port Pull the knob out and turn it CW so that gauge reads 25 PSI Using the Elevator Override switches test the operation of the elevators moving any of the elevators up and down Insure that the readin
13. Shuttle to Stage Alignment 40 Annual Shuttle Preventive Maintenance By Field Service Engineer 42 Shuttle Pictorials 43 REMOVAL AND INSTALLATION OF SHUTTLE COVER amp BOTTOM COVERS Tools required 11 32 nut driver 2 Phillips screwdriver 5 64 Allen wrench 7 64 Allen wrench Procedure Shut off power to instrument Remove four nuts 2 on each side underneath that secure shuttle cover to shuttle frame Lift the cover up and carefully remove so that the pipetting tips are not damaged SHUTTLE UNDERNEATH RIGHT SIDE Fig 23 Shuttle Cover Nuts 2 per side Floppy Drive Air Regulator Adjustment TOMTEC QUADRA 3 Service Manual 32 SECTION IV THE SHUTTLE ELEVATOR NEST PLATE Fig 24 Nest Plate Phillips screw 4 Adjustment Screw VIEW OF SCREW LOCATIONS FOR SIDE COVER TYPE I COVER SHOWN Fig 25 Thumbscrew holding side cover to frame one on each bottom corner Screw holding side cover to elecator 1 per elevator Access hole for Plate Escape adjustment Bottom left cover Remove the left side cover by unscrewing the two screws that are located over the elevator positions Loosen but do not remove the two thumb screws that are on the bottom with your fingers Remove nest plate by removing the adjustment screw and Phillips screw from elevator plates in the front and rear Also remove the cover screw under the elevator nest plate The cover is now free to pull off TYPE II COVER
14. 1 890 600 01 BARCODE READER 2 00 0632 02 36 32 NUTS 2 10 0600 10 6 FLAT WASHERS 2 52000 3 5 M3 X 5mm FHS SCREWS INSTALLATION PROCEDURE 1 2 3 4 To install 890 600 01 BARCODE READER in the QUADRA 3 be certain to turn off power and disconnect line cord Open the front panel and locate connector J111 a male 9 pin sub d on the upper left side of the main circuit board behind the head NOTE It is not necessary to remove the pipetting head to install the barcode reader If you are changing heads plan to do it at the same time but installation with the head installed will alleviate the need to realign the head To insert connector from the barcode reader with the head installed hold cord behind connector with forceps long tweezers or wrap masking tape around cord and a long screwdriver Insert connector and tighten hold down screws with a six inch or longer 1 blade screwdriver Attached 024524 BRACKET to barcode reader with 2 52D00M3 05 M3 x 5mm FLAT HEAD SCREWS Position barcode reader bracket assembly over 6 studs on left right side of electronics shroud above stage Slide bracket to lowest position and install with 2 10 0600 10 6 FLAT TOMTEC QUADRA 3 Service Manual 10 SECTION I GENERAL INFORMATION 5 6 7 8 9 WASHERS and 2 00 0632 02 6 32 KEP NUTS Just snug to allow for bracket adjustment Route cord back and up through cut out behind barco
15. 1 1 1 0 gt 6 96 well NON backfill for Quadra PLUS 1 1 1 1 7 96 well backfill 450ul 0 0 0 0 gt Cherry Pickers 20001 0 0 0 1 gt 8 tips Nano head 0 0 1 0 gt 10 16 tips Nano head 0 0 1 1 gt 11 384 DSV heads input p112 s1s3 shuttle X out of position interlock from Board A J2 24 input p111 s1s2 shuttle Y rear light switch 22 20 input p110 1 1 shuttle Y front light switch 92 16 p227 EXP input msb input p226 EXP input msb 1 input p225 Quadra Door Opened 24V disabled 23 4 input p224 Pump head type bit 4 MSB J3 2 output p223 Yshut position interlock to Board U17 p112 or J2 24 22 15 pull out U13 and connect pin 9 and pin 15 in that socket output p222 SPARE BIT output p221 SPARE BIT output p220 SPARE BIT interrupts INTERRUPT 0 int0 processor extint 8 bit analog A D converter rxd rxdl rpc receiver PC 21 16 txd txdl tpc transmitter PC 21 20 no connection rxc no connection Be e e e e e e de e de dee dede de dede de dee de dee ede dee ede TT de ee de dee ee dece e de eee dee e dede ede de eee de eee eee dede e RRR de e de d e n n n n 8256 address 0000 to 000 CHIP 28 PC board Z8 U21 e e de e e ee de de dee de dee dede dee dede eee e eee ee dee eee ee eoe e ede e e ede eee ode e eee eee dee ede ee dee eee e eee eee ee e e d e e d d n n n x output p017 Shaker 2 Vacc Box Vaccuum 63 33 output 016 Shaker 1 63 36 ou
16. 60psi adjust for adjust for Values Manifold Elevator Down Elevator Up SOLENOID VALVE MANIFOLD Fig 44 Muffler SV Manifold Hose connection between SV104 and the top of the System Pressure Manifold Clear hose To bottle via connector at top of the instrument SV 104 V 103 SV 102 Sv 101 Green hose From tee between SV103 bottle and Bottle Pressure Monitor Port to Q96B Board Port B on the sensor TOMTEC QUADRA 3 Service Manual 48 SECTION V THE STACKERS COMPRESSOR AND SYSTEM PRESSURE MANIFOLD DIAGRAM Fig 45 To SV 104 SV Manifold To 0 5 PSI Precision Regulator System Pressure Manifold To SV 101 SV Manifold To the 5 PSI and 25 PSI Elevator Regulators To Compressor Pressure Monitor Port To CV Cylinder Valve Manifold Refer to Figures Quantity 3 in Compressor Removal and Installation on page Compressor Pressure Vacuum To SV 102 SV Manifold TOMTEC QUADRA 3 Service Manual 49 SECTION V THE STACKERS SOLENOID VALVES LOCATED ON THE SV MANIFOLD Fig 46 Exhaust SV104 261013 To Bottle via the connector at the top of the instrument Pas PR a rE i These connections System internal to the manifold Pressure Manifold SV103 SV101 NC NC 261013 261013 EU To Mises Green Green Q96B Board NUUAM cues Monitor Port
17. Fig 26 TOMTEC QUADRA 3 Service Manual 33 SECTION IV THE SHUTTLE FLOPPY DISK DRIVE Fig 27 Floppy Drive is not installed on later Quadra 3 s Power and ribbon cables are in front display Note location of the red side of the cable To remove the right cover unscrew the air regulator adjustment then remove the screws in the same relative positions as the left side With the floppy disk drive cables attached carefully pull the side cover free and remove the two cables Since the gray ribbon cable can be inserted either way note the side of the cable that is red faces inboard on the drive LOWER FRONT COVER Fig 28 Screws spring loaded washers both sides Thumb screw underneath To remove the lower front cover remove the thumb screw underneath and the pull the front cover off NOTE The spring loaded washers on each side do not require any adjustment TOMTEC QUADRA 3 Service Manual 34 SECTION IV THE SHUTTLE LOWER FRONT AREA FRONT COVER REMOVED Fig 29 Screws spring loaded washers both sides INSTALLING SIDE COVERS ELEVATOR Fig 30 Mounting Plate Nut Plate Prior to installing the covers on each elevator center the nut plate in order locate the nut with the screw once the cover is on 2980 Replace the plate nest Tighten the Phillips screw to secure it to the cylinder With no air pressure power still off lift the elevator and from underneath push
18. Fig 61 Plate Release Air Cylinder Plate Sensor Allen screw 2 PLATE SENSOR Fig 62 Mode Switch shown in Light Position STACKER NEST Fig 63 Direction of Beam TOMTEC QUADRA 3 Service Manual 65 SECTION V THE STACKERS ANNUAL STACKER PREVENTIVE MAINTENANCE DO NOT lubricate the air cylinder piston rod that is located in the center of the elevator air cylinder This is factory lubricated with grease and should last the life of the cylinder Other lubricants could cause the grease to break down resulting in damage to the cylinder Check for movement and binding In Utilities exercise each elevator insuring that it goes up and down smoothly without any binding or jerking motion They can also be exercised using the switches on the pneumatic panel Check for alignment to shuttle Test each elevator with a stacker nest on it exercising it up and down insuring that the nest sits squarely on the elevator when it is lifted and that it sits squarely on the X table when it is lowered Pins should not hang up on the lips of the holes Stacker test Place stacker nests in shuttle positions and four and place micro plates in the stackers appropriately Exercise the left and right elevators changing shuttle positions as necessary in order to test each stacker Do enough iterations of infeed and outfeed of each stacker so you are satisfied that the plates are not catching on the flippers and that they are
19. Light Switch X Direction Left Flag Backplane Forward Position Light Switch Y DIRECTIONAL MOTOR BELT AND PULLEYS Fig 42 Y Direction Motor Rear Spindle Front Spindle To adjust the belt tension use 1 16 Allen wrench rotating the spindle in the shown above Once desired tension is achieved tighten the adjustment bolt in place TOMTEC QUADRA 3 Service Manual 44 SECTION V THE STACKERS SECTION V THE STACKERS Quadra 3 Air System 45 Elevator Air Pressure Control Setup 47 Compressor Removal and Install 55 Elevator Removal and Install 57 Stacker Elevator Alignment 59 Stacker Escapement Test and Adjustment 62 Plate Present Sensor Adjustment 64 Annual Stacker Preventative Maintenance 66 QUADRA 3 AIR SYSTEM NOTE In addition to the following information please refer to the Q3 PNEUMATIC DIAGRAM in the envelope at the back of this manual The air system consists of these main elements Combination compressor vacuum pump Three pressure regulators high low and precision Four solenoid valves Pressure gauge GENERAL THEORY OF OPERATION The compressor supplies its output to the systems used for reagent time dispense backfill dry tubes as well as the plate elevator system Also the cassette based plate handling is pneumatically controlled Pressure can be monitored at four points on the pneumatic control panel Solenoid valves are used on the inlet vacuum side and outlet pressur
20. Power Connector 5 Channels TN CH1 4 5 27121 disconnected Re 5 3 2 5 BM ang Drive Cable Expansion Board COMPUTER AND KEYPAD ASSEMBLY Fig 67 P2 P1 Keypad Assembly TOMTEC QUADRA 3 Service Manual 70 SECTION CPU 4 ELECTRONICS COMPUTER AND KEYPAD ASSEMBLY Fig 68 Ethernet Port not used PS2 Connector cable goes Communications Port 5 to P1 on keypad Connector CRT Connector cable goes to Display on Auxilliary Connector Panel UT Display Cable 1 and Connector Pin 1 Expansion Board screws 2 removed FRONT PANEL DISPLAY Fig 69 Phillips screws 4 Cable to Computer TOMTEC QUADRA 3 Service Manual 71 SECTION VI THE CPU amp ELECTRONICS TOP COVER REMOVAL amp INSTALLATION Top is one piece Fig 70 Remove top Phillip screws 4 Remove rear Phillip screws 2 BACK COVER REMOVAL amp INSTALLATION Fig 71 Remove Screws 6 Cooling Fans mS 1774 1 Remove the screws 6 on the rear panel along with the quick release screw the bottom of the rear service door and disconnect the fans TOMTEC QUADRA 3 Service Manual 72 SECTION VI THE CPU 4 ELECTRONICS Q96A BOARD REMOVAL amp INSTALLATION Fig 72 Q96B Board Power Supply Q3 UPPER BACKPLANE Q96A Board Screws 2
