PATHCENTRE™

75210151
Service Manual
Issue 3

Shandon Scientific Limited is an ISO 9001 and TickIT Accredited Company

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1PES00GB Iss 03
 The information contained in this document is intended for use by
qualified personnel only. The calibration, scheduled servicing,
troubleshooting, loading of software, and parts replacement
procedures should only be undertaken by personnel who have
been formally trained to service the instrument.

SAFETY NOTICES
Shandon instruments are designed to operate safely and consistently for many years. However, incorrect
actions by a user may damage the equipment, or cause a hazard to health. It is Important to know that:

i All persons who use or service the instrument must read and understand the Operator Guide supplied with the
instrument. Only operate the instrument in accordance with the instructions. Understand the functions and
construction of the instrument before you do work on it.
ii Hazardous and potentially lethal voltages above 90v A.C. are present in the equipment. Do not undo or
remove any access covers unless you are trained to do so. Make sure that the mains power is switched off at
the supply and at the instrument before you do work inside an area enclosed by an access panel. Always follow
the safety instructions.
iii It is very important that you use normal safety procedures and follow good housekeeping practice at all times.
Think about your actions, and use common sense.
iv Refer any problems or queries to the Shandon Service Department.
v Correct maintenance is essential to keep the equipment safe.
vi Only use accessories or replacement parts that are supplied or approved by Shandon.
vii The instrument is heavy (160 Kg; 352 lbs). Get help to move it or to lift it.
viii Many of the reagents used are highly volatile and flammable. Wipe up any spillage and make sure that the
electrical systems are safe before you operate an instrument that contains, or which has recently operated
with, reagents.
ix Wear appropriate protective clothing and make sure that the work area is well ventilated before you work with
reagents. Fill and empty reagent bottles in a fume cupboard. Close the storage containers with a tight seal
and store bottled reagents in a cool dry place at >0°C.
x If panels are removed while a program is running, make sure that no fingers or articles of clothing are allowed
within the area defined by the frame assembly. Mechanical components may suddenly start moving under
computer control and cause injury.
xi A number of the electronic components inside the Electronics Module can be damaged by static electricity
from your body. Make sure you wear earthing (grounding) wrist straps and that you are properly earthed
(grounded) before handling connectors or components associated with the Electronics Module. Static damage
may take weeks or months to manifest itself - do not take chances.
xii All earth (ground) straps and connections MUST be replaced on the Electronics Module after service and
before the Pathcentre is powered up.

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SECTION PAGE

INTRODUCTION 1.1
Warnings; Symbols; Safety; Tissue Processing; Toolkit; Abbreviations Used.

GENERAL DESCRIPTION 2.1

Principles of Operation ; Electronics Unit; Command Unit; Extensions

TECHNICAL DESCRIPTION 3.1

PCB Operation; Instrument Chassis; Power Supply; Components; Console; Software

INSTALLATION INSTRUCTIONS 4.1

To Unpack; To Install; To Level; To Load; To Load Software.

FUNCTIONAL TESTS 5.1

TO FIND AND REPAIR FAULTS 6.1

Error Messages; Flow Charts

PARTS REMOVAL AND REPLACEMENT 7.1

SETTINGS, ADJUSTMENTS AND AMENDMENTS 8.1

SPECIFICATION, ACCESSORIES AND SPARE PARTS LIST 9.1

DRAWINGS 10.1

INDEX 11.1

Appendix 1 (Notes)

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1.1 GENERAL

1.1.1 Pathcentre™ is an entirely new Enclosed Tissue Processor from Shandon. It is made with care
from good quality materials, and is designed for high reliability and ease of use. Many new features are
incorporated to make it easy to service, and advanced on-screen help facilities are provided.

1.1.2 This manual provides details of the service and maintenance requirements of the product. It is
intended for use by both Shandon trained engineers, and service engineers who may be unfamiliar with the
requirements of tissue processors. Consequently, a brief description of the job that Pathcentre™ does is
incorporated in this introduc tion.

1.1.3 Full technical details of the construction and scheduled service requirements of the instrument
are provided, supported by explanatory diagrams where appropriate, and fault finding and analysis procedures
are described together with disassembly and reassembly instructions. Circuit diagrams and descriptions
are provided, as well as a list of service replaceable parts.

1.2 NEW INSTRUCTIONS

1.2.1 If changes are made to servicing or maintenance procedures, you will get new instructions. These
will be on a new page that has a letter after the page number. Put the new page in the manual, take out the
old page that has the same number, and destroy it. The differences between the new page and the old page
will be underlined and the revision sheet provided with the new pages will provide details of the change.

