DRAFT CETAC ASX-560 Autosampler Service Manual
Contents
1. 11 Recommended Service Tools 11 General Tips and Tricks 12 Returning the Product to CETAC 12 Shipping the Product 12 Where to Go for More Information 13 2 Basic Maintenance 15 Cleaning the Autosampler 15 Replacing the Z Drive 16 How Does the Z Drive Work 16 How Should I Care for the Z Drive 17 Removing the Old Z Drive 17 Installing the New Z Drive 18 Replacing2. 29 Configuring C Term 29 Autosampler Commands 30 4 Disassembling the Autosampler 31 Remove the Tray 31 Remove the Z Drive 31 Remove the Cover 32 Remove the Splash Shield 32 Remove the Base 33 Remove the Left Endplate 34 Remove the X Drive Assembly 36 Disassemble the X Drive Assembly Carriage 39 Remove the Y Arm from the Carriage
3. 41 Remove the Motor from the Carriage 42 Remove the Sensors 42 Remove the E Chain 43 5 Repair Procedures 45 Replacing the Pump 45 Replacing the Rotor Stator 46 Replacing the Z Axis Motor 48 Replacing the Crash Block 48 Replacing the X Axis Drive Belt 49 Replacing the USB Port 52 Replacing the Main Circuit Board 53 6 Diagrams 55
4. Figure 5 7 Parts of the Rotor Stator Assembly Set Screw Stator Mounting Screws Z Cable Clamp and Thumbscrew Rotor Stator Crash Sensor Z Axis Sensor ASX 560 Autosampler Operator s Manual Chapter 5 Repair Procedures 48 Replacing the Z Axis Motor 1 Remove the rotor and stator 2 Remove the cover 3 Remove the splash shield 4 Follow the wire from the motor to the main circuit board and unplug it You will need to thread the wire out of the flex tubing 5 Remove the 2 screws under the rotor Figure 5 8 Z Motor Screws 6 Replace the motor 7 Replace the rotor and stator Move the rotor and carefully listen and feel for friction In rare cases it may be necessary to align the motor contact Teledyne CETAC Technologies if you think the alignment might need to be adjusted Replacing the Crash Block The crash block is also called the guide block or anti kink block The block pivots when the probe hits an obstruction allowing the Z drive cable to bend naturally without kinking As the block pivots a sensor inside the stator detects the crash software or firmware can then potentially react to this signal The autosampler firmware does not currently use the crash signal A spare crash block is provided with each Z drive In most cases the crash block does not need to be replaced 1 Loosen the nut on the old crash block 2 Free the Z drive cable from the rotor 3
5. Pull the Z drive cable out of the crash block 4 Remove the screw and pull off the old crash block ASX 560 Autosampler Service Manual Chapter 5 Repair Procedures 49 5 Pull the old washer off of the standoff and discard it 6 Place the new washer wave spring on the standoff 7 Apply a drop of Loctite 242 to the threads of the new screw 8 Use the new screw to secure the crash block to the standoff 9 Check that the block moves freely with the flag moving into the slot in the side of the stator 10 Replace the Z drive cable Replacing the X Axis Drive Belt 1 Remove the cover 2 Remove the splash shield 3 Remove the guide shaft screw from the right end plate ASX 560 Autosampler Operator s Manual Chapter 5 Repair Procedures 50 Figure 5 9 Guide Shaft Screw 4 Remove the remaining 3 screws from the right end plate Figure 5 10 End Plate Screws 5 Remove the 4 motor mounting screws from the right end plate Figure 5 11 Motor Screws ASX 560 Autosampler Service Manual Chapter 5 Repair Procedures 51 6 Remove the old belt 7 Place the new belt over the end of the lead screw and over the sprocket on the motor Figure 5 12 Threading the Belt Over the Lead Screw 8 Reattach the end plate and secure the guide shaft 9 Lightly attach the screws which hold the motor The motor should still be free to move around a bit 10 Engage the belt on the motor sprocket and on the
6. Wire Routing and Cable Connections 55 Power Serial Cable 55 Motors Home Sensors LED Pump 56 E Chain 56 5 1 Introduction About This Manual This manual describes the procedures for repairing the CETAC ASX 560 autosampler Who Should Read This Book This manual is intended for use by customers who have experience repairing laboratory equipment and by service technicians at CETAC authorized service centers Performing repairs or modifications beyond the ones described in this manual may void the warranty on the instrument Important Safety Precautions SHOCK AND MECHANICAL INJURY HAZARDS The Operator s Manual contains safety related information which is not repeated in this Service Manual The Operator s Manual is supplied on the CD with the autosampler It may also be downloaded from www cetac com If you need safety information in a language other than English refer to the included Autosampler Safety Manual SHOCK HAZARD Ensure the power cord is turned off and disconnected before touching the autosampler or opening any protective covers Replace all covers and guards before