21. Screw removed 2 per side Lift and pull the shuttle forward insuring that the side plate on the shuttle stays vertical TOMTEC QUADRA 3 Service Manual 37 SECTION IV THE SHUTTLE SHUTTLE TABLE LIFTED Fig 35 SHUTTLE TABLE LIFTED Fig 36 X MOTOR MUST CLEAR TOMTEC QUADRA 3 Service Manual 38 SECTION IV THE SHUTTLE SHUTTLE REMOVED SHOWING CABLES Fig 37 gt 72 xs y 2 um 4 Plug to J315 on the Lower Y Motor Cable Connector Back circuit panel Reverse this procedure to install TOMTEC QUADRA 3 Service Manual 39 SECTION IV THE SHUTTLE SHUTTLE TO STAGE ALIGNMENT Each of the six stations on the shuttle must have the same relationship with the stage in the X and Y directions In each station this is tested by raising and lowering the stage with a nest on it and verifying that it rest squarely on the shuttle The stacker elevators are checked in the same way If the nest does not seat squarely on the station the shuttle needs to be calibrated with the stage as a reference Changes can be made to the number of steps in the shuttle movement under SHUTTLE CALIBRATION in the Factory Setting screen but it is better to use F2 Shuttle Calibration SHUTTLE CALIBRATION TEXT SCREEN Fig 38 CEN QUADRA 3 Factory Settings STAGE SHUTTLE STAGE FORMATTING Run Spd 1 Shuttle Speed
22. and for thoroughly rinsing the system after use Damage resulting from improper use of liquids and lack of cleaning are the user s responsibility and are not covered by TOMTEC s warranty WARNINGS CAUTIONS NOTES AND SYMBOLS Throughout this manual there may be blocks of text printed in bold type within boxes or italic type These blocks are warnings cautions and notes and they are used as follows WARNING A WARNING INDICATES THE POTENTIAL FOR BODILY HARM AND TELLS YOU HOW TO AVOID THE PROBLEM CAUTION A CAUTION INDICATES EITHER POTENTIAL DAMAGE TO HARDWARE OR LOSS OF DATA AND TELLS YOU HOW TO AVOID THE PROBLEM NOTE A NOTE indicates important information that helps you make better use of your Quadra TOMTEC QUADRA 3 Service Manual 3 SECTION I GENERAL INFORMATION Throughout this manual there may be symbols within triangles and they are used as follows The lighting flash with arrowhead symbol within an equilateral triangle is intended to alert the user to the presence of non insulated dangerous voltage within the product s enclosure that may be of sufficient magnitude to constitute a risk of electric shock The exclamation point within an equilateral triangle is intended to alert the user to the presence of important operating and maintenance servicing instructions in the literature accompanying the appliance SPECIFICATIONS QUADRA 3 Environmental Specifications Operating
23. bottom of the elevator Replace the nest plate of the elevator and ensure that the nest plate and mounting plate are flush The plate escapement adjustment screw will be centered in the alignment hole Tighten both screws Insure that the elevator moves up and down without binding If the anti rotation device rubs the elevator body loosen the hex screw and realign the anti rotation device In order to not change the timing place 090 spacers under the top plate to simulate the side cover Confirm that sheet metal flags pass through the center of all three light switches and do not contact the light switch housing Turn on power and initialize the Quadra 3 From the main menu select System Settings 4 and press enter Select Shuttle Stacker Stage Pump Utility 4 and press enter Press 5 to move the shuttle so that station 5 is over the stage Place a plate nest on the station over the elevator In the utility screen use the infeed or outfeed to raise and lower the nest When raising the nest it should go smoothly into the stacker cassette When lowered the locating pins on the nest should seat squarely and smoothly into the locating holes on the shuttle station If this does not happen adjust the elevator laterally to compensate for the error For example if the locating pin on nest hangs up slightly on the forward part of the hole in the shuttle then move the elevator slightly toward the back Test again after each adjustment I
24. dee dee de ede de dede dede dede de dede dece de dede dee de ede dee dee de dede de ede dee eee dee dee de de de e d d n d KR e de de e de de de de de HH TH dede dede dede eoe dede ede dede dede dede dede ede eoe de dece de dede TT TTR ede dede dede de e de e de d d n QUADRA 3 BOARD MAP 222222222225 de dede dede dede de dee de dee de de de de de de de de de de de de de de e e e e e de de ee 8256 address 0010 to 001F CHIP 27 PC board 27 U17 He de e e e de e de e de e e de de dede de ede TCT dede dee de dede dee de ede dee de RRR dece dee e dece dee de dee de e e d n d amp input p117 sot tips on off switch for DSV heads also goes to BrdB 22 14 For DSV heads the tip load LS and stage safety should be electrically isolated input p116 srd tip load LS stage safety up down for non DSV heads 42 10 input 115 shuttle x right light switch 23 16 input 114 sls shuttle x center light switch 72 8 input p113 5154 shuttle x left light switch 22 28 input p112 s1s3 shuttle Y out of pos interlock from Board B 22 24 input 111 1 2 ARM home LS 22 20 input p110 1 1 stage 2 home light switch 22 16 input p227 EXP input msb input p226 EXP input msb 1 ground this pin for No Stacker NS Q3
25. enable RIFE bit DATAIN 0 LEFT tips feeder enable LIFE bit DATAIN 3 LEFT tips feeder tips present sensor DATAIN 2 LEFT tips feeder home top LS like elevator DOWN DATAIN 1 LEFT tips feeder opened solenoid bottom LS TATRA lll ee rM di ee A sa meu me uS de e e de e de de de de de dee e de dede de dede ee de e dede de ee e de de de de dede e e e n fn de de e de e de de de de dede dee ede dede de dee ede de dede de eoe de de de de de eee e n dn de dn Re dex dn n Ed dee de Rae 93 63 63 63 63 63 23 93 23 23 23 93 23 23 63 63 23 93 93 24 24 24 24 24 24 24 24 24 24 24 24 de e de e e de e de de dede eee de de de de deje eee de de de eee e de de de de de e e n n fn de e de de e de de de de dede ee dede de de de de eee ede de dee e e e e de de de e e e 12 14 16 10 13 15 20 22 24 18 17 19 28 32 26 36 38 40 34 20 22 24 18 28 30 32 26 36 38 40 34 5 6 4 9 10 11 4 3 SECTION VI THE CPU amp ELECTRONICS QUADRA 3 BOARD B I O MAP TOMTEC QUADRA 3 Service Manual 91 SECTION VI THE CPU amp ELECTRONICS e e de dee de dede dede de jede ode de jede ode dee ode de ede de deje dede eoe de de e ede deje dede dee dede e eode de ede de ee dede ee dede eee dee dede de e dede je eode d e de de d e de d e Be e
26. falling onto the nests properly TOMTEC QUADRA 3 Service Manual 66 SECTION VI THE CPU amp ELECTRONICS SECTION VI THE CPU amp ELECTRONICS Accessing The CPU 67 Changing The Quadra 3 CPU 67 Front Panel Display Computer and Keypad Removal amp Installation 69 Top Cover Removal 72 Back Cover Removal 72 Q96A Board Removal and Installation 73 Q96B Board Removal and Installation 74 Factory Settings Service 13 Fuse Replacement 80 QUADRA 3 Embedded Software Control Schematic 81 PWA Circuit Board 82 The PWA Circuit Board B 84 Circuit Board A Expansion Board 86 QUADRA 3 Board A I O Map 87 QUADRA 3 Board B I O Map 92 ACCESSING THE CPU The Main CPU of the Quadra 3 is located directly behind the TUI Display on the front of the instru ment To gain access to it simply pull the front door straight out use a firm grip on both sides of the front door until it is able to swing open freely Fig 64 Pull firmly on both sides of the front door to access the Main CPU CHANGING THE QUADRA 3 CPU Before removing the old computer you must record the factory settings To do this From the main panel press 5 System Settings 2 From the System Settings menu press 4 Factory Settings 3 When Prompted enter the password 41560 TOMTEC s Zip Code Backwards 4 Insert floppy disc when prompted 5 Record the current factory settings 6 Press ESC several times until you get to the ma
27. loss in movement when the pump reverses direction TOMTEC QUADRA 3 Service Manual 76 SECTION VI THE CPU amp ELECTRONICS Half Steps ul 1 300 Number of steps the pump moves per microliter to aspirate or dispense SHUTTLE Shuttle Speed 1 4 Four is the fastest SHUTTLE CALIBRATION shuttle parameters are adjustable form 0 to 99 and are used to adjust the shuttle in reference to the stage See Shuttle to Stage Alignment on page 60 which uses F2 SHUTTLE CALIBRATION This is the preferred method STACKERS Stacker In Delay 10 2000 The time in milliseconds that the flippers are open to release one plate from the cassette It is also the amount of time that the elevator remains in the up position Stackers are always enabled in the firmware they must be jumped between pins 3 and 19 AI3 to take out the firmware Later versions contain a disable function in the TUI STAGE FORMATTING stage formatting parameters are adjustable from 0 to 300 They are set to the number of steps the top plate of the stage will travel in the X and Y directions in order to index from 96 to 384 96 to 1536 and 384 to 1536 Note that going from 96 to 1536 there are near and far parameters since the stage must index twice in the same direction to go from a one well to a grid of sixteen STAGE XYZ ADJUSTMENTS The X amp Y offsets are 50 The X and Y are to set the stage so that the tips are dead center over the wells in a
28. orientated the opposite way that the left side is orientated On the left side the circuit board faces forward On the right side it faces the back of the instrument This is for proper orientation of the side cover screw holes on the elevator top plate Remove the hose on the top of the valve located on the on the circuit board side while holding the valve A flat blade screwdriver may be needed to pry it off Remove the hose on the opposite side on the upper part of the cylinder Remove the cable attached to J1 Note that the connector is not keyed so care must be used when reinstalling it Remove the four Allen bolts that secure the elevator to the frame The Allen bolts are screwed in to a plate underneath the frame There are two screws per plate TOMTEC QUADRA 3 Service Manual 57 SECTION V THE STACKERS STACKER ELEVATOR FRONT LEFT INSTALLED Fig 55 Nest Plate Nest Plate Adjustment screw Mounting plate Plate Escapement Adjustment Elevator allen hold down Anti rotation device Valve fitting shown with hose removed TOMTEC QUADRA 3 Service Manual 58 SECTION V THE STACKERS STACKER ELEVATOR ALIGNMENT Tools required 3 32 Allen wrench NOTE This procedure may be used for any one of the four stacker elevators Procedure Turn off power Remove the left or right side cover according to the procedure on page 33 Fig 25 Loosen the four hold down bolts on the