1.2.2 Make sure that your instrument operates correctly when you use the new instructions. If it does
not operate correctly, contact Shandon Service Department.

1.3 WARNING NOTICES

THIS SYMBOL APPEARS IN DOCUMENTS AND ON THE EQUIPMENT TO WARN THAT

INSTRUCTIONS MUST BE FOLLOWED TO ENSURE CORRECT OR SAFE OPERATION.

This symbol appears in documents and on the equipment to warn that high temperatures may
be present

A warning is given in the document if there is a danger of personal injury or damage to

WARNING
equipment.

Note
Notes give more information about a job or instruction but do not form part of the instruction.

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1.4 TISSUE PROCESSING

1.4.1 Live tissue cells continue their natural living processes after they are removed from body sites.
However, because they no longer have their normal blood supply or other supporting environment, they quickly
begin to degenerate as they run out of required nutrients and gases. Eventually, each cell activates internal repair
mechanisms that result in the cell digesting itself by a process known as autolysis. It is therefore important that
the tissue sample (specimen) is not allowed to dry out, and that it is fixed or processed as soon as possible after
removal to prepare it for histological, cytological, or pathological analysis by microscope.

1.4.2 Histology looks at the shape and structure of live organisms in tissues; cytology is the study of
how cells behave in tissue, and pathology is the study of the effect of disease on tissue. For each of these
sciences, very thin sections of a sample of tissue are required for examination by microscope.

1.4.3 To preserve a specimen of tissue from decay, and to make it strong enough to be cut into
very thin sections, it is treated with a variety of reagents before being embedded in a high quality wax. The
wax physically supports the specimen so that it can be sectioned by microtome. Each section of
specimen is usually only three or four microns thick.

1.4.4 Specimen samples are put into individual holders (cassettes) and then loaded into Random or
Organised Pathcentre tissue baskets. Neurological, (or large Block) specimens are also accommodated in
specially designed tissue baskets. Loaded tissue baskets are then inserted into the Reaction Chamber of
the instrument where they are immersed in a variety of chemicals (reagents), one after the other, in
order to stabilise and preserve the specimens. The function of these reagents is to:

i ‘Fix' the specimen and stop decay;

ii Dehydrate the specimens ;
iii Clear the specimens of dehydrant;
iv Embed the specimens with a mechanical carrier (wax).

1.4.5 Most of the reagents used are highly volatile and Pathcentre™ employs specially selected materials
to ensure that the instrument does not contaminate the reagents, or interfere with the chemical reactions. Also,
because most of the reagents used are highly volatile and evaporate easily in air, they give off heavy inflammable
vapours when exposed to the atmosphere. Pathcentre™ is therefore of totally enclosed design which means that
the system is never open to the atmosphere during processing. There are two distinct benefits from this:

i The atmosphere within the Pathcentre contains saturated reagent vapours that prevent the
specimens drying out, and

ii The room or laboratory in which the Pathcentre is situated remains odour free and pleasant to work in.

1.4.6 It is important that the integrity of the totally enclosed design is maintained for the instrument to
function correctly.

1.4.7 Different process techniques affect the condition of specimens presented for analysis. Because the
results of analysis can often make the difference between life or death, and it is sometimes very difficult to
obtain a new sample if one is spoiled, it is extremely important that specimens are processed consistently well
and to repeatable criteria.

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1.4.8 Pathcentre™ can process up to 324 cassettes loaded in organised fashion. To ensure
consistently good processing of all specimens, under all conditions, facilities are provided to enable:

i the application of pressure or vacuum to the Reaction Chamber during processing to increase
penetration of the specimen by the reagent.

ii periodic gentle movement of the reagent into and out of the Reaction Chamber to refresh the contact
area of the specimen with reagent.

iii rotational movement of the of the tissue baskets while immersed in reagent to provide a stirring
motion.

iv heating of the reagent while it is contained in the Reaction Chamber.

v the use of Displacement Blocks which ensure correct filling of the Reaction Chamber to compensate
for volume when only a few cassettes are being processed.

1.4.9 The same options are available during the wax (paraffin) impregnation cycles. When impregnation
is completed the specimen are removed from the tissue processor and passed for embedding where each
specimen is repositioned to present the best surface for sectioning. More wax is then added and the specimen
is placed on a cooling tray to harden the wax so that sectioning by microtome can take place.

1.4.10 Wax is held in the tissue processor in four heated reservoirs whose temperature is sensed by a
digitising temperature encoder that enables software control of the wax bath temperature to within very
close limits.

1.4.11 It is recommended that Service Engineers familiarise themselves with the contents of the
Operator Guide before proceeding to perform any maintenance or repair functions on the Pathcentre™
Enclosed Tissue Processor.