7. reconnecting power WARNING WARNING ASX 560 Autosampler Operator s Manual Chapter 1 Introduction 6 CHEMICAL INJURY HAZARD The autosampler may have been contaminated with hazardous materials Make sure you know about any materials which may have contaminated the autosampler and take precautions appropriate for the hazards associated with those materials Exposure to laboratory chemicals may result in serious injury General Precautions for Protecting the Autosampler Static Discharge Discharge static buildup and ground to the autosampler base or cabinet before performing any maintenance Do not touch or short circuit the contacts on the communication ports Moving the Z Drive Do not allow the cable to bend sharply Avoid pushing up on the slider or pushing on the Z drive cable Move the Z drive by rotating the rotor on the back of the autosampler Do not move the Z drive or sample probe directly as damage to the drive cable may result Lubrication Never lubricate the autosampler Oil or other lubricants will accumulate contaminants and cause the moving parts to bind NOTE To prevent contamination wear gloves when handling the probe or other surfaces which may come in contact with samples Repair Strategy In general the repair strategy for this product is board replacement or mechanical assembly replacement Circuits are protected by a conformal coating so component level repair of the circuit boards is strongly d
8. rotor to allow the cable to pass through the clamp with about 2 mm of cable extending past the clamp Figure 2 5 Position of Cable on Rotor ASX 560 Autosampler Operator s Manual Chapter 2 Basic Maintenance 20 7 Verify that there is a small gap between the Z axis slider and cap at the top of the Z drive approximately 1 3 mm Adjust the cable a bit if necessary Figure 2 6 Sample Probe at Top Position With Gap 8 Hold the cable flat against the rotor and secure the cable by tightening thumbscrew on the rotor The thumbscrew should be as tight as possible using just your fingers Figure 2 7 Securing Cable to Rotor The cable is pre cut to the proper length and does not need to be trimmed when properly installed ASX 560 Autosamplers Service Manual Chapter 2 Basic Maintenance 21 9 Rotate the rotor back and forth to ensure that it moves freely If there is excessive friction check that the full width of the cable is under the clamp Also check that the end of the cable is not rubbing on the shroud around the rotor Never push the Z axis slider to move it up or down Pushing on the Z axis slider can kink the drive cable Instead rotate the Z drive rotor on the back of the autosampler Figure 2 8 Z Drive Rotor 10 Install a sample probe 11 Use the utility software to align the probe over the rinse station 12 Use the utility or your instrument control software to move the probe to several rack positions to make
9. stick to the endplate which is okay If it sticks to the guide shaft remove it and set it aside Figure 4 9 Lead Screw Washer ASX 560 Autosampler Operator s Manual DRAFT Chapter 4 Disassembling the Autosampler 36 Remove the X Drive Assembly 1 Remove the 2 screws which are just below the arm Figure 4 10 Screws Holding X Drive Cable Assembly 2 Disconnect the first sensor cable whichever one you can reach Figure 4 11 X Sensor cable 3 Slide the carriage and disconnect the other sensor cable Figure 4 12 Y Sensor Cable ASX 560 Autosamplers Service Manual DRAFT Chapter 4 Disassembling the Autosampler 37 4 Disconnect the motor cable Figure 4 13 Motor Cable The shelf which holds the cables should now be free Figure 4 14 All X Assembly Cables Disconnected 5 Remove the screw which secures the guide shaft to the right end plate ASX 560 Autosampler Operator s Manual DRAFT Chapter 4 Disassembling the Autosampler 38 6 Pull the X drive assembly out of the autosampler Figure 4 15 X Drive Assembly Guide Rail X Axis Lead Screw Y Arm Lead Screw Bearing X Axis Carriage Y Axis Motor ASX 560 Autosamplers Service Manual DRAFT Chapter 4 Disassembling the Autosampler 39 Disassemble the X Drive Assembly Carriage 1 Slide the guide rail out of the carriage 2 Remove the bearing from the left end of the X axis lead screw You may need to use a small ge
10. 32 E mail custserv cetac com 15 2 Basic Maintenance Many routine maintenance tasks are described in the Operator s Manual and are not repeated in this Service Manual Those tasks include Checking for Leaks Replacing Peristaltic Pump Tubing Setting the Z Axis Travel Replacing the Z Drive Replacing the Rinse Station Replacing the Sample Tray Cleaning the Autosampler Use of the autosampler often results in spills on autosampler components such as the sample tray To avoid spreading contamination which could cause injury or equipment damage it is a good practice to thoroughly clean the exposed surfaces before performing repairs SHOCK HAZARD Do not allow any liquid to enter the instrument cabinet other than as intended through the specified tubing or come into contact with any electrical components The instrument must be thoroughly dry before you reconnect power or turn the instrument on Do not allow the cleaning agent to come into contact with the lead screws Also never lubricate either of the two lead screws Do not clean with carbon tetrachloride WARNING CAUTION CAUTION ASX 560 Autosampler Operator s Manual Chapter 2 Basic Maintenance 16 1 Shut down and unplug the autosampler 2 Remove the sample tray 3 Wipe loose particles off the Y axis lead screw with a dry lint free cloth The Y axis lead screw is the large metal screw located inside the autosa
11. 4 Disassembling the Autosampler 44 Figure 4 27 X and Y Sensors 5 Remove the 2 mounting screws 6 Lift the E chain out of the autosampler Wire Tie Removed E Chain Mounting Screws 45 5 Repair Procedures Replacing the Pump The peristaltic pump can be replaced without opening up the autosampler 1 Remove the 4 screws from the pump Figure 5 1 Pump Screws 2 Disconnect the cable from the pump Figure 5 2 Pump Connector 3 Install the new pump ASX 560 Autosampler Operator s Manual Chapter 5 Repair Procedures 46 Replacing the Rotor Stator The Z axis rotor and stator can be replaced without opening up the autosampler Replacing the motor requires access to the interior of the autosampler 1 Disconnect the Z drive cable from the rotor 2 Remove the 4 screws from the stator Figure 5 3 Stator Screws 3 Turn the rotor counterclockwise so that the flag is visible 4 Lift off the stator Figure 5 4 Removing the Stator 5 Unplug the two connectors Rotor Flag ASX 560 Autosampler Service Manual Chapter 5 Repair Procedures 47 Figure 5 5 Stator Sensor Connectors 6 Remove the rotor set screw using a 1 16 Allen wrench Figure 5 6 Rotor Set Screw The stator contains two sensors One detects when the Z axis has returned to the home position The other is triggered when the probe hits an obstruction causing the Z drive cable to bend and pivoting the crash block