29. plate The Z offset is 25 and 15 to set the stage at a consistent height The number will be the same asset at the factory TIP TOUCH OFF OFFSETS This offsets the stage movement in the X direction by the set amount in order to touch the tips on the side of the wells This only applies to a 45031 head which has disposable tips TTO 96 96 0 300 TTO 96 384 0 300 MISCELLANEOUS Wash Piston Height 0 2300 This is the height the stage is set to for washing the pistons in the ultrasonic tip wash system This only pertains to the 965 and 384 heads TOMTEC QUADRA 3 Service Manual 77 SECTION VI THE CPU amp ELECTRONICS F1 SAVE changes will be saved and the Factory Settings screen will be closed F2 SHUTTLE CALIBRATION Pressing F2 initializes the shuttle and opens the shuttle calibration screen See Shuttle Alignment below F3 COPY TO FLOPPY Copies all current settings to a floppy disk ESC CANCEL The screen is closed without saving any changes 24 VOLT POWER SUPPLY VOTING MODULE Refer to Fig 72 Fig 78 and Fig 79 When the instrument is turned on 5 volts is applied to the Q96A and Q96B control boards When the 5V is sensed at each board a FET is turned on and effectively sends a ground to a corresponding relay on the voting module energizing it When the two relays on the voting module are energized 5 Volts is connected through the serially connected contacts to the solid state relay on the voting m
30. the other in the Y direction front back Both motors may operate simultaneously permitting a quick diagonal move when required The software counts steps between stations Step per motors may loose steps if overloaded This could happen if the shuttle is obstructed This is a nice safety feature but not good as a control element The Quadra shuttles stop ping position is determined by fixed position sensors at each station They confirm that the shuttle is where it should be A certain level of precision is required for the shuttle to stop on its mark When the stage rises the plate nest must fall precisely onto the stage locator pins Rather than tune the shuttle position sensors mechanically they are tuned with software The sensor has a wider area of actuation than the final mark The shuttle calibration procedure in the manual describes tuning the final stopping mark to its exact point The shuttle should stop so that the stage lifts the plate nest and drops it back cleanly with little to no sideways or front back motion This will center the plate nest on the stage locator pins STACKERS The Quadra stackers are pneumatically actuated by the onboard air compressor A low air pressure of approximately 5psi is constantly applied to hold the stacker cylinder down To lift the plate nest from the shuttle into the cassette air pressure of approximately 20psi is applied to the cylinder This gives a smooth upward motion due to the 15psi differe
31. up on the anti rotation device Insure that the anti rotation device does not rub up against the elevator body and that the flags do not touch the light switches Tighten the nest plate adjustment screw Turn on power and test lift the elevator with a plate on it to insure smooth operation Repeat adjustment procedure if necessary TOMTEC QUADRA 3 Service Manual 35 SECTION IV THE SHUTTLE REMOVAL OF SHUTTLE TABLE Tools required 5 32 Allen wrench 2 Phillips screwdriver Procedure Follow the procedure Removal amp Installation of Shuttle Cover and Bottom Covers pg 32 34 Remove the back cover in accordance to the procedure 72 Fig 71 Remove two screws in the upper right and left corners of the pneumatic panel PNEUMATIC PANEL REMOVING SCREWS Fig 31 e ny sin sio PNEUMATIC PANEL TILTED FORWARD Fig 32 Y Motor Disconnected Follow the cable to the Y motor on the shuttle base on the left side of the instrument TOMTEC QUADRA 3 Service Manual 36 SECTION IV THE SHUTTLE LOWER BACKPLANE Y MOTOR CONNECTORS REMOVED Fig 33 5 32 Allen Screw 2 per side Connector Plug from Y motor Connector Plug from J315 Remove the four Allen bolts on both sides of the frame that secure the shuttle base to it It would be helpful to have a second person feeding the cable as the shuttle is removed SHUTTLE TABLE FORWARD Fig 34 5 32 Allen
32. 2 transparent latches enabled via p313 p312 Either motor can be totally disabled with Ox0f Xshuttle Stage stepper output 51 3 pb2 msb 23 5 sb2 msb 22 5 output 1 2 pbi 23 7 801 22 7 output 1 1 2 23 9 2 22 9 output p1 0 pal lsb 73 11 1 lsb 92 11 pea 63 13 sea 602 12 peb 63 15 seb 62 13 INTERRUPT 4 rxd rxd3 rdis Spare rcv port 2400 baud txd txd3 tdis Spare xmit port 2400 baud t0 24khz tl no connection de e de e de e e ede de dede ede de de ede dee de ede dede dee de ede de dede ede ede de eode ede dede dede de ede de dede ede ede de ede eode ede de dede ee ee de ede e de e de d e d n n x A D CONVERTER pressure sensor input address 0030 8 bit A D de de de de de de de de dede dede de dede dede dede dede dede dede ode dede dede dede RRR oe deed ode dede oe dede deed dede dede dede dede dede dede dede ode dede dede dede ode dee eoe e Use write strobe starts a conversion approx 100 usec conversion read strobe reads the data interupt routed to 8256 above address 0010 001F Notes 12 mv psi 60 mv full scale no pot adjustments see wih Should probably dummy up 0 to readf at approx 25 lbs Should probably dummy up full scale 5 psi at 4 90 lbs The specs suggest waiting clk 8 cycles 768kc 8 to read data and henceforth guarantee a inta reset TOMTEC QUADRA 3 Service Manual 89 SECTION VI THE CPU amp ELECTRONICS t p
33. 23 3 input p225 Quadra Door Opened 24V disabled 23 4 input p224 SPARE BIT with dip switch jumper 2 pull out U13 and U12 Use 2 jumper sockets and connect pin 9 and 15 pin 8 and 1 on both sockets output 223 Stage elevator up interlock to Board U17 p112 or J2 24 22 15 output p222 IMS Arm motor driver step clock J2 19 output p221 IMS Arm motor driver direction 62 23 output p220 IMS Arm motor driver enable 22 27 Use the HALF step jumper on the IMS driver board interrupts INTERRUPT 0 int0 processor extint 8 bit analog A D converter rxd rxdl rpc receiver embedded PC 16 txd txdl tpc transmitter embedded PC 21 20 txc no connection rXC no connection e de e e de de e de dede de dede dede dede dede ode dede ede dee dede dee dede e de e e d d n n n n x 8256 address 0000 to 000F CHIP 28 PC board Z8 U21 de de e e e de e de e de e e de de dede e dede dee de de de dee de dede dee de ede dee de dede dece de e de dede de dede dede de ede dede dee de dede dee de dece e ede dee dee de de de de e de d e d output 017 RIGHT lid handler plate plunger gripper valve J3 33 output p016 RIGHT lid handler plate lifter valve 23 36 output p015 LEFT lid handler plate plunger gripper valve J3 37 output 014 LEFT lid handler plate lifter valve 63 35 output p013 SPARE BIT input p012 AUX generic 9 Pin connector input p011 AUX generic 9 P
34. ENT 450uL BACKFILL AND NON BACKFILL HEAD Tools required 2 3 and 2 stubby Phillips screwdrivers 5 32 Allen wrench scribe or small screwdriver Lubricants required O ring lubrication Parker Super O Lube part number 092 001 00 and silicon spray Kit needed 020570 00 Consist of 100 pieces each of 020046 01 Tip Pin Assembly 120 008 70 008 O ring 120 009 70 009 O ring Procedure Remove front panel and top covers in accordance with the procedure on page 32 Removal amp Installation of Shuttle Covers Fig 23 and on 72 Cover Removal amp Installation Fig 70 It will be helpful spray the pistons with silicone so that the block can be more easily removed Bring the pump to its apex and spray the pistons Cycle the pump a number of times in order to spread the lubricant Shut the instrument off and remove the head in accordance with procedure page 12 amp 13 Head Removal Installation Fig 3 amp 4 Remove the tip load safety reed switch from the shuck plate Remove four shoulder bolts and pull the shuck plate off Remove the four large Phillips screws on the sides of the head assembly that secure the piston block Pull block off of the pistons If there is any foreign matter on the bottom of the pistons remove it with a lint free cloth You may find working on the piston block easier if the head were removed If so refer to the procedure on page TBD The pump initialization photo sensor brac
35. Environment INDOOR USE ONLY Temperature 5 C to 40 C 41 F to 104 F INDOOR USE ONLY Humidity 5 90 no condensation Storage environment Temperature 0 C to 60 C 32 F to 140 F Humidity 5 90 no condensation Physical Specifications Dimensions Width 30 00 in 762 00 mm Depth 20 50 in 520 70 mm Height 32 50 in 825 50 mm Shuttle Extension each side 9 50 in 241 30 mm Weight 210 Ib 98 26 kg Electrical Specifications Power Requirements 100VAC NOM 4 0A 60Hz 105 125 4 0A 60Hz 220 240V AC 2 0A 50Hz NOTE When sighting a location for the Quadra 3 be sure to include room for the shuttle to travel freely without striking anything in the front and both sides TOMTEC QUADRA 3 Service Manual 4 SECTION I GENERAL INFORMATION QUADRA 3 FRONT VIEWS Fig 1 Plate Follower Cassette Plate Nest Stacker accessible Indexing Stage Located under Station Five with Shuttle in Home position Small Volume Pipetting Tips Text User Interface TUI VGA Flat Panel Display Front Panel Door Six Station Auxiliary Shuttle Lower Left Connector Panel Side Cover Lower Front Lower Right Cover Side Cover TOMTEC QUADRA 3 Service Manual 5 SECTION I GENERAL INFORMATION QUADRA 3 RACK VIFWS Fig 2 Hinged Cover Plate for Pneumatic Control Panel Access Power On Off Switch Floppy Disk Drive Battery Reset Button UPS Air Reg
36. F 8 Ne 4 SION BOARD ata a 2 lock for Nano X indexer irection for Nano X indexer 2 nable for Nano X indexer SHXEA OUT 2 DATAOUT 3 1 stage y stepper DATAOUT 2 XA2 stage y stepper DATAOUT 1 1 stage y stepper DATAOUT 0 XB2 stage y stepper DATAOUT 3 Hand control on the ARM DATAOUT 2 SPARE BIT DATAOUT 1 RIGHT tips feeder fire release Open Closed solenoid DATAOUT 0 LEFT tips feeder fire release Open Closed solenoid DATAOUT 3 flow wash ultrasonic enable DATAOUT 2 trap Vacuum DATAOUT 1 trap Drain DATAOUT 0 trap Pressure OUT 5 JP6 to B 24V DATAOUT 3 elevator RR Right Rear pressure DATAOUT 2 elevator RF Right Front pressure DATAOUT 1 elevator LR Left Rear pressure DATAOUT 0 elevator LF Left Front pressure OUT 6 Use 24V since JP6 to B is 24V DATAOUT 3 Lid vacuum valve DATAOUT 2 DeLidder up down valve DATAOUT 1 RIGHT tips feeder Up Down pressure driver DATAOUT 0 LEFT tips feeder Up Down pressure driver OUT 7 JP7 to 24V DATAOUT 3 stacker RR Right Rear fire release solenoid DATAOUT 2 stacker RF Right Front fire release solenoid DATAOUT 1 stacker LR Left Rear fire release solenoid DATAOUT 0 stacker LF Left Front fire release solenoid DATAIN 3 hand inductive sensor back DATAIN 2 hand inductive sensor front DATAIN 1 RIGHT tips feeder