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1.5 TOOLKIT

1.5.1 In addition to the standard toolkit it is recommended that the following tools are also carried
when servicing Pathcentre:

i Square drive torque wrench

ii 27mm square drive socket, ratchet, and Torque Driver.

iii 22mm open-ended spanner cut down in length to 160mm overall (Heated pipe connections).

iv Selection of Allen keys and torque drivers.

v Special tool P13509 - hinge adjustment.

vi 10mm open ended spanner (flatted) for access to reagent pipes at rotary valve.

1.6 TORQUE SETTINGS

Except where otherwise stated in Method or Assembly Drawings, all screws into brass or steel should be set
to the torque values listed below:

3mm 0.5 Nm 4.42 in-lbs

4mm 1.8 Nm 15.92 in-lbs
5mm 3.0 Nm 26.53 in-lbs
6mm 7.0 Nm 61.91 in-lbs

For Aluminium or Copper, the following apply:

3mm 0.3 Nm 2.65 in-lbs

4mm 1.2 Nm 10.61 in-lbs
5mm 2.0 Nm 17.69 in-lbs
6mm 5.5 Nm 48.65 in-lbs

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2.0 GENERAL DESCRIPTION

2.1 GENERAL

2.1.1 Pathcentre™ satisfies an International demand for a safe, reliable, easy to use, high volume
tissue processor for Histological, Cytological, Pathological, and general laboratory use. It uses a totally
enclosed system that combines simplicity of operation with high performance.

2.1.2 Two versions of the instrument are available:

i) Processing Module . Each Processing Module 2

3
(1) features a Command Console (2) mounted at
the rear of the top deck. Processing Modules can
each operate as a single stand-alone unit,

ii) Extension Units. Extension Units (3) provide

additional processing capacity. They are similar 1
to Processing Modules but do not have a
Command Console. Up to 3 Extensions can be 4
'daisy-chained' to o n e P r o c e s s i n g M o d u l e
b y p l u g - i n c o m m u n i cation links (4) to make
a maximum of four units controlled from a
single Command Console.

2.1.3 The main body of each unit comprises a rectangular frame 1320mm high X 550mm wide X 600mm
deep. The Command Console screws on to the Processing Module during installation. Processing Modules are
not interchangeable with Extensions and it is not possible to convert an Extension Unit into a Processing
Module simply by adding a Command Module. The frame is clad with decorative side panels held in position by
quarter-turn quick-release fasteners. To connect an Extension Unit, refer to Section 4.4.

3
2.1.4 The upper body of each unit contains a Reaction Chamber (1) in
which loaded tissue baskets are placed. A see-through lid (2) seals the Reaction 4
Chamber and locks shut before processing commences. Wax is stored in four
heated and sealed baths under a hinged lid (3) that removes by pulling gently
from its half-open position. Each wax bath is sealed with a positively
latching lid (4).
2 1

2.1.5 Wax bath temperature is controlled electronically from digitising

temperature sensors on the side panel of each bath. The processing reagents are
stored in two rows of six bottles behind the top-hinged upper and lower front
doors.

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2.1.6 An Electronics Module in the top rear right hand corner of each
processor (Processing Module or Extension Unit) controls the processing
cycle of that processor from instructions contained in programs held in the
Electronics Module of the Processing Module. The Operator defines the
programs via the keyboard of the Command Console. Programming
instructions are provided on screen and additional information is available
from a dedicated help key ( ). All programs stored in the memory of the
Electronic Module are protected from loss during power-down by two size
AA 1.5V batteries located in battery carriers in the Electronic Module. The
complete fuseholder assembly removes from the housing for fuse replacement.

2.2 PRINCIPLES OF OPERATION

2.2.1 The main components of the processor comprise:

i four wax (paraffin) baths (1) with lids and a removable lift
up cover, on an electrically heated manifold assembly
that also supports the Selector Valve

2 ii an electrically heated Reaction Chamber with a rear

3 hinged see-through lid (2)
1
4
iii a hollow central pillar in the Reaction Chamber with a
concentric drive shaft for a tissue basket carrier

iv an air inlet aperture in the side wall of the Reaction

Chamber, and an OVERFILL detector displaced
approximately 90º from the air inlet aperture

v an electrically driven and heated, 32 position, rotary

indexing Selector Valve (3)

vi an electrically driven Agitation Unit underneath the

Reaction Chamber

vii an electrically heated tube from the Reaction Chamber to

the indexing Selector Valve

viii tubes from the Selector Valve to the Reagent Bottles (4)

ix Solenoid Valves (5) and an electrically driven air pump(6)

with associated pneumatic tubing

x a programmable Electronic Module

6 5 xi a Command Console interface unit (Processing Module

only)

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2.2.2 When the Reaction Chamber is loaded
with tissue cassettes, its lid is closed and locked
shut before a processing program starts. The
rotary Selector Valve indexes under the control of
the program to make a connection between the
Reaction Chamber and the reagent bottle
specified in that step of the program. This fluid
can be reagent or wax (paraffin).