12. ASX 560 Autosampler Manual Part Number 480218 Draft 0 Service Manual COPYRIGHT 2015 Teledyne Technologies Incorporated All rights reserved 480218 Draft 0 June 2015 Teledyne CETAC Technologies authorizes its customers to reproduce transmit or store this document in its entirety including this page for the express purpose of installing operating or maintaining the product described herein Teledyne CETAC Technologies Customer Service amp Support 14306 Industrial Road Omaha Nebraska 68144 USA Phone 800 369 2822 USA only Phone 402 733 2829 Fax 402 733 1932 E mail custserv cetac com REVISIONS Teledyne CETAC Technologies strives to provide the scientific community with an unparalleled combination of effective technology and continuing value Modular upgrades for existing instruments will continue to be a prime consideration as designs progress Teledyne CETAC Technologies reserves the right to revise this document and improve products described herein at any time without notice or obligation TRADEMARK ACKNOWLEDGEMENTS Windows is a registered trademark of Microsoft Corporation in the United States and other countries PharMed and Tygon are registered trademarks of Saint Gobain Performance Plastics DuPont Kapton Teflon Tefzel and Viton are trademarks or registered trademarks of E I du Pont de Nemours and Company Superthane is a registered trademark of NewAge Indu
13. Operator s Manual DRAFT Chapter 4 Disassembling the Autosampler 42 5 Pull the Y arm and lead screw away from the carriage 6 Remove the Y axis lead screw from the arm It is possible to remove the lead screw with the nut still attached by tilting the lead screw into a corner of the arm If this proves to be too difficult turn the lead screw until the nut comes off of the end REASSEMBLY NOTE When reassembling apply a little Loctite 242 on the set screw Remove the Motor from the Carriage 1 Note the orientation of the motor so that you can reinstall it properly 2 Remove the 2 M3 x 8mm screws which hold the motor to the carriage Remove the Sensors The X and Y axis home position sensors are each held in place with a single screw Figure 4 23 X and Y Sensors X Sensor Y Sensor ASX 560 Autosamplers Service Manual DRAFT Chapter 4 Disassembling the Autosampler 43 Remove the E Chain The E chain is the wiring harness for the sensors and motors on the Y axis assembly encased in a protective plastic chain 1 Remove the 2 connectors from the main circuit board Figure 4 24 E Chain Detached from Circuit Board 2 Remove the grounding lugs Figure 4 25 Grounding Lugs 3 Unfasten the center cable strap lift and pull the latch Figure 4 26 Cable strap 4 Cut the wire tie and lift the wires to expose the mounting screws ASX 560 Autosampler Operator s Manual DRAFT Chapter
14. SX 560 Autosampler Operator s Manual Chapter 3 Troubleshooting the Autosampler 26 1 Check that the USB cable to ensure it is plugged into the port on the autosampler 2 Check the host computer to ensure that the USB cable is connected to the appropriate USB port Note that if you move the USB cable to a different USB port the driver may assign a new COM port number 3 Check that the USB cable is not damaged in any way 4 Check the host computer to ensure that the USB drivers are installed for USB operation of the autosampler Load the proper USB drivers to the host computer from the CD that was provided with the autosampler Software Configuration Problems If the communication cable is connected properly and the system is still not functioning with the instrument control software ensure that the software is communicating correctly with the autosampler To do so use the supplied ASX Dashboard software 1 Connect to the autosampler using the Autosampler IQ OQ utility which in the ASX Dashboard 2 Toggle the pump on and off If the commands have no effect and a USB connection is being used check that the autosampler is plugged into the same USB port as it was when the driver software was configured Unlike many consumer devices each USB port used as a virtual COM port must be individually configured 3 If manual controls work but the autosampler does not operate with the instrument control software car
15. WIPES Delicate Task Wipers PTFE lubricant Super Lube multi purpose synthetic grease or equivalent LOCTITE Threadlocker Blue 242 or equivalent Plastic wire ties Clean paintbrush for brushing away dust Large sink or tub for washing the sample tray Laboratory grade cleaning agents PC with at least one free USB port and at least one free serial port Voltmeter General Tips and Tricks Use the standards tray to organize small parts as which have been removed from the autosampler Tighten KYNAR thumbscrews using only your fingers never use pliers Do not lubricate the lead screws Lubricants of any type may lead to fouling sample contamination and increased friction Returning the Product to CETAC Refer to the following information if you need to return the product to Teledyne CETAC Technologies for service Shipping the Product Follow these guidelines when shipping the product Do not return products which are contaminated by radioactive materials infectious agents or other materials constituting health hazards to CETAC employees Use the original packing materials If the original shipping materials are not available place a generous amount of shock absorbing material around the instrument and place it in a box that does not allow movement during shipping Seal the box securely Contact Teledyne CETAC Technologies before sh