37. Right Center 5 5 Pr 40 JeyryjoBunjid Way 5 q3dq38W3 Spe EI vuawvno Fig 80 TOMTEC QUADRA 3 Service Manual 81 SECTION CPU amp ELECTRONICS THE PWA CIRCUIT BOARD A 56 7 8 9 60 4 1 2 3 4 Li E 1 2555 ooooooooooooo 40000000000000 eh z TOMTEC QUADRA 3 Service Manual 82 SECTION VI THE CPU amp ELECTRONICS 1 2 3 4 5 6 7 8 9 Enable 24 Volt Relay Fuse Valves 2A LED DS 4 Touch off Driver PWA Fuse Pinch Tube 5A LED DS 3 LED DS 2 Fuse F2 Stage Led DS 1 10 Fuse F1 X Shuttle 11 SEA 01 Q4 Q14 E2 Pump 12 PEA Q5 Q8 Q9 Q10 F1 Y Shuttle 13 Communication 14 Dip Switches 15 RAM 16 Air Sensor A Port Auto Mini Trap Vacuum Feedback 17 Board A Firmware Version XXX 0 NOTE Quadra 3 board A or B XU12 9 15 XU12 1 8 XU13 1 8 It does not matter if 9 15 is there or not TOMTEC QUADRA 3 Service Manual 83 SECTION VI THE CPU amp ELECTRONICS THE PWA CIRCUIT BOARD B 5 6 7 8 9 60 a 1 0000000000000 Quadra 3 Bd B ver 2 1 3 CO 2 3 4 E
38. This is strictly a cleaning of possible spilled liquids Lubrication may foul the linear bearings Remove the X direction shuttle table and wipe the rods clean You MUST NOT remove the guide rods from the bearing blocks unless you suspect that a foreign substance has fouled the blocks Exercise shuttle and check for binding or excessive play Develop a program to move the X and Y tables table to the extent of their range left and right forward and backward Insure that the movement is smooth and steady while listening for irregularities Check shuttle to stage alignment raise and lower With a nest or tip load fixture on one of the stages raise and lower it in each shuttle station It should move smoothly in and out of the guide holes Some compromise between stations may be necessary Use your own judgment to determine what is acceptable TOMTEC QUADRA 3 Service Manual 42 SECTION IV THE SHUTTLE SHUTTLE PICTORIALS SHUTTLE SKELETON Fig 39 X Direction Motor Y Direction pec acad ji Y Direction Motor Table Center Light Switch X Direction Fig 40 Table Left Light Switch a Tension Block for X Belt 2 X Direction Guide Rod 2 Table Right Light Switch TOMTEC QUADRA 3 Service Manual 43 SECTION IV THE SHUTTLE SHUTTLE SKELETON Fig 41 NOTE View is with shuttle upside down Movable Flex X Direction Right Flag Rear Position
39. U amp ELECTRONICS Accessing The CPU Changing The Quadra 3 CPU Front Panel Display Computer and Keypad Removal amp Installation Top Cover Removal amp Installation Back Cover Removal amp Installation Q96A Board Removal amp Installation Q96B Board Removal amp Installation Factory Service Settings Fuse Replacement Quadra 3 Embedded Software Control The PWA Circuit Board A The PWA Circuit Board B Quadra 3 Board A I O Map Quadra 3 Board B I O Map SECTION VII ABOUT TOMTEC Warranty Return Policy Decontamination Form If You Need Help TOMTEC Worldwide Distributors SECTION VIII ERROR CODES 67 67 69 72 72 73 74 45 80 81 82 84 86 91 94 94 95 96 97 TOMTEC QUADRA 3 Service Manual 2 SECTION I GENERAL INFORMATION SECTION I GENERAL INFORMATION Caution Warnings Cautions Notes and Symbols Specifications Quadra 3 Pictorials Operational Functionality Bar Code Installation Kit 330 10 Tn RU CAUTION IF THE EQUIPMENT IS USED IN A MANNER NOT SPECIFIED BY THE MANUFACTURER THE PROTECTION PROVIDED BY THE EQUIPMENT MAY BE IMPAIRED The Quadra 3 is designed for use with various liquids These are primarily aqueous solutions with a near neutral pH As the pH of the solution moves away from neutral various parts may be affected depending on the length of time they are in contact The user has full responsibility for the selection of compatible liquids
40. ated with the pinch tubes closed photo sensor is facing down This is automatic during initialization When aspirating the pump motor pulls the pistons up creating suction in the tips The motor is stepped to turn the lead screw a certain distance corresponding to a specific amount of liquid When dispensing the motor pushes the pistons down forcing liquid out of the tips NOTE The pinch tubes are automatically closed during initialization and must be manually opened before shutting off power so that the pinch tubes are not permanently damaged Pump initialization photo sensor senses flag on top of the pinch tube assembly which during initialization sets the reference at its highest point which equates to 450ul The pump will reverse direction and count down to it lowest point 0711 Tip Load Light Switch senses that tips have been loaded at the required height and signals that the stage can be lowered Reed switch senses the magnet on the tip load fixture and temporarily disables the stage safety switch allowing the stage to exert more pressure overcoming resistance in loading the tips to the proper position Photo Sensor NC Pinch Tubes Closed conducts when the gap on the right actuator is facing straight down Photo Sensor NC Pinch Tubes Open conducts when the gap on the left actuator is facing straight down TOMTEC QUADRA 3 Service Manual 16 SECTION II THE HEAD TIP PIN amp O RING REPLACEM
41. ble at the top of the compressor Note that the cable on the compressor has black and white wires if it operates on 115 or blue and brown wires if the unit operates on 220VAC Disconnect the pressure hose from the quick disconnect fitting on the left side of the compressor Disconnect the vacuum hose from the fitting on the right side of the compressor A flat blade screwdriver may be required to pry the hose off Remove the compressor mounted on the Bracket screws 4 two brackets by removing the four screws that hold the brackets to the frame Remove the two brackets from the compressor by removing the four screws and nuts holding the brackets to the shock absorbers on the compressor Install the new compressor by reversing the order COMPRESSOR BOTTOM VIEW Fig 52 Electrical connector Vacuum fitting and hose TOMTEC QUADRA 3 Service Manual 55 SECTION V THE STACKERS COMPRESSOR WITH BRACKETS Fig 53 Vacuum Fitting Bracket Mounting Screws 4 Shock Absorbers Pressure Quick release Fitting 24V COMPRESSOR AND BOTTLE Fig 54 F 3 m TOMTEC QUADRA 3 Service Manual 56 SECTION V THE STACKERS ELEVATOR REMOVAL AND INSTALLATION Procedure Shut off power Move shuttle table to toward the opposite side that you are working on Remove the side covers in accordance with the procedure on page 33 Fig 25 NOTE The elevators on the right side of the instrument are
42. d assembly to get rid of any air This is done by forcing water down the system first and then up completely filling it First the pinch tubes are opened The pinch tube motor operates a set of gears which turns a cam shaft The flat part of the cam faces forward the spring loaded clamping rod assembly will come all the way back unclamping the pinch tubes allowing water to flow through them At this point the gap on the actuator associated with the pinch tubes open photo sensor is facing down Compressed air forces water out of the reagent bottle through the hose to a manifold in the pinch tube assembly From there water is forced down through 96 pinch tubes through the pistons and out of the tips into a backfill pan When vacuum is applied the liquid is drawn out of the backfill pan through the head and TOMTEC QUADRA 3 Service Manual 15 SECTION II THE HEAD into the reagent bottle This is done a short period of time to insuring air is not sucked into tips This sequence should be done until no more bubbles are visible in the hose connection to the buffer bottle The system now completely filled with water is in the backfill mode Since water is incompressible this method is more accurate than air displacement AIR DISPLACEMENT MODE In this mode the pinch tubes are in the closed position This happens when the pinch tube motor turns the cam pushing the clamping rod assembly forward The gap in the actuator associ
43. de de de e e de e dede de dede dede e e de e de dee e de dee ede de dee de ede de dee e e dee de de ede e dee ede dee de de dede e de dee de dee ede ee e de eoe e de de de de e e d e e n n n REESE d d dn dn 1 xxn QUADRA 3 BOARD B I O MAP eee don n x x do dn dn 6 X de de de de ede dede dede ode dede de dede dede dee dede dede de eoe dede dede dede eode dede dede dede oe dede dede dede ode ode dede dede ode oe ode ode dede dede eode ode dede dede eoe dede dede ee n d d d n n x X de de de de dede dede de dede dede de dede ode dede dede dede dede dede dede ode ode ode ode ode ode ode dede eode ode dede ode ode ode dede eode ode dede ode oed dede ode ode ode ode dede ode dede dede ode ode ode dede ode ode dede dee n RRR 8256 address 0010 to 001F CHIP Z7 PC board Z7 U17 e e de e e e dede de ede de KK TK HK ede eee KKK ede ee ede ede eee ede eee dede ee e dee dede eee ede eee dede ede e deed de e e d e d e d n t input p117 sot tips on off LS 60ul and DSV heads 22 14 input p116 srd pump or Cherry Pickers X Bridge home LS 22 10 input p115 pls Pump head type bit 3 23 16 input p114 sls Pump head type bit 2 02 8 input 5113 5154 Pump head type bit 1 15 22 28 bit p224 bit 115 bit p114 bit 113 LSB 1 0 0 0 0 Cherry Pickers 60ul 1 0 0 1 gt 96 DSV heads 1 0 1 gt 96 well 20041 1 0 1 1 gt 384 well 20041 1 1 0 0 gt 4 384 well 6041 1 1 0 1 gt 5 96 well small volume 60ul
44. de reader Place 193 001 30 GROMMET CUT around cord and insert into cut out Coil excess cord and use 830 001 01 CABLE TIES and 831 001 02 CABLE TIE BASES to hold cord to the inside of the left right side panel Place LASER RADIATION sticker of appropriate language on panel in front of the barcode reader Connect 828 001 06 NULL MODEM CABLE to Barcode Out connection on left side panel and Barcode in connection to allow the Quadra 3 to log the bar codes If using an external device to monitor the bar code reads connect the device to the Barcode Out connection Reconnect line cord and turn on power to Quadra 3 From main menu go to 5 SYSTEM SETTINGS Enter 1 PREFERNECES Enter Mode must be set to 1 UP 2 DOWN or 3 BOTH For standard setting use 1 UP NOTE If an external device is to store barcodes BCR Connection must be set to 1 EXTERNAL Press Fl to save and press STOP ESCAPE twice to return to main menu 10 For logging options refer to system settings in the Operator Manual also sample logs can be found in system function section 11 Close front panel to enable the 24 volt safety mechanism Go to 1 INITIALIZE Enter Place a nest on station 5 with you bar coded plate facing left right Go to 4 SYSTEM FUNCTIONS Enter Press F2 Press 38 JOG STAGE UP DOWN Enter 12 Press the PAGE UP button until stage lifts nest off of shuttle Press and