2.2 . 3 Energising solenoid valve 1 (SV1)

completes a pneumatic connection between the
air inlet aperture on the side wall of the Reaction
Chamber, and the inlet (vacuum) side of the air
pump. The outlet (pressure) side of the air pump
connects to the Air Bag and the reagent bottle via
solenoid valve 2 (SV2) in its de-energised state.
When the air pump operates, air is drawn from the
Reaction Chamber and passed to the selected
reagent bottle. 2.2.3

2.2.4 The imbalance of pressure that arises as the Reaction Chamber is evacuated, and the reagent
bottle pressurises, results in the transfer of fluid from its container to the Reaction Chamber, via the
Selector Valve. This results in the immersion of the cassettes in the selected fluid.

2.2.5
2.2.5 On completion of the immersion cycle,
fluid is discharged from the Reaction Chamber by
energising SV2 which connects the outlet (pressure)
side of the air pump to the air inlet aperture of the
Reaction Chamber. Simultaneously de-energising
SV1 connects the inlet (vacuum) side of the air
pump to the Air Bag and the appropriate
reagent bottle . The imbalance of pressure is
now oppo site that in 2.2.4 above resulting in the
transfer of fluid from the Reaction Chamber to the
container from which it came. The program then
advances to the next step.

2.2.6 When fluid transfer is complete, a third solenoid valve (SV3 on drawing 2.2.6 - page 2.4)
energises to release internal pressure or vacuum build-up. The metallised plastic Air Bag in the Accessories
Drawer operates as a temporary store to prevent the build up of pressure in the enclosed air system. It
allows variations in the volume of air in the system as it is subjected to temperature fluctuations or
dynamic changes in system pressure. A Vapour Trap Bottle (VTB) is interposed upstream of the Air Bag.
Its function is to receive condensate before it passes to the Air Bag. Fumes in the air condense in this
bottle which MUST be emptied weekly. Both the Air Bag and the Vapour Trap Bottle are held in the
Accessories Drawer.

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 Note
PRV1 not fitted in instruments
manufactured after June 1998

2.2.6 The Pneumatic System

2.2.7 The maximum output (dead end pressure) of the air pump is between 1.5 and 2 bar. Up to
and including June 1998 system pressure was regulated to 0.3 bar by pressure relief valve PRV1 which
by-passed excess air to the inlet side of the air pump. After June 1998, over pressurisation is presented the
pressure limiting function is performed by software switching of SV1, SV2 and SV3A second. Pressure
Relief Valve (PRV2), and a Vacuum Release Valve (VRV) are incorporated as additional safety precautions.
Should a blockage or other malfunction cause serious over pressurisation in the Air Bag (0.05 bar). PRV2
operates to discharge air safely to atmosphere via the activated Charcoal Filter (CF) in the Accessories
drawer. If the pressure in the air line to the Air Bag drops below 0.05 bar for any reason, then VRV operates
to allow air to be drawn into the system.

2.2.8 Pressure within the Reaction Chamber is monitored continuously by pressure transducer PTX
whose output comprises a frequency signal directly proportional to the pressure/vacuum in the Chamber.
Software converts this output into a pressure reading that is displayed on-screen as follows:

Actual Pressure Output of PTX Screen Display

(Bar) (kHz) (mBar)

0 3.0 0
0.6 3.90 600
1(Atmospheric) 4.50 1000
1.3 4.95 1300
2 6.00 2000

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2.2.9 An OVERFILL sensor in the Reaction Chamber signals to the Electronics Module to generate an
alarm when Reaction Chamber overfills with reagent or wax - normally due to over-loading with cassettes,
over-filling reagent or wax containers, or failure of the Reaction Chamber to drain properly. Similarly, if the
Reaction Chamber over-heats, an OVERTEMP alarm is generated.

2.2.10 Program instructions control the immersion times for samples. Optionally applied agitation
during this time can be by cyclically importing and exporting fluid between the Reaction Chamber and the
containers (bottles/baths)- or by angular movement of the tissue basket carrier, or both, according to program.

2.2.11 A built-in delay of not less than 15 seconds at the end of each process step allows reagent to
drain from the Reaction Chamber. The delay can be extended in 1 second increments, to a maximum of 120
seconds. When the delay times out the Electronics Module causes air to blow momentarily through the
Selector Valve at the existing valve position, and then indexes the valve to the next position.