16. ag w o probe guide Easy Page 22 amp Operator s Manual SP7446 Y Axis Stepper Motor Advanced Page 42 SP7437 Z Axis Drive Assembly Easy Page 16 Instructions are also supplied with part SP7174 Z Axis Tubing Replacement Kit Easy Instructions with part SP7447 Z Axis Stepper Motor Advanced Page 48 How to Obtain Spare Parts To see what parts are available refer to the Spare Parts and Accessories Catalog available from CETAC It is recommended to order parts by telephone so you can discuss your particular needs Setting Up a Service Area The work surface should meet the same space requirements as specified for the laboratory in the Operator s Manual An ESD work surface is recommended Recommended Service Tools Laboratory gloves to prevent personal exposure to hazardous substances and to prevent contamination of equipment which may come in contact with samples Protective eyewear Other personal protective equipment as needed for protection from hazardous materials which may have contaminated the autosampler ESD wrist strap Set of slotted screwdrivers Short handled slotted screwdriver Set of Phillips screwdrivers Set of hex keys or Allen wrenches English measurements Gear puller approximately 1 1 5 inch 2 4 cm ASX 560 Autosampler Operator s Manual Chapter 1 Introduction 12 Lint free laboratory wipers such as KIMTECH SCIENCE KIM
17. ar puller to pull off the bearing You do not need to remove the bearing or the sprocket from the right end of the lead screw Figure 4 16 Gear Puller 3 Thread the lead screw out of the carriage If you wish you may defer the following steps until after the arm has been removed from the carriage 4 Remove the 4 screws which hold the collar over the lead screw nut 5 Remove the lead screw nut Figure 4 17 X Axis Lead Screw Nut ASX 560 Autosampler Operator s Manual DRAFT Chapter 4 Disassembling the Autosampler 40 6 Remove the screws which hold the linear bearings which ride along the guide rail Pull out the two linear bearings Figure 4 18 X Axis Linear Bearings Figure 4 19 X Axis Linear Bearings REASSEMBLY NOTE When reassembling coat the first of the X carriage bore on both sides using PTFE grease Ensure the ball raceways are opposite each other and not in line ASX 560 Autosamplers Service Manual DRAFT Chapter 4 Disassembling the Autosampler 41 Remove the Y Arm from the Carriage 1 Remove the black PEEK screw from which secures the end cap of the Y arm Figure 4 20 Y Arm End Cap 2 Pull off the end cap 3 Locate and set aside the wave spring washer It may be in the end cap or on the end of the Y axis lead screw Figure 4 21 Y Axis Wave Washer 4 Use a 3 32 Allen wrench to loosen the set screw in the X axis carriage Figure 4 22 Y Arm Set Screw ASX 560 Autosampler
18. cable is damaged replace the Z drive ASX 560 Autosampler Operator s Manual Chapter 3 Troubleshooting the Autosampler 28 Contamination and Carryover Problems 1 Check the rinse station tubing Rinse solution should flow upward from the bottom of the rinse station 2 Check the end of the rinse solution drain tube It should be above the surface of the liquid in the waste container 3 If recycling the rinse solution check whether the rinse solution needs to be changed 4 Examine the sample transfer tubing Make sure that it is as short as possible while still free to move Make sure that there are no unnecessary fittings on the sample transfer tubing fittings can create small reservoirs where contaminants can hide 5 Watch for liquid dripping from the sample probe as it moves It may be necessary to slow the autosampler down to reduce droplet shedding This can be adjusted using the Speed Shift utility in the ASX Dashboard software 6 Check that the sample probe remains in the rinse station long enough This can be adjusted using the Speed Shift utility Using the C Term Terminal Program The autosampler can be controlled by sending it simple commands This can be helpful for troubleshooting You can use any terminal emulation program This chapter explains how to operate a CETAC autosampler using the C Term terminal program which is provided on the software CD C Term is a simple terminal program developed to vali
19. cess it from different angles while you work 1 Turn the autosampler upside down 2 Remove the four screws from the base Figure 4 5 Screws in Autosampler Base 3 Remove the rubber gasket and feed the cables into the autosampler head ASX 560 Autosampler Operator s Manual DRAFT Chapter 4 Disassembling the Autosampler 34 NOTE There are levelling screws which protrude from the bottom of the autosampler head These screws do not normally need further adjustment even if you are installing a new base on the autosampler Figure 4 6 Levelling Screw Bottom of Autosampler Head REASSEMBLY NOTE The gasket is keyed to fit one way on the base Remove the Left Endplate Be sure to remove the left endplate as seen from the front of the right side up autosampler first The right endplate does not need to be removed for any field service procedure 1 Remove the three screws from the left endplate Figure 4 7 Screws Holding Left End Plate ASX 560 Autosamplers Service Manual DRAFT Chapter 4 Disassembling the Autosampler 35 2 Remove the screw which holds the guide shaft to the left endplate Figure 4 8 Screw Holding Guide Shaft 3 Loosen but do not remove the screw which secures the guide shaft to the right end plate This will reduce strain and make it easier to remove the shaft from the right end plate later 4 Pull off the left end plate 5 There is a washer at the end of the lead screw It may