45. e side of the pump to allow one or the other function to be performed with its opposite function open to the atmosphere A muffler is mounted on the normally open side of SV102 the valve that provides vacuum doing backfill During other modes two other solenoids are used to select different pressures PLATE ELEVATOR SYSTEM The plate elevator system uses a 2 125 PSI regulator set to approximately 25 PSI to raise the elevators and a 0 10 PSI regulator set to approximately 5 8 PSI to provide air spring to return the system to its rest position This return pressure is presented to the cylinders at all times Each of the four elevators has a solenoid valve to control the high pressure actuation The exhaust side of these valves outputs to the atmosphere In humid conditions some condensation dripping should be expected at these points Backfill System TOMTEC QUADRA 3 Service Manual 45 SECTION V THE STACKERS When SV102 is energized the vacuum side of the pump is connected from the pump through a manifold directly to the reagent bottle for the purpose of suctioning reagent aspirating from a shuttle mounted reservoir in the backfill mode At the same time 5 104 is energized allowing the pressure from the compressor to be vented to the atmosphere via the NC port The other solenoid valves are at rest at this time SV102 and SV104 are at rest when not in backfill during which time pressure is allowed to pass through SV104 to the r
46. e top of the power entry module by pulling outward on the fuse holder s lower tab With the fuse holder out of the power entry module remove the fuses Replace fuses according to the following chart 5MM X 20MM FUSE TIME DELAY TOMTEC FUSE Input Vac 2 Replacement Kit Catalog Number 100 5 AMP 5 AMP 020640 50 105 125 5 AMP 5 AMP 020640 50 230 240 2 5 AMP 2 5 AMP 020640 25 CAUTION FOR CONTINUED PROTECTION AGAINST FIRE HAZARD REPLACE ONLY WITH SAME TYPE AND RATINGS OF FUSING Return the fuse holder to its position in the power entry module by pushing in until it is seated Reconnect the power cord into the power entry module Turn Main Power switch on TOMTEC QUADRA 3 Service Manual 80 SECTION VI THE CPU amp ELECTRONICS y jexoejs JYS seuosseooy jeuondo any E uogejs use dij pibog uoisuedx 2 emsseig USEM Moly xog 40 uo set won st ied Sup pul AX 5 S ayvog en 95010 uado g Guvogd du v soqn your E 1 vyavno 0 e o OO 1 00504 r Left WANIBA Xog DA 2 1exeus HOMO AvZ Chopper Drive 21 5 Back Front ILS
47. eservoir and vacuum is vented through the muffler via SV102 Time Dispense System The reagent time dispense system uses a precision 0 5 PSI regulator set to 5 PSI This regulator is located on the lower right side of the instrument When SV103 is energized 5PSI is transferred through it to the reagent bottle The other three solenoid valves are off at this time SV103 is off all other times Dry Tubes In this function SV101 which is connected to the reservoir is energized allowing unregulated pressure no more than 32 36 PSI to enter the bottle The other three solenoid valves are off at this time SV101 is off position all others times SOLENOID VALVE CONDITIONS Mode SV101 SV102 SV103 SV104 Backfill off on off on off off off Time Dispense off off on off Pneumatic Control Panel The control panel is provided for set up and troubleshooting A single pressure gauge can be connected to key points of the system through a patch cord arrangement of four shut off type disconnects The following ports can be monitored 1 Compressor Pressure monitors pressure at manifold 2 Bottle Pressure monitors pressure going to reagent bottle and is adjustable by the precision regulator on the lower right side of the instrument 3 Return Pressure monitors elevator down pressure and is adjustable by the low pressure regulator on the pneumatic panel with a flat blade screwdriver TOMTEC QUADRA 3 Service Manual 46
48. evator Cylinder Cylinder Elevator Cylinder Elevator Cylinder Elevator Pressure Monitor 25 PSI Regulator Elevator Up Located on pneumatic panel To System Pressure Manifold Refer to figures 3 in Clear Elevator Removal and Installation on pages TOMTEC QUADRA 3 Service Manual 53 SECTION V THE STACKERS ELEVATOR MANIFOLD LEFT SIDE Fig 50 Elevator Manifold Middle Section two hoses go to front elevator Inboard Section green hose lt from the 5psi Regulator The clear hose comes from the 25psi Regulator Outboard Section two hoses go to rear elevator STACKER MANIFOLDS Fig 51 Left Stacker Manifold Right Stacker Manifold Cover removed Cover removed TOMTEC QUADRA 3 Service Manual 54 SECTION V THE STACKERS COMPRESSOR REMOVAL AND INSTALLATION Tools required 2 Phillips screwdriver socket set with 11 32 socket minimum 8 inch extension Procedure Shut off power and remove the power plug from the outlet In order to remove the compressor the instrument has to be put on its back This will require a minimum of two people to lift the instrument safely The instrument should rest on something like a piece of wood for example in order to keep the ground terminal and various connectors from being damaged Disconnect the in line connector of electrical ca
49. g on the gauge returns to 25 PSI If the elevator stays up when the switch is in the off position refer to step 3 2 Insure the shuttle has been initialized or at least positioned correctly Place a full stack of plates in one stacker and use the override switch on the pneumatic panel to activate the corresponding elevator If necessary turn the pressure up to lift the full stack of plates 3 Move the pressure gauge to the Return Pressure port With no plates in the cassette raise one of the elevators up using the Elevator Override switch If the elevator stays up starting at 5psi adjust the Return Pressure regulator using a flat blade screwdriver CW to increase the down pressure Do not go any higher on the down pressure than necessary to lower the empty elevator smoothly Recheck the elevator s ability to lift a full stack of plates and readjust the up pressure regulator if necessary pushing the knob in to lock it when complete TOMTEC QUADRA 3 Service Manual 47 SECTION V THE STACKERS PNEUMATIC CONTROL PANEL Fig 43 Four monitor System Pressure Vacuum Input Input pressure from Compressor points Gauge quick from Compressor Compressor connects Control Relay disconnect connects to 5 102 to Manifold Imm hy l 3 cv4 CV2 cvi Right Right Left Left Front Rear Rear Front Pressure Gauge Return pressure Return pressure Stacker Cylinder Cylinder Vavle 0
50. hat there is no leakage when the tubes are pinched Lubricate pistons Initialize the head and turn off the power when it reaches the top of its stroke Spray pistons with silicon based lubricant Do not use WD40 or a similar product as it will displace moisture and premature breakdown of the rings may Occur Check guide rod shuck adjustment Initialize the instrument Place a tip load fixture on one of the stations In Utilities shuck tips and insure that the guide rods and shuck plate move in unison If they don t check the position of the guide rods when the head is at rest 0 position after initialization The flat on the guide rod should be flush with the bottom of the tip plate In order to adjust them use a 3 16 Allen wrench to loosen them on the front of the head TOMTEC QUADRA 3 Service Manual 26 SECTION THE STAGE CROSS SECTION VIEW Fig 16 Guide Tip Rod Plate Flush LL ip Shuck Plate Replace tip pins tip pin plate rings and piston plate rings Tip Pin Kit 195 500R includes a set of 100 tip pins with tip pin rings installed a set of 100 tip plate O rings and a set of 100 piston plate rings Piston Plate i 008 O Ring Piston Block Tip Plate 009 0 Ring Tip Shuck Plate Tip Pin with two 006 O Rings TOMTEC QUADRA 3 Service Manual 27 SECTION III THE STAGE SECTION III THE STAGE Stage Remova
51. he B Q96 control board mounting plate if necessary and install the top cover NOTE Check connector to B Q96 board and J202 on backplane if B board is lifted Remember that the software will configure to the head installed TOMTEC QUADRA 3 Service Manual 13 SECTION II THE HEAD HEAD INSTALLED Fig 5 Electrical connections Q96 B board Mounting Plate Captive Screw 4 HEAD ALIGNMENT Tools Required 2 Phillips screwdriver 2 flat blade screwdriver or 1 4 inch nut driver 1 8 Inch Allen wrench 3 16 Inch Allen wrench Procedure The front panel door should be closed the stage needs 24VDC to work and the front door interlock shuts it off Turn on the power Initialize the Quadra 3 Load the tips while aligning to the tip load jig using the stage utility to jog the stage up until the tips are fully loaded on the tip pins Put a nest with a 384 well plate on the station over the stage The 384 well plate is used the alignment of either 96 or 384 well heads Using the utility screen raise the stage to a height so that the tips are just slightly over the wells Be careful in setting the height so that you avoid damaging the tips Then back out all four jacking screws If the tips are not level across the plate use the jacking screws to adjust the head If any TOMTEC QUADRA 3 Service Manual 14 SECTION II THE HEAD adjustment is made with the jacking screws be sure that all jacking
52. he quadrant calculates to be X and Y To move the plate to the right causing the tips to be closer to the left side of the well enter a negative number for X To have the plate move forward causing the tips to move toward the back wall of the well enter a negative number for Y The numbers you are entering are actual stepper motor steps Each step will movethestage inches For Serial Dilution testing the stage moves approximately half way in both directions Assume a full plate dilution is to be made in the twelve tip direction A single row of twelve tips is loaded in Row D The stage shifts half way forward so the single row of tips starts at Row A and then indexes to the rear so that they end up in Row H The Quadra stage has a built in safety feature It is spring loaded Should it meet an obstacle with more resistance than the spring force approximately 10 15 pounds the spring collapses and operates a safety switch The stage reverses and moves down away from the obstacle This prevents injury to you if your hand is the obstacle or damage to the tips if a plate is inserted incorrectly error When loading a rack of tips on the 450uL head considerably more force than 10 15 pounds is required This is accomplished with a small magnet embedded in the tip jig After the stage has closed the tips on the tip pins a reed switch is actuated by the pres ence of the magnet This bypasses the safety switch and the stage goes to full powe