2.2.12 Processed specimens are impregnated with hot wax from the electrically heated baths A, B, C, D
in sequence. The wax baths are mounted on a common manifold that is heated by four cartridge heaters.
Each cartridge heater is associated with one wax bath but cannot individually control the temperature of that
bath. The overall temperature of the baths is programmable between 45°C - 65°C.

2.2.13 The rotary Selector Valve is mounted directly on the Wax Bath heated manifold and is itself heated
electrically by two small cartridge heaters wired in series (230V instruments) or parallel (110V instruments).
The connecting tube between the Selector Valve and the Reaction Chamber is also electrically heated.

2.2.14 Wax is transferred into and out of the Reaction Chamber by the same means as that used for
transferring reagent i.e by creating a pressure differential between sealed compartments. Immersion times,
Reaction Chamber temperature, and the methods of agitation, if any, are programmed in exactly the same
manner as for reagents, as is the application of pressure or vacuum.

2.2.15 Flushing of the Reaction Chamber is mandatory after selection of a wax stage during processing
or testing. A STANDARD flush imports and exports reagent between the Reaction Chamber and bottle 15
for ten washes and the Reaction Chamber is heated to and held at 60°C; rotational agitation is applied.
After 20 minutes the First Flush reagent is replaced by the Second Flush reagent from bottle 16 for 5 more
minutes. During the second flush cycle 3 washes plus agitation are employed, and the Reaction Chamber
heaters are switched off. The total time for a standard flush is approximately 35 minutes including the time
taken for transferring reagents.

2.2.16 An EXTENDED flush operates in the same manner except that the time for the first flush is
extended to 40 minutes, with 20 agitations plus stirring. The second flush is again for 5 minutes with a
Reaction Chamber temperature of 35°C and with 5 agitations. The total time for an Extended Flush is
approximately one hour including the time taken for transferring fluids.

2.2.17 Draining contaminated wax from any of the four wax baths is a purely mechanical process and
fully explained in the Operator Guide. However, always check that the Wax Drain taps are fully closed after
use.

DO NOT OPERATE THE TAPS WHEN THE WAX (PARAFFIN) IS SOLID OR YOU MAY
WARNING DAMAGE THE TAP SEALS.

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2.3 ELECTRONICS MODULE

2.3.1 The Electronics Module comprises a metal box in the top right hand corner of the unit (viewed
from the rear) where it is held by a front plate and six screws. It contains programs and logic for operating
the instrument, and incorporates circuitry for fault analysis and for driving the LCD. It is a service
replaceable item and must be exchanged for a factory supplied replacement unit if found to be
faulty. A tamper evident seal is attached to the Electronics Module Box.

2.3.2 Principal components of the Electronics Module are:

1 Power Supply unit (P12593).

2 Batteries and holders (P12733).
3 Filtered mains inlet with filter switch fuses (75200087).
4 Reaction InterFace PCB (75230072).
5 I/O Connectors.
6 An audible alarm sounder (75220058) in the front closure panel.
7 EB 186 PCB (75230071)
8 Motherboard (75230071).

2.4 COMMAND CONSOLE

HIGH VOLTAGES ARE PRESENT IN THE COMMAND CONSOLE . TAKE CARE WHEN YOU
DISCONNECT OR DISASSEMBLE.

2.4.1 The Command Module is the user interface to input commands to the Controller PCB of the
Electronics Module, and to display the output. It comprises touch sensitive membrane keys, and a Liquid
Crystal Display (LCD). The Command Module does not itself perform command functions but translates
mechanical movement into logic signals for the Controller PCB of the Electronics Module. The logic signals
are acted upon by the Electronics Module to produce the desired response, and inputs to the display driver
PCB of the Command Module change the display to reflect the new status. The output of the display driver
can be to the screen and/or a printer of the type that typically connects to the LPT1 Centronix printer port of
an IBM compatible computer. The printer port of the Command Console is at the rear of the Console.

Note.
1 Wiring to the plugs and sockets is delicate. DO NOT pull the wire to disengage a connector. Use an
instrument screwdriver to gently separate the plugs and sockets.
2 Do not disturb or disconnect the white 15 way, 5 pitch connector attached to the LCD board.

WARNING U N P L U G T H E CONNECTOR AT THE COMMAND INTERFACE BOARD. UNDO THE

CABLES AT THE NON LCD END WHEREVER POSSIBLE.

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3.0 TECHNICAL DESCRIPTION

3.1 GENERAL

3.1.1 Pathcentre™ can be split into four basic sections:

i The Electronics Module.

ii The Main Chassis.
iii The Command Console.
iv The Software.