20. crews or nuts with anything other than your fingers Removing the Old Z Drive 1 Place the autosampler on a flat surface and turn the unit off 2 Remove the two thumbscrews from the Y axis slider block 3 Remove the cable from the rotor by loosening the thumbscrew on the rotor and also removing the two thumbscrews from the guide block Remove the old Z drive from the arm by pulling the whole Z drive forward and off the autosampler arm CAUTION Sleeve Protects Z Drive Cable Nut Z Drive Cable Home Flag Z Axis Slider Y Axis Slider Block Spiral Wrap ASX 560 Autosampler Operator s Manual Chapter 2 Basic Maintenance 18 Installing the New Z Drive 1 Remove Z drive from the bag 2 Slide the Z drive onto the y arm until the two holes in the Y axis slider block align with the matching holes in the Y axis carriage Figure 2 2 Sliding the Z Drive Onto the Arm 3 Secure the Z drive to the carriage using the two thumbscrews Tighten the thumbscrews using your fingers Figure 2 3 Securing Z Drive Onto the Arm ASX 560 Autosamplers Service Manual Chapter 2 Basic Maintenance 19 4 Feed the cable through the rear guide block and around the rotor then tighten the nut to secure the cable sleeve to the guide block Figure 2 4 Guide Block with Nut 5 Turn the rotor clockwise as far as it will go 6 Finish sliding the cable around the rotor on the back of the autosampler Loosen the thumbscrew on the
21. date the installation and functionality of various CETAC devices C Term communicates through a serial RS 232 port on the host computer If the autosampler is connected to a USB port the device driver will create a virtual serial port ASX 560 Autosamplers Service Manual Chapter 3 Troubleshooting the Autosampler 29 Starting C Term 1 Check that the autosampler is connected to the PC 2 Close any programs which might be communicating with the autosampler 3 On the Start Menu click All Programs Teledyne CETAC Technologies Support Tools C Term Overview of the C Term Window Figure 3 1 C Term Window Commands typed in this window are sent to the CETAC device connected to the opened port The typed commands will appear in light green in the terminal buffer Responses from the autosampler will appear in red Non printing characters such as carriage returns will appear as ASCII hexadecimal numbers surrounded by square brackets for example 0D is the carriage return character Configuring C Term By default C Term attempts to open COM1 the first time it is executed If the autosampler is connected to another COM port configure C Term to use the desired port 1 On the Tools menu click Setup Serial Port 2 Select the desired COM port and click OK NOTE The autosampler communicates at 9600 baud which is the default Only installed COM ports including USB virtual COM ports will appear in the Comm Port men
22. efully check that the software is configured to use the COM port where the autosampler is plugged in If a USB connection is used and if the manual commands work but the instrument control software fails to operate the autosampler check that the same COM port number is configured in the software and in the USB device driver Z Drive Problems An autosampler malfunction may be caused by a problem in the Z drive assembly You can easily determine that a malfunction is related to the Z drive if you hear a loud chattering noise when the autosampler power switch is on or if the sample probe is not moving To troubleshoot Z drive problems complete the following steps ASX 560 Autosamplers Service Manual Chapter 3 Troubleshooting the Autosampler 27 1 Ensure that the Z drive is installed correctly 2 Check the Y axis home position flag When the Z drive returns to the home position the flag should enter the corresponding slot If the flag is damaged replace it 3 Ensure the sample probe is moving freely Gently rotate the rotor on the back of the autosampler to move the sample probe up and down If the sample probe is binding free the sample probe assembly NOTE If you cannot free the Z drive you will need to replace it See page 16 for information about mounting a new Z drive You can order a new Z drive from Teledyne CETAC Technologies 4 Inspect the Z drive cable for sharp bends kinks or rough spots If the
23. erator s Manual SP7448 Arm Tube Assembly Advanced Page 41 SP7456 Base Plate Easy Page 33 Bearings X Axis Leadscrew Advanced Page 39 SP7453 Bearings X Axis linear Advanced Page 39 Various Carbon Fiber Sample Probes Easy Operator s Manual Various Front Cover Easy Page 32 SP7451 Guide Shaft Advanced Page 39 SP7460 LED Assy Factory SP7452 Main Board Advanced Page 53 Peristaltic Pump Shoe Roller Band Easy Operator s Manual Various Peristaltic Pump Tubing Easy Operator s Manual SP7443 Power Switch Advanced Power RS 232 Cable Assy Factory SP7440 Pump Motor Kit 2 Channel Advanced Home 45 SP7457 Rinse Station Easy Operator s Manual Various Rinse Drain Tubing Easy Operator s Manual SP7438 Rotor Assembly Advanced Page 46 SP7439 Tray Assembly with 10 Standards Positions Easy Operator s Manual USB Cable Assy Factory SP7475 USB Connector internal Advanced Page 52 SP5222 X Axis Drive Belt Advanced Page 49 SP7450 X Axis Lead Screw Kit Advanced Page 39 SP7444 X Y Z Crash Sensor Advanced Page 42 X Y Page 46 Z ASX 560 Autosamplers Service Manual Chapter 1 Introduction 11 SP7445 X Axis Stepper Motor Advanced Page 49 SP7442 Y Axis Cable Assembly E Chain Advanced Page 43 SP7449 Y Axis Lead Screw Kit Advanced Page 41 SP7458 Y Home Flag w probe guide Easy Page 22 amp Operator s Manual SP7459 Y Home Fl