53. hold TEST button on barcode reader for 5 seconds this turns beam on in test mode Press PAGE UP until test beam is parallel and centered on your bar code label The barcode reader will flash a green light next to the OK NG and the signal strength should read at least three bars this would be a satisfactory read Readjust position of reader for parallel the lowest parallel position is usually the best if necessary Tighten the nuts with 11 32 wrench Press TEST button again to turn off test mode 13 Run QA program BAR CODE TEST TOMTEC QUADRA 3 Service Manual 11 SECTION II THE HEAD SECTION II THE HEAD Head Removal amp Installation 12 Head Alignment 14 Maintenance of Heads 450uL Backfill Head Theory of Operation 15 Tip Pin amp O Ring Replacement 17 450uL Backfill Head Front View 19 450uL Backfill Head Back View 20 Tip Block Assembly 21 e 965 60uL Head 22 384 60uL Head 23 Annual Preventive Head Maintenance By Field Service Engineer 26 HEAD REMOVAL amp INSTALLATION Tools Required 2 Phillips screwdriver 2 flat blade screwdriver or 1 4 inch nut driver 1 8 Inch Allen wrench 3 16 Inch Allen wrench Access to 3 8 inch allen head draw bolts that secure Tips and Seak Assemblies for 96SV and 384 Heads TOP BACK VIEW Fig 3 Procedure Shut off power Take off the top cover by removing the ten Phillips head screws Open the front panel by pulli
54. ig 22 Home Switch gt Up safety Switch TOMTEC QUADRA 3 Service Manual 30 SECTION III THE STAGE ANNUAL STAGE PREVENTIVE MAINTENANCE BY FIELD SERVICE ENGINEER Lubrication Lubricate lead screw with lithium grease Check the function of the stage safety switches Run one of the stages up and as it is rising push down on the top It should try to reach its set height three times then stop and report a Stage Safety Error Check alignment of stages to head With 96LV Head On one of the stages place a tip load fixture Move the stage up until it reaches the two guide rods insuring they are centered in the holes on the fixture With 965 or 384 heads Place a corresponding microplate on a nest and place it on the stage Raise the stage until the plate is just below the level of the tips Insure that the tips are centered over the wells With 450 Backfill Head only check operation of tip load switch and tip load height setting Load a set of tips Then push up on a single tip and if it loaded properly it should not move up more than a millimeter It the tip load height is was set too low then the tips may not seal properly and if the height is too high then the stage may end up flexing the frame TOMTEC QUADRA 3 Service Manual 31 SECTION IV THE SHUTTLE SECTION IV THE SHUTTLE Removal amp Installation of Shuttle Covers amp Bottom Covers 32 Installing Side Covers 35 Removal of Shuttle Table 36
55. in Kit includes a set of 100 tip pins with tip pin rings installed a set of 100 tip plate rings and a set of 100 piston plate rings TOMTEC QUADRA 3 Service Manual 24 SECTION II THE HEAD PISTON BLOCK ASSEMBLED Fig 15 NOTE Be sure to observe the ANNUAL PREVENTIVE CHECKLIST FOR SERVICE ENGINEERS TOMTEC QUADRA 3 Service Manual 25 SECTION II THE HEAD ANNUAL PREVENTIVE HEAD MAINTENANCE BY FIELD SERVICE ENGINEER Refer to figures 7 15 450uL BACKFILL 965 amp 384SV AND 384 200uL HEADS Grease head motor lead screw Apply lithium grease to the lead screw with a brush and initialize head to distribute Lubrication Kit 020564 00 NOTE The 96SV and 384 heads have nothing else specifically to PM When it is req uired the tip and seal assemblies are replaced in the field as a unit and sent to Tomtec for refurbishment 450uL BACKFIIL HEAD Check pinch tube assembly for excessive wear and misalignment of components Remove the top cover and front panel In Command System under Quadra open and close pinch tubes repeatedly Check for good contact between the gears on the end and between the cams and roller bearings Look for excessive particles deposited on the frame below the assembly Backfill unit and check head integrity Check that the air pressure is set to no more than 1 0 psi Check each tube to insure water is flowing out when the tubes are open and t
56. in connector output p010 SPARE TOMTEC QUADRA 3 Service Manual 87 SECTION VI THE CPU amp ELECTRONICS output p027 Smart Button De multiplexing output 026 Smart Button De multiplexing output to 5 1 STA2 STA3 STA4 output p025 Smart Button De multiplexing Outputs 5 1 STA2 5 5 4 are controlled by p027 p026 025 27 P26 P25 HEX values at Port P2 0 0 0 0 00 IButton 1 STA1 92 32 0 0 1 0 20 IButton 2 STA2 42 33 0 1 0 0 40 IButton 3 STA3 92 35 0 1 1 0x60 IButton 4 STA4 92 37 1 0 0 0x80 output p024 Touch Off solenoid on formatting non indexing stage 62 6 output p023 SPARE BIT output p022 AUX generic 9 Pin connector output p021 AUX generic 9 Pin connector output p020 AUX generic 9 Pin connector interrupts INTERRUPT 2 intl processor extint external interrupt source interupt of 8256 0020 to 002F rxd rxdO receiver spare txd txdO tbc transmitter spare txc no connection rxc no connection e e ee de de e de dee dede ede de ede ee de dee dede ede e ede dee ede ede de eee ee dee eee dede eee ede de ee ee ede eee ee de ee eee eee e e e d n d KR 8256 address 0020 to 002F CHIP 79 PC board Z9 U26 e Se e de e e de dede e dede ede de ede de e de dee de de ee de e dede e de dee dede eee output p317 EXP select output output p316 EXP select output output p315 EXP select output output p314 bar code enable trigger output
57. in menu TOMTEC QUADRA 3 Service Manual 67 SECTION VI THE CPU amp ELECTRONICS 7 Press 6 Shutdown to shut the unit down properly Following the on screen instructions NOTE Attached to the CPU cover there should be a print out of the original factory settings These will most likely not reflect the current settings since changes and adjustments will have been made over the years However most of the settings will be the same and it can be used as a guide when recording the current settings or when attempting to re create the settings on a CPU that has completely failed TESTNG THE COMPUTER AND CHECKING THE FACTORY SETTINGS 1 2 3 4 5 6 7 8 Turn the unit as normal It should boot up with no errors If you realize an error call TOMTEC on further issues You do not to initialize the unit at this time Once the computer is on go to the factory settings as described above and enter in any settings that are different than the original Once ALL the settings match enter 1 to save the changes Shut down the machine and then restart Press 0 to initialize the unit Assuming all is working try connecting to the unit using the QUADRA Command Software Connect and disconnect several times to be sure the communications between the computer and instrument are working correctly Using the Command Software move the shuttle to each shuttle position then raise and drop the
58. ket may be removed to facilitate this procedure Place the block upside down on a flat surface and remove the eight screws that hold the tip plate on the block Holding it together turn it right side up and place it in a tip fixture Lift the block off the tip plate exposing the 009 O rings With a scribe or small screwdriver remove them and discard Remove and discard the 96 tip pin assemblies tip pin with two O rings Clean the tip TOMTEC QUADRA 3 Service Manual 17 SECTION II THE HEAD plate and the block with paper towels Remove any foreign matter in the block with a pipe cleaner or Q tip Replace the tip pins with part number 020046 01 Check for height uniformity in the seat Lubricate the new 009 O rings part number 120 009 70 and place them on the tip plate Place the block back on the tip plate and holding it with both hands turn it upside down and replace the eight screws Tighten them in the following pattern and sequence A B C D then A B C D again then E F G H Repeat this pattern until it is tight TIP PLATE Fig 6 Place unit back on the tip fixture Remove the piston plate by removing nine screws Note that the center screw does not have a lock washer Clean with paper towels Lubricate the 008 O rings part number 120 008 70 and install them on the piston plate Replace the piston plate and tighten the screws down in a criss cross manner Replace the shuck plate with the four shoulder bolts
59. l amp Installation 28 Annual Stage Preventive Maintenance By Field Service Engineer 31 STAGE REMOVAL AND INSTALLATION Prior to removing the stage follow the procedure Removal amp Installation of Shuttle Cover and Bottom Covers pg 32 34 and Removal of Shuttle Table pg 36 39 Tools Required 7 16 nut driver Phillips Screwdriver Procedure Once all the covers have been removed and power is shut off take off the cable guard by removing the two screws in front Disconnect the cable going to J1 on the circuit board on the stage Note that pin 1 the red and white wire goes down Remove the four hex bolts that secure the stage to its mounting plate Lift the stage tilting it back until the shafts on the bottom clear the mounting plate Pull the stage forward sliding the shuttle frame forward simultaneously Avoid hitting the pipetting tips in the process To install the stage reverse this procedure INDEXING STAGE Fig 18 Flags TOMTEC QUADRA 3 Service Manual 28 SECTION III THE STAGE INDEXING STAGE 020775 Fig 19 Stage Z Light Switch Stage Safety Up Light Switch Front Stage Safety Down Light Switch Lead Screw b Flags INDEXING STAGE 020775 Fig 20 Stage X Proximity Sensor Stage Y Proximity Sensor Stage Z Light Switch TOMTEC QUADRA 3 Service Manual 29 SECTION III THE STAGE L3 INDEXING STAGE W COVER Fig 21 L3 TOUCH OFF STAGE F
60. lable should the service technician request it Our phone and fax numbers in the United States are Phone 203 28 1 6790 Fax 203 248 5724 www tomtec com Our shipping address is Tomtec Inc 1000 Sherman Avenue Hamden CT 06514 USA Toll Free Number for USA amp Canada 877 TOMTEC3 Phone Number for Local Sales amp Service 203 281 3683 Tomtec offers distribution and service in many countries throughout the world Please see our Worldwide Distributors section for a representative in your area Please contact Tomtec Inc USA between the hours of 8 30 am 4 30 pm EST if you need any technical support or have any questions or concerns about any Tomtec product NOTE Be sure to receive authorization from a Tomtec Service Representative before returning machines for service or repair These returns MUST be accompanied by a completed signed decontamination form TOMTEC QUADRA 3 Service Manual 96