3.2 THE ELECTRONICS MODULE

The Electronics Module is situated in the top right hand corner of the instrument, viewed from the rear. It
houses all the control electronics and comprises a Controller Printed Circuit Board (PCB); the Interface (I/F)
PCB; the Motherboard; the Power Supply; and the Power Inlet which combine to control all functions of
the instrument.

From instrument No PAT415, all the Solid State Relays that drive the Air pump and all the heaters, pumps,
motors, chambers, wiring, pneumatics, and plumbing necessary to contain and transfer processing fluids
applicable for tissue processing are contained within the Main Chassis of the instrument.

Data is input to the Electronics Module via the Command Console which provides the user interface with the
Electronics Module, and the output is displayed on the Liquid Crystal Display (LCD) of the Command
Console.

3.2.1 The Controller PCB (EB186) is the principal logic and processing PCB in the Electronics Module.
The Controller PCB provides the functions that follow:

i It monitors the outputs of the temperature sensors.

ii It monitors the outputs of the pressure sensor.
iii It monitors the position of the 32 position rotary selector valve.
iv It monitors the switches of a three-way keypad, and drives the seven segment display digit.
v It drives the interface PCB to switch the mains and DC drives.
vii It provides a serial communications port to a Personal Computer (PC) to permit remote updating
of the system software. This is achieved by 1mByte ROM/FLASH memory microchips and an
on-board programming voltage selector.
viii It has a balanced serial drive to facilitate remote control of extension units which rely on 'daisy
chaining' to pass data from the master system from one extension unit to the next. This is a
provision for multi-unit installations when incorporated in the production units.
ix It provides battery backup of stored data. Data is lost if power is removed when the batteries
are discharged or disconnected.
x It provides expansion data/address/control bus updates for the RAM microchips of the screen
controller PCB which enables updating of the display.
xi Most significantly, the Controller Board provides hardware monitoring of software functions. If
the software becomes corrupted, U22 provides a reset signal for the microprocessor after 1.6

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3.2
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 seconds. A second function of U22 is as a power fail monitor whereby if the 5v line drops below
4.65 volts the reset line becomes active and is maintained active for 200msec after power up.
U22 also provides a warning to the microprocessor when a power fail is imminent by using a
comparator input to pin 9. The U22 chip also switches the SRAM power rail from 5V to battery
backup. Both the NMI and RESET lines have LCD indicators on the PCB for condition
monitoring. If the NMI LED is lit the indication is that the 5V line is low, or VR1 for the
comparator is set incorrectly. If RESET is lit permanently, the indication is that the 5V line is
below 4.65V. A flashing RESET LED indicates a software problem.

The principal components of the Controller PCB are:

i 186EB 20MHz microprocessor.

ii 4Mb ROM/FLASH.
iii 256Kb Random Access Memory (RAM).
iv RS232 Interface connector.
v RS485 Interface connector.
vi 48 Input/Output (I/O) connections.
vii Real time clock.
viii IIC communications.
ix Data/address/control expansion bus.
x Watchdog circuitry.

3.2.2 The Interface PCB has no controller of its own. The Interface PCB connects to the Controller PCB
via PL4, PL5 and PL6 and all system control passes through this PCB with the exception of those for the
Command Console and external communications.

Its main components are:

i Solid state relays.

ii DC drives.
iii Watchdog circuitry for the hardware.
iv Simple switches.
v Opto Electronics.
vi Overfill sensor.

3.2.2.1 The Solid State Relays (SSR) switch mains voltages to the agitate motor, and to the heaters, and
comprise four main types:

i S472 1 amp, low leakage.

ii ZPV4003b; 3 amp.
iii CX240D5: 5 amp.
iv and ZRA6010A 10 amp that is mounted in the centre of the PCB within a Heatsink.

The 230/115VAC switches 1 and 2 are used to configure the cartridge heaters of the Reaction Chamber inlet
in series with the heating mat for 240V operation, or in parallel for 110V operation. Switch 4 is for the single
voltage agitate motor which can be 240V or 110V depending upon instrument specification.

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3.4
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Switch 3, which is also marked for 230/115V selections, is monitored by the Controller Board to vary the
heater 'on' time and accommodate the two voltage ranges.

It is important that these switches are set appropriate to the local supply voltages
WARNING or over or under heating will result.