24. ernal devices such as an autodilutor USB Port The USB port can be used to interface the autosampler with the host computer Power Switch Serial Ports USB Port Power Connector Z Drive Rotor Peristaltic Pump Access Cover for Auxiliary Connector Guide Block ASX 560 Autosamplers Service Manual Chapter 1 Introduction 9 Figure 1 3 ASX 560 Autosampler Z Drive Assembly Sleeve Protects Z Drive Cable Nut Z Drive Cable Home Flag Z Axis Slider Y Axis Slider Block Spiral Wrap ASX 560 Autosampler Operator s Manual Chapter 1 Introduction 10 List of Replaceable Parts Difficulty levels are defined as Easy The part can be replaced by the user with no special training Minimal disassembly is required Advanced The part can be replaced by users who are confident in their electrical and mechanical repair skills Some procedures require good manual dexterity and the use of special tools Factory The autosampler should be returned to Teledyne CETAC Technologies for repair Custom made tools or specific adhesives may be required or the procedure may be especially complex or error prone Part numbers and availability are subject to change without notice See the Spare Parts and Accessories Catalog for the latest list of spare part numbers Part Number Description Difficulty Level Where to Find Service Instructions SP6103 24 Volt Power Supply Easy Op
25. igned Refer to the Operator s Manual for Z drive assembly installation Power System Problems A possible cause of system malfunction is a problem in the power system If the system is not functional it is possible that it is not receiving power If this is the case the LED power indicator light on the autosampler will be off To troubleshoot this problem complete the following steps in sequence until the problem is solved 1 Check that the power switch on the autosampler is turned on 2 Check that the power cord is plugged in firmly between the power input on the autosampler and the external power supply and also between the power supply and the wall outlet If the cable is plugged in ensure that it is not damaged in any way 3 Check that the LED on the power supply is illuminated If the LED is not illuminated check the wall outlet using a device approved for that purpose If the wall outlet is working and the voltage is acceptable unplug the external power supply from the autosampler but leave it plugged into the wall If the LED is not lit the power supply is faulty and requires replacement ASX 560 Autosamplers Service Manual Chapter 3 Troubleshooting the Autosampler 25 If the LED is lit when unplugged from the autosampler but turns off when plugged into the autosampler the autosampler may have an internal short and requires repair 4 Check the wall outlet 5 If the external power supply LED i
26. inated Plug DC power cord firmly into plug at back of cabinet Autosampler does not move when commanded RS 232 or USB cable not connected or connected properly Reconnect cable Make RS 232 and USB are not connected at the same time Correct COM port is not selected Use C Term to verify correct COM port Verify that ICP program uses same COM port Download and run CETAC test software from www cetac com Power supply LED flashes when autosampler power is turned on Possible short on main control board Contact CETAC ASX 560 Autosampler Operator s Manual Chapter 3 Troubleshooting the Autosampler 24 Axis does not Home after power has been applied PIC for that axis did not initialize properly Turn off autosampler power wait 30 seconds and turn on power Home sensor for that axis is not working Connect digital voltmeter DVM to sensor output and manually move axis to and from home position A 4VDC change should be detected Axis tries to keep moving after reaching Home position Home sensor for that axis is not working Connect DVM to sensor output and manually move axis to and from home position A 4VDC change should be detected No movement in X direction X axis belt is not properly on Open the unit Make sure that on the right side of the unit the belt is on the leadscrew and the X motor sprockets Z axis chatters when the system is turned on Z drive is misal
27. ipping the product Pre pay all shipping expenses including adequate insurance Write the following information on a tag and attach it to the product Name and address of the owner Product model number and serial number Description of service required or failure indications ASX 560 Autosamplers Service Manual Chapter 1 Introduction 13 Mark the shipping container as FRAGILE In all correspondence refer to the instrument by model name or number and full serial number Where to Go for More Information NOTE This service manual is not intended to stand alone You will need to refer to information in other documents especially the Operator s Manual and the Spare Parts and Accessories Catalog In addition to this manual you can refer to the following resources New versions of this manual may be available under Service and Support on CETAC s Web site www cetac com ASX 560 Autosampler Operator s Manual available on the CETAC Web site and on the CD which comes with the autosampler ASX 560 Autosampler Spare Parts and Accessories Catalog available on the CETAC Web site CETAC Autosampler Safety Guide provides basic safety related information in a variety of languages Online help within the ASX Dashboard software Teledyne CETAC Technologies Customer Service and Support Phone 1 800 369 2822 USA only 1 402 733 2829 Fax 1 402 733 19