61. ng on the bottom left to snap it open from the left side then pulling it out straight It will then be able to be swung to the right If the head is a 450 backfill first insure there is no water in the head bottle or hoses Then loosen the clamp holding the hose on to the fitting on the back left over the back plane and remove the hose Loosen the four hold down screws and pull the head forward enough so that you can reach the two connectors on the top left of the backplane Once these are disconnected lift the head up and forward being careful not to damage the tips if they are still attached You may want to remove the connectors first To do this loosen the two forward captive screws that secure the B Q96 control board mounting plate all the way out Loosen the two back ones enough to pivot the plate and then tilt the plate up in front enough to TOMTEC QUADRA 3 Service Manual 12 SECTION II THE HEAD access the two connectors Place the head in the storage stand Never stand the head on the tips Place it where the tips will not be damaged TOP BACK VIEW Fig 4 4 Hold down bolts 4 Jacking screws 4 24VDC Interlock Install the desired head holding it while putting on the two connectors then set it in its proper location If it is the backfilll head connect the hose Screw in the four Allen hold down screws part way Align the head in accordance to the procedure in Section III Alignment Secure t
62. ntial An air pressure gauge on the inside back panel will indicate these pressure settings The high and low air pressure regulators are located there also The escapements that release the plate from the cassette are also pneumatically driven The force available with pneumatics provides very reliable escapement operation There are no springs The force of the air cylinder both opens and closes the escapement As the stacker carries the plate nest into the cassette the escapement opens releasing a plate to the plate nest As the plate nest is lowered the escapement closes to catch the TOMTEC QUADRA 3 Service Manual 8 SECTION I GENERAL INFORMATION next plate If all microplates had the same total height and flange height then only one setting would be required This not being the case the timing of the escapements must have some adjustment to enable handling a wide variety of microplates This is accomplished with a sensor mounted on the stacker air cylinder It tells the escapement when to open and when to close It is adjusted with a 3 32 inch Allen wrench through a clearance hole The hole is located on the side of each stacker top plate Turning the Allen wrench one full turn clockwise moves the sensor down 1 32 inch two turns equal 1 16 inch Moving the sensor down will cause the escapement to stay open longer Turning the Allen wrench counter clockwise provides the opposite effect It may be necessary to use trial and err
63. o move away from the operator Y direction Pressing down arrow will cause the shuttle toward the operator Y direction F1 SET Saves any changes made in the Shuttle Calibration text screen and closes it F2 NEXT POSITION Moves the shuttle so that the next station is positioned over the stage and repeats the movement 2 and 5 from the opposite direction See the sequence under Procedure Using F2 below F3 STEP PER ADJ The number of steps per depression of the arrow keys can be set to 1 5 or 10 ESC CANCEL Closes the screen without saving changes PROCEDURE USING F2 In order to align the shuttle to the stage place a plate nest on all six shuttle stations In the Factory Settings display Press F2 which will open the Shuttle Calibration text screen and initialize the shuttle leaving it with station 1 over the stage Pressing F2 after each movement will continue to move each shuttle station over the stage in the following sequence Moves left to station 2 Moves left and then right back to station 2 Moves left to station 3 Moves backward to station 4 Moves right to station 5 Moves right and then left back to station 5 Moves right to station 6 Moves forward and returns to station 1 This sequence will continue as long as F2 is pressed after each shuttle movement NOTE If a station is selected out of sequence by pressing numbers one to six pressing F2 again will continue the sequence where it was left off
64. o one year following shipment Labor required for warranty related repair will be done at no charge for one year providing the equipment is returned to our factory for repair The cost of Trans portation both ways must be paid by the customer This warranty is valid providing the equipment is utilized within the guidelines of the operation manual Failures due to misuse or neglect are not covered by this warranty This warranty is exclusive and is in lieu of other warranties whether written oral or implied including the warranty of merchantability and fitfiess for any particular purpose TOMTEC s liability is in all cases limited to the replacement price of its product TOMTEC shall not be liable for any other damages whether consequential indirect and incidental arising from the sale and use of its products NOTE that disabling the screen saver will void the warranty on the front panel display RETURN POLICY It is the responsibility of the user to determine the suitability of the product for specific application While defective products will be replaced without charge if promptly returned no liability is assumed beyond such replacement Authorization for return must be received from Tomtec Inc before returning any equipment for inspection or warranty repair Assigned completed Decontamination Form must accompany all returns This is to verify to our employees that the unit is biologically and radioactively safe to work on
65. odule which when energized allows 24VDC to be present on the load Jumpers JP1 amp JP2 are jumped from B and C in their normal configuration and B would be jumped to bypass the boards for troubleshooting or maintenance purposes JP1 corresponds to the Q96A control board JP2 corresponds to the Q96B control board And JP3 is jumped from A to B In the normal configuration B and C of 7 4 are jumped allowing the 5 VDC to pass through the front panel cut off switch to the solid state rectifier SSR 24V POWER SUPPLY VOTING MODULE Fig 78 H wi Bin 714009 X a gt n 1 20 t gs Solid State Rectifier TT PWA cw d 690393 TOMTEC QUADRA 3 Service Manual 78 SECTION VI THE CPU amp ELECTRONICS 24V POWER SUPPLY CONTROL MODULE INTERFACE Fig 79 Dual Output Power Supply Note This diagram is shown in a power off state with the front panel shut QS6A Contro Board Confirmation of 5 volt initialization Control Confirmation of 5 volt initialization 24 Volt Control TOMTEC QUADRA 3 Service Manual 79 SECTION VI THE CPU amp ELECTRONICS FUSE REPLACEMENT CAUTION SHOCK HAZARD NEUTRAL IS FUSED DISCONNECT POWER BEFORE SERVICING Turn Main Power switch off Disconnect power cord from the power entry module located on the back of the Quadra Remove the fuse holder located at th
66. or to determine the best position You should count turns clockwise or counter clockwise from your starting point to know where you are In general terms if the plate to be released is still hanging in the cassette it probably means the escapement closed to quickly and pinched the plate before it cleared In this case turn the sensor clockwise to cause it to go down holding the escapement open longer If two plates were released instead of one then the opposite is true Turn the adjusting screw counter clockwise to cause the sensor to move up The top sensor mounted on the stacker cylinder PC Board tells the logic system that the air cylinder has completed its upward stroke This initiates the escapement opening sequence After a software time delay the stacker air cylinder up solenoid valve closes and vents the up motion allowing the 5psi to drive the stacker cylinder down The flag actuates the bottom sensor to indicate the stacker is down and the system is ready for the next motion If the bottom sensor is not actuated the logic system assumes the stacker is up and will not move the shuttle An error signal is generated at that time ACCESSORIES There are a number of accessories that are available from Tomtec to extend the value of the Quadra in specific applications Custom Reservoirs Tomtec will specially machine custom reservoirs to match your pipetting pattern For example many firms leave the first row of wells open without com
67. p313 pe xshut enable output p312 se stage enable input p311 EXP input 15511 set HIGH to disable RIF for NS Q3 24 13 input p310 EXP input lsb set HIGH to disable LTF for NS Q3 24 15 output p327 Not used output p326 EXP select input msb output p325 EXP select input output p324 EXP select input lsb output p323 EXP output msb output p322 EXP output msb 1 output p321 EXP output 15511 output p320 EXP output lsb interrupts INTERRUPT 2 interrupt routed to extint of 8256 0000 000F extint off card 0 rxd rxd2 rsp receiver for external Serial Box future requirement 21 15 txd txd2 tsp transmitter for external Serial Box future requirement 91 19 txc off card I O rxc off card I O TOMTEC QUADRA 3 Service Manual 88 SECTION VI THE CPU amp ELECTRONICS He e de de de de e de e de dede dede dee de de de dee dee dede dede e e e e dede dede de ede dee dede de e e dee de ede de dede dede ede de de dee de e ede dede ee ede dee de e e de de de de d n d n PROCESSOR e de de de de de KK dede dede ode ode ode ode ode ode dede dede ode deed ode ode ode ode dede ode ode ode ode ode ode ode ode dede ode dede ode ode ode ode RRR carrousel and spare stepper are muxed only enable 1 at a time input 1 7 spare bit output 1 6 resets other chips output 1 5 msb bank switching 3 32k banks 00 01 02 8000 to FFFF output 1 4 lsb bank switching NOTE the next 4 bit port pl 3 p1 0 contains
68. pounds to facilitate adding standards and controls to the pattern Tomtec can provide a special reservoir with specific wells joined in the first row Using pipeline pipetting the pipettor would aspirate the standards and controls from the first row and air in the balance of the tips When moving to the compound plate the pipettor will aspirate air in the empty first row and compounds from the rest Stirring Reservoir A self contained battery operated stirring reservoir nest will sit on the shuttle It has three magnetic fleas to stir the contents of the reservoir TOMTEC QUADRA 3 Service Manual 9 SECTION I GENERAL INFORMATION Constant Level Reservoir A peristaltic pump is used to circulate fluid to a weir type reservoir It maintains a constant liquid level This provides a means of controlling the depth of pipette tip insertion when aspirating It eliminates refilling the reservoir for long runs of plates It can also be used as a means of keeping particulate matter re suspended Vacuum Boxes Several types are available Typical examples are for Solid Phase Extraction applications The filtrate may be captured or passed to waste The vacuum box rests on the Quadra shuttle thereby maintaining registration with the pipette tips 330 10 BARCODE READER INSTALLATION KIT PARTS INCLUDED 1 025424 BRACKET 1 193 001 30 GROMMET CUT 1 828 001 06 NULL MODEL CABLE 4 830 001 01 CABLE TIES 4 831 001 02 CABLE TIE BASES