The SSR are driven by the Controller PCB through PL6 and the two latch microchips (U7 and U8). Light
Emitting Diodes (LED) are fitted to the PCB and are lit when the associated SSR is being switched. They
can be used in conjunction with the PRODUCTION SERVICES SCREEN to assist in fault finding and
diagnosis (see Table 3.1 Page 3.10).

i SSR1 CX240D5 Wax D 5 Amp LED 7

ii SSR2 ZPV4003B Selector valve 3 Amp LED15
iii SSR3 ZPV4003B Reaction Inlet 3 Amp LED16
iv SSR4 S742 Agitate Motor 1 Amp LED14 (inverse lit)
v SSR5 CX240D5 Wax C 5 Amp LED12
vi SSR6 CX240D5 Wax B 5 Amp LED11
vii SSR7 CX240D5 Wax A 5 Amp LED10
viii Chassis ZRA6010A Reaction Mats 10 Amp LED 17

3.2.2.2 The D.C. Drives are all controlled from the Controller PCB via PL6, (U6 and U7) for the following
functions:

i The bi-directional motor drive for the 16 way (32 position) Selector Valve is provided by U5
which is a 2 amp 'H' bridge driver. Control on pins 10 and 12 provide clockwise and anti-clockwise
rotation control, and rapid stop control. Pin 11 provides a drive disable facility which can be
used to provide a slow motor stop.

ii The Air Pump operates from 240 V (P13516) or 110 V (P13515) mains a.c. controlled through a
Solid State Relay (SSR) assembly (P13519). Up to Instrument Number PAT 415 the SSR
assembly was mounted on top of the pump; after PAT415 the SSR assembly is on the Interface
PCB. Drive for the SSR is derived from Transistors TR8 and TR9 via connector PL2z pins 15 and
16 to the Motherboard. The Motherboard routes these supplies to its PL4, pins 23 and 24, and
then via cableform 75220325 to the SSR. Switching of transistors TR8 and TR9 is from U8 of the
Interface PCB under the control of the EB186 PCB, via plug PL6.

iii The Lid Solenoid is a high current device that exceeds the capacity of the power supply. To
ensure that the lid circuit operates correctly, C11 is charged up to 24V then discharged by
switching the 8 Amp rated RL2 through the lid solenoid. Darlington driver U4 drives the relay
chip.

iv The Remote Alarm facility provides a Normally Closed (N/C) or Normally Open (N/O) switch for an
external alarm circuit. There is no power output from PL7. When an alarm condition exists, relay RL1
switches to enable the external circuit to detect the change of status. As long as the instrument is
powered up, U4 ensures that RL1 is energised. If power fails, or if a software error or failure

3.5
1PES03GB Iss 03
 occurs, RL1 is de-powered which signals a fault condition.

v Air Solenoids in the instrument are supplied with 24V to one side. The second side is driven to
ground to operate, by the action of the 500mA darlington driver chip U4.

vi The Heated Tube to the Reaction Chamber is heated by heater tape with one side connected
to 24V. The second side is switched through TR6 to ground. The capacity of TR6 is 2 Amp.

The status of each of these drivers can be monitored in the PRODUCTION SERVICES SCREEN facility, via
the Command Console.

3.2.2.3 The Watchdog Circuitry for the Hardware should not be confused with the software monitoring
watchdog of the Controller PCB. The hardware watchdog cuts all DC and 230/115V drives in the event that
the cable from the Controller PCB is faulty or not fitted, or if there is a failure of software control. Monitoring
is effected by looking for a pulse on pin 7 of U10 within 400ms of the receipt of the last pulse. When tripped
the Interface PCB stops all driving to force pin 6 of U10 low. This results in U9 driving the 'Enable' pins of
U6,7,8 with the consequence that all DC and mains voltage drives are disabled.

The combination of U10 and U9 also prevents sporadic driving of the power circuits when the input power
supply is inconsistent in that if the 5V power line falls to a value below 4.75V, then all drives are again
disabled.

U10 delays the powering up of the drives by 250ms during power up. The action of U9 produces a further
delay as the output from U10 is not allowed to pass until U9 is clocked from the output of the Controller
PCB.

3.2.2.4 The Simple Switches are as follows:

i thermal switches, in the manifold at the bottom of the Wax Baths, that cut-out at 110ºC.
ii the Lid Latch Closed lid detector microswitch.
iii the Accessories Drawer open detector microswitch.
iv the 3 way keypad of the Miniature Control Panel.

All these use the Interface PCB as an interconnecting board to pass signals to the I/O on the Controller
PCB. - mainly via PL4 and PL2.

3.2.2.5 The Opto-electronic devices operate on the 16 way Rotary Selector Valve to pass encoder signals
into the PCB on PL20. They comprise photo transistors configured with the collector as a normally open
switch that shorts to 0V on sensing the specified condition. The output is buffered through transistor array
U2, to provide greater drive, then through the Schmitt trigger chip U1. The buffered signals then pass to the
Controller PCB I/O via PL5. The status of the signals is displayed on LED 4 and LED 7.