28. iscouraged WARNING CAUTION CAUTION CAUTION ASX 560 Autosamplers Service Manual Chapter 1 Introduction 7 External Parts Identification Figure 1 1 ASX 560 Autosampler Front View The following components are located on the front of the autosampler and are shipped with the autosampler see Figure 1 1 Sample Tray The sample tray holds the rinse station sample racks and standards vials in place The tray also contains small spills Sample Vial Racks Standards Vials Rinse Station Arm The arm moves the sample probe horizontally Z Drive The Z drive moves the sample probe vertically The Z drive assembly includes a Y axis slider block and guide plate as well as the sample probe The Z drive attaches onto the autosampler arm Power Indicator Lamp The LED indicates that the autosampler is connected to a power source and turned on Sample Tray Head Sample Vial Racks Rinse Station Arm Z Drive Assembly Power Indicator Lamp Base Z Y X ASX 560 Autosampler Operator s Manual Chapter 1 Introduction 8 Figure 1 2 ASX 560 Autosampler Back View The following components are located on the back of the autosampler and are shipped with the autosampler On board peristaltic pump Serial Ports The COM1 port connects the autosampler with the analytical instrument s host computer The COM2 port connects the autosampler to other ext
29. ler Operator s Manual Chapter 6 Diagrams 56 Motors Home Sensors LED Pump E Chain
30. mpler arm Figure 2 1 Y Axis Lead Screw Never lubricate the lead screws The lead screw nuts are compounded with a dry film lubricant which is intended to be used without additional lubricants Oiling the lead screws will cause gumming galling and binding of the moving parts 4 Wipe the autosampler exterior and base until they are clean using a towel dampened with a lab grade cleaning agent followed by a towel dampened with clear water Pay special attention to the Y axis slider block and the autosampler arm 5 Wash the sample tray in a warm detergent solution Make sure you remove all spills and stains 6 Rinse the sample tray with water and then dry it Ensure that the sample tray is thoroughly dry 7 Replace the sample tray on the autosampler base Replacing the Z Drive These instructions assume you are installing a new standard model Z drive How Does the Z Drive Work The Z drive is driven by a length of cable A rotor on the back of the autosampler moves the cable which slides the probe up and down on the Z drive A mounting block on the back of the autosampler pivots back and forth to allow free motion of the cable while preventing the cable from kinking CAUTION ASX 560 Autosamplers Service Manual Chapter 2 Basic Maintenance 17 How Should I Care for the Z Drive Do not allow the cable to bend sharply Avoid pushing up on the slider or pushing on the Z drive cable Do not tighten the thumbs
31. ray from the base Remove the Z Drive Removing the Z drive reduces the chance of accidental damage and allows you to remove the cover from the autosampler Reverse the steps in Replacing the Z Drive beginning on page 16 1 Loosen the nut on the crash block 2 Loosen the thumbscrew on the Z axis rotor and pull out the Z drive cable 3 Remove the thumbscrews which secure the Z drive to the Y axis carriage 4 Slide the Z drive off the Y arm ASX 560 Autosampler Operator s Manual DRAFT Chapter 4 Disassembling the Autosampler 32 Remove the Cover 1 Remove the 4 screws from the back of the autosampler Figure 4 1 Cover Screws 2 Pull the cover forward Remove the Splash Shield The splash shield protects internal components from corrosive or conductive chemicals 1 Remove the 2 screws from the top of the splash shield Figure 4 2 Splash Shield Top Screws 2 Remove the 2 screws from the front of the splash shield Figure 4 3 Splash Shield Front Screws ASX 560 Autosamplers Service Manual DRAFT Chapter 4 Disassembling the Autosampler 33 3 Lift the right side of the splash shield as viewed from the front then slide the shield to the left Figure 4 4 Lifting the Splash Shield 4 Lift the shield up and out of the autosampler Remove the Base It is not always necessary to remove the base from the autosampler head but doing so can make it easier to move the autosampler around to ac
32. s illuminated while plugged into the autosampler cycle the autosampler power switch The autosampler sample probe should move up and the autosampler should initialize After initialization the power LED on the front of the autosampler should light up If the cords are properly connected power is available the external power supply is good and the unit still does not initiate continue troubleshooting Communications Interface Problems Operation of the autosampler is directed by the host computer A malfunction can indicate a problem with the RS 232 or USB cable connected between the host computer and the autosampler or with the configuration of the software on the host computer The following sections explain how to troubleshoot these problems RS 232 Serial Cable Problems 1 Check the RS 232 cable to ensure it is plugged in to the COM1 port on the autosampler If the cable is plugged in ensure that it is tightened properly and not damaged in any way Note that the cable must be plugged into the COM1 port not the COM2 port 2 Check the host computer to ensure that the RS 232 cable is connected to the appropriate COM port If the cable is plugged in ensure that it is tightened properly and not damaged in any way 3 Check the serial port settings 9600 N 8 1 If the wrong port or baud rate is selected change the configuration USB Cable Problems Either RS 232 or USB may be used but not both at once A