69. r loading the tips The tip switch confirms that the tips are properly loaded The stage reaches its vertical position by counting steps to the number set in the program If it becomes jammed or loses steps for any reason it must initialize The stage travels down to its bottom or home position sensor is operated at this point that resets the software counter back to zero TOMTEC QUADRA 3 Service Manual 7 SECTION I GENERAL INFORMATION There is another potential error point If for some reason an attempt to lower the stage is made when it is offset indexed away from its home position then it will not clear the opening in the shuttle This is recognized by the software and the stage error message is given The error must be corrected to proceed QUADRA SHUTTLE The concept of the shuttle is what sets the Quadra apart from its competition The shuttle can take plates from any of the stackers and move them to and from the pipettor On flat bed pipettors a separate device such as a conveyor or robotic arm is required The six stations of the shuttle add to its utility One station can bring in the assay plate while another brings in the compound or test variable plate One station may be used for tip washing This leaves three stations to handle the reagents for the assay Using pipeline pipetting complete assays may be completed in one pass The shuttle is driven by two stepper motors one in the X direction left right and
70. screws make contact before completing the adjustment Tighten the hold down bolts and confirm that the tips are still level with reference to the stage Loosen the hold down bolts and continue For a 96 SV or 450ul head move the head laterally to align the tips the center of the crosshairs on a 384 well plate The cross hairs are the plastic between four wells of a 384 well plate that correspond to a single well in a 96 well plate For a 384 head move the head laterally to align the tips to the centers of the wells Confirm that the head will still index 96 to 384 without the tips hitting the plate Insure that straight tips are used on the 450 head Tighten the hold down bolts then recheck the alignment and indexing Secure the B Q96 control board mounting plate if necessary and install the top cover NOTE The software will configure to the head installed 450uL BACKFILL HEAD THEORY OF OPERATION BACKFILL MODE The head works in conjunction with a reagent bottle buffer bottle and a compressor The buffer bottle will be filled with water up to the black line Compressed air and vacuum are used at different times A hose is connected to the fitting on top of the pinch tube assembly which is connected to the reagent bottle The reagent bottle is connected to three valves in parallel which will supply either vacuum unregulated or regulated pressure Initially when starting to use the instrument it is necessary to prime the hea
71. stage Look for the nest to pick and place properly to ensure the shuttle is aligned to the stage Load and shuck the tips Perform any other tests to ensure that the instrument is functioning properly Shut down the unit using the proper procedure Install the CPU cover and reboot the system then initialize the unit If all is well the operation is complete SWAPPING THE COMPUTERS 1 2 3 Open the front panel by pulling both sides evenly straight out The panel will move out a few inches and then swing open Open the back side of the panel and you will find a black cover Remove this cover four screws one in each corner Disconnect all the cables to the CPU paying careful attention to where they are connected TOMTEC QUADRA 3 Service Manual 68 SECTION CPU amp ELECTRONICS 4 Remove the CPU Use the replacement CPU as a guide to where the mounting screws are located The Display and Keyboard should remain in the unit 5 Install the new CPU and reconnect all connections DO NOT replace the cover at this time FRONT PANEL DISPLAY COMPUTER AND KEYPAD REMOVAL amp INSTALLATION FRONT DOOR OPEN Fig 65 Computer Shroud SERIAL NUMBER 1013 Screws 2 Screws 2 List of Factory Settings by Serial number TOMTEC QUADRA 3 Service Manual 69 SECTION CPU amp ELECTRONICS COMPUTER Fig 66 Communications Port Plugs 2
72. t may take a number of iterations to get it satisfactory Tighten the four hold down bolts Raise and lower the nest again to verify smooth operation Shut off power and replace the covers TOMTEC QUADRA 3 Service Manual 59 SECTION V THE STACKERS STACKER ELEVATOR FRONT LEFT INSTALLED Fig 56 b amp Nest Plate Nest Plate Adjustment screw Mounting plate Plate Escapement Adjustment Elevator allen hold down bolts Anti rotation device Valve fitting shown with hose removed TOMTEC QUADRA 3 Service Manual 60 SECTION V THE STACKERS ELEVATOR RAISED Fig 57 Nest Plate Guide rod Cylinder Access hole to Nut Plate for screw that secures cover Mounting plate Access hole for Plate Escapement adjustment TOMTEC QUADRA 3 Service Manual 61 SECTION V THE STACKERS STACKER ESCAPEMENT TEST AND ADJUSTMENT Tools required 3 32 Allen wrench Procedure Use two of each of the following plates in the stacker to be tested with no special order of placement Standard 96 or 384 Whatman deepwell PCR plate ABI 384 Nunc 1536 96 well microtube rack In the main menu select System Functions 4 and press enter Select Shuttle Stacker Stage Pump Utility 4 and press enter Using the utilities screen infeed plates verifying that that stacker is releasing one plate at a time Remove the plates from the nest by hand You ma
73. tage Hght 2268 XY Safe Height 1158 LOAD AND SHUCK TIPS Load Tip Speed 2 Load Tip Ramp 1 Load Tip LS 1 ENABLE Load Tip Hght 2858 Shuck Tip Hght 1708 PUMP Pump Speed Shuck SpdiRmp Pump Shck Step Asp Spd Ramp Dsp Spd Ramp Backlash Factr Half Steps uL SHUTTLE Shuttle Speed 3 SHUTTLE CALIBRATION 45 68 35 35 58 Stckr In Delay 8288 Stackers B DISRBL Factory Settings STAGE FORMATTING 96 384 X Offst 96 384 Offst 96 1536 X near 96 1536 Y near 96 1536 X far 96 1536 Y far 384 1536 X 015 384 1536 Y 04 STRGE 2 SETTINGS Stage 015 80 00 Stage Z Offset 808 Stage Type 4 L3TOFF Backlash X Y 08 68 Stage X Motor 8 STNDRD MISCELLANEOUS Wash Pist Hght 1958 Auto firm DISABLE Max Arm Height 4200 Arm Safe Hght 6808 Tray UP Delay 83 F1 SAVE FZ SHUTTLE CALIBRATION F3 COPY TO FLOPPY ESCI CRNCEL On older Q3 s the Stackers can not be disabled in the TUI They must be jumped from qrd pin 3 to 19 13 connector TOMTEC QUADRA 3 Service Manual 75 SECTION VI THE CPU amp ELECTRONICS STAGE Stage Run Speed Speed at which the stage moves up and down Parameters are 1 to 6 6 being the fastest 7 amp 8 are for future use Stage Run Ramp The relative time it takes for the stage to go from stop to its run speed or to accelerate Parameters are 1 to 4 4 being the fastest Maximum Stage Height
74. tput p015 Magnetic Bead 2 Vacc Box Door 23 37 output p014 Magnetic Bead 1 Vacc Box Tray 23 35 output p013 SPARE BIT input p012 pinch tube open LS Diluent ON 23 25 input p011 pinch tube closed LS Diluent OFF 63 28 output 010 pinch tubes open closed 23 26 Ground J3 39 output p027 SPARE BIT 24494244 z a2DADET SECTION VI THE CPU amp ELECTRONICS e e e de e e e de dede dee HK KKK e dede oe dee eee dee ede de KR RR dede ede dee dee oe dee dee ede eoe de dee dede eee dede ede eoe dee ede ed e de d e d d 2 PROCESSOR de de dede dede dede dede dede dede dede de dede dede ode ode ode oe ode dede dede dede dede dede dede dede ode ode dede ode ode ode dede dede dede dede dede dede dede ode ode oe oe oe ode ode de dede dede dede dede dede RRR carrousel and spare stepper are muxed only enable 1 at a time input 1 7 spare bit output 1 6 resets other chips output 1 5 msb bank switching 3 32k banks 00 01 02 8000 to FFFF output pl 4 lsb bank switching eee deiam A ide ama fma e Cetera dae A SECTION ABOUT SECTION VII ABOUT TOMTEC Warranty 95 Return policy 95 QUADRA 3 Decontamination Form 96 If you Need Help 97 Tomtec Worldwide Distributors 98 WARRANTY Tomtec Inc guarantees the Quadra3 against defects in materials workmanship Defective material will be replaced at no charge for a period of up t
75. ulator Adjustment knob Safety Ground Terminal Input Power connector and fuses Connections to 450uL Backfill Head to Reagent bottle Air Reagent Cooling Fans Electrical connection for Autotrap Auxiliary Connector Panel TOMTEC QUADRA 3 Service Manual 6 SECTION I GENERAL INFORMATION OPERATIONAL FUNCTIONALITY QUADRA STAGE The stage lifts the plate nests from the Quadra shuttle to the tips Four pins on the top of the stage locate into the corresponding holes on the bottom of the nests This permits the precision necessary for 384 and 1536 operation The stage height is set in the program It also has the ability to index in both the X and Y direction This indexing allows format ting from 96 to 384 or 1536 Since it provides full motion it also permits serial dilution testing when used with the 450uL head To reformat the stage must rise above the shuttle to clear it It also must be below the tips to clear them This distance 18 referred to as the safe height The stage must rise to this safe height before it can offset The X motion of the stage is your left and right when you are facing the Quadra The Y motion is front to back The software will automatically set the coordinates for the required offset for the quadrants of the 384 or the 1536 plate However you may wish to modify these for a particular plate or application Use quad rant 1 of the 384 well plates as an example The mathematical center of t
76. y want to outfeed them also but the adjustment has to be made based on the performance of the flippers on infeed The adjustment for changing the amount of time the flippers are open allowing a plate to drop is located on the associated elevator and accessed through the shuttle station On the left side of the instrument access to the adjustment is on the front of the elevator top plate On the right side of the instrument the access is on the back of the elevator top plate View the Stacker in Delay on the factory settings screen It should be at least 200 If it is not call Tomtec service If a plate does not drop when it s supposed to adjust in a CCW direction to lengthen the time the flippers are open If two plates drop at the same time adjust in the clockwise direction to shorten the time the flippers are open If an adjustment is made then all of the test plates have to be run through again The test is not complete until all test plates are run through without any adjustment TOMTEC QUADRA 3 Service Manual 62 SECTION V THE STACKERS LEFT FRONT STACKER Fig 58 Flipper Access to Plate Escapement Adjustment LEFT FRONT ELEVATOR Fig 59 Plate Escapement adjustment TOMTEC QUADRA 3 Service Manual 63 SECTION V THE STACKERS PLATE PRESENT SENSOR ADJUSTMENT Tools required 3 32 Allen wrench jewelers flat blade screwdriver LIGHT SWITCH STATUS Fig 60 PLATE PRESENT

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