33. sprocket on the lead screw Figure 5 13 X Axis Drive Belt In Position 11 Tighten the motor screws ASX 560 Autosampler Operator s Manual Chapter 5 Repair Procedures 52 Replacing the USB Port 1 Remove the cover 2 Remove the splash shield 3 Disconnect the cable from back of the USB port PCB Figure 5 14 USB Port Connector 4 Unscrew the USB port Figure 5 15 USB Port PCB 5 Install the new port ASX 560 Autosampler Service Manual Chapter 5 Repair Procedures 53 Replacing the Main Circuit Board EQUIPMENT DAMAGE FROM ELECTROSTATIC DISCHARGE Use standard ESD precautions such as a wrist strap and a static free work surface 1 Remove the cover 2 Remove the splash shield 3 Slide the arm to the right 4 Disconnect all of the cables Note where each cable was plugged in On each edge of the circuit board no two connectors are identical If you don t bend the cables to far out of the way it should be pretty easy to get them back in the right spot Figure 5 16 Removing the Cables 5 Remove the 4 screws Figure 5 17 Removing the Screws 6 Replace the board CAUTION ASX 560 Autosampler Operator s Manual Chapter 5 Repair Procedures 54 Figure 5 18 Main Circuit Board with Connections 7 If necessary use the ASX Dashboard software to program the firmware version and personality 6 Diagrams Wire Routing and Cable Connections Power Serial Cable ASX 560 Autosamp
34. stries Inc KYNAR is a registered trademark of Arkema Inc KIMWIPES is a registered trademark and KIMTECH SCIENCE is a trademark of Kimberly Clark Worldwide Inc Super Lube is a registered trademark of SYNCO Chemical Corporation All other marks are the property of their respective owners 3 Contents 1 Introduction 5 About This Manual 5 Who Should Read This Book 5 Important Safety Precautions 5 General Precautions for Protecting the Autosampler 6 Repair Strategy 6 External Parts Identification 7 List of Replaceable Parts 10 How to Obtain Spare Parts 11 Setting Up a Service Area
35. sure the probe is hitting positions correctly CAUTION Rotate to Move the Z Drive Z Drive ASX 560 Autosampler Operator s Manual Chapter 2 Basic Maintenance 22 Replacing the Home Flag Guide Plate The autosampler uses a Y axis home position flag to verify that the Z drive is fully in the home position over the rinse station Some applications use a version of this part which also extends forward to provide a guide plate for the sample probe The home flag can be replaced if it is damaged You will need a short handled slotted screwdriver 1 Shut down and unplug the autosampler 2 Remove the screw 3 Replace the home flag 4 Replace the screw The home flag does not need to be adjusted or trimmed Figure 2 9 Home Flag Home Flag Screw 23 3 Troubleshooting the Autosampler In the event that the product does not function properly isolate the problem to determine if it originates in the host computer the analytical instrument or the autosampler This chapter explains how to troubleshoot autosampler problems If you cannot solve a problem using the steps given in this chapter you should contact Teledyne CETAC Technologies Customer Service and Support Summary of Common Problems Problem Possible Cause Solution Autosampler does not initialize AC Power Cord or DC power cord not connected Plug AC power cord firmly into wall plug and into desktop power supply Power LED is not illum
36. the Home Flag Guide Plate 22 3 Troubleshooting the Autosampler 23 Summary of Common Problems 23 Power System Problems 24 Communications Interface Problems 25 RS 232 Serial Cable Problems 25 USB Cable Problems 25 Software Configuration Problems 26 Z Drive Problems 26 Contamination and Carryover Problems 28 Using the C Term Terminal Program 28 ASX 560 Autosampler Operator s Manual DRAFT Contents 4 Starting C Term 29 Overview of the C Term Window
37. u Connect Disconnect Clear Terminal Buffer Copy Paste COM Port amp Status Baud Rate ASX 560 Autosampler Operator s Manual Chapter 3 Troubleshooting the Autosampler 30 Autosampler Commands The following commands are helpful for verifying autosampler operation This is not a comprehensive list of commands Command Description VER Returns firmware version HOME Returns probe to home position ABS x y z Moves to position defined in steps of 0 1 mm from the home position Example ABS 1000 1000 0 moves to X 100 mm Y 100 mm Z top PMP ON Turn the peristaltic pump on PMP OFF Turn the peristaltic pump off RINSE Moves probe to the rinse position extends and retracts the probe 3 times and starts rinse pump Stays in down position with pump running UP PMP OFF stops the pump DOWN n Moves the z axis down by n mm UP Moves z axis to the top position Table 3 1 Autosampler Commands Make sure that there is enough space for the probe to move Equipment damage can occur if the probe collides with an obstruction such as a vial or rack CAUTION 31 4 Disassembling the Autosampler This chapter presents a suggested sequence for disassembling the autosampler in order to reach its internal components NOTE In most cases complete disassembly is not necessary You only need to perform as many steps as are required to access the part you are replacing Remove the Tray Simply lift the t
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