3.2.2.6 The Overfill Detector circuit monitors the change in resistance of a hot thermistor as cooler fluid
covers it. A resistor (R4) in series with the thermistor across 12V restricts the current flow through the
thermistor. The thermistor cools when immersed in fluid, and its internal resistance rises rapidly which

3.6
1PES03GB Iss 03
results in a rapid increase in voltage at the junction of R4. The incremental change of voltage passes via the
de-coupling capacitor (C10) to operational amplifier U3 whose output now switches transistor TR1. One of
the Controller PCB I/O lines monitors this change in TR1. Variable resistor VR1 enables the gain of the
amplifier to be adjusted to compensate for variations in transistor parameters.

3.2.3 The Motherboard is mounted on the back panel of the Electronics Box and comprises a small 'L'
shaped printed circuit that acts purely and simply as an interconnecting component. The Motherboard
performs no logic functions.

3.2.4 The Power Supply is an 80 Watt switch mode unit that can supply:

i 5 Volts @ 8 Amp
ii +12 Volts @ 2.5 Amp
iii -12 Volts @ 2.5 Amp
iv 24 Volts @ 2 Amp

Note
1 A resistor (P13903) is fitted across pins 2 and 6 of connector J2 to load the 5V supply sufficient to
provide a consistent output.
2 The 24 Volt rail is fully loaded.

The power supply meets all international safety standards, and has a leakage of less than 500µAmp. The
power for the mains operated devices is switched directly from the mains by the solid state relays on
the reaction Interface PCB.

Mains inlet power is connected to the instrument via a three pin plug and socket that inputs to a high grade
medical filter. An integral live and neutral mains switch is incorporated, with a fuse holder in both the live
and neutral lines. Both fuses are 10 Amp fast blow approved fuses.

WHEN YOU SERVICE OR REPAIR THE PATHCENTRE IT IS POSSIBLE TO APPLY

POWER WHILE THE ELECTRONICS MODULE IS NOT IN ELECTRICAL CONTACT
WITH THE INSTRUMENT CHASSIS.

ALWAYS MAKE SURE THAT THE EARTH STRAP FROM THE CASING OF THE
ELECTRONICS MODULE IS ELECTRICALLY CONNECTED TO THE PATHCENTRE
CHASSIS BEFORE YOU CONNECT MAINS SUPPLY TO THE INSTRUMENT.

IF IT IS NOT, THE INSTRUMENT CHASSIS COULD BECOME LIVE UNDER CERTAIN

FAULT CONDITIONS .

3.3 THE MAIN CHASSIS

The instrument chassis houses all the components necessary to store reagents and wax (paraffin) and to
transfer these fluids into and out of the Reaction Chamber, Fluid transfer is achieved by suction at the
destination receptacle. An air pump operates to provide pressure at its outlet, and suction at its input. The

3.7
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application of the pressure and suction for fluid transfer is controlled by three solenoid valves. The selection
of source and destination receptacles is controlled by the setting of the multi-way Selector Valve.
The status of the pneumatic system is monitored by the pressure sensor.

The Reaction Chamber is fitted with an OVERFLOW sensor, and there is a small motor that operates a
crank mechanism to reciprocate the specimen holder through the fluid in the Reaction Chamber to ensure
thorough penetration. The Wax reservoirs are heated, and temperature controlled, and the Selector Valve
and melted-wax-transfer- tube to the Reaction Chamber are also heated. Failure of the heating system here
can result in the wax solidifying in the tubes and valve which involves a major strip-down to clear.

Heating is by a combination of mains operated cartridge heaters in the Selector Valve and wax reservoir
manifold, mat and band heaters on the Reaction Chamber, and low voltage heater tape on the transfer tube.
The performance of all the heaters (apart from the transfer tube heaters) is monitored by temperature
sensors and the signals generated by the temperature sensors are used to switch on and off the SSR on the
Interface Board in the Electronics Module.

Manually resettable electrical cut-out switches in the Reaction Chamber inlet, the Reaction Chamber, the
wax reservoir manifold, and the Selector valve serve to provide additional protection against over-
temperature of any of these components.

Each TEMPERATURE SENSOR produces a square wave whose mark-to-space ratio is in proportion to the
temperature of the subject device. A typical signal output from a temperature sensor is shown.
T0 T1 T2

The actual temperature of the device is established from the formula:

((T1 / T2) - 0.32) / 0.0047

The repetition frequency is in the range 1 - 4 kHz and the signal line is sampled by the microprocessor, via
the xilinks programmable port. The conversion from time period to calculated temperature is then displayed.
Each transducer is a three wire device supplied from 5V, 0V and the signal line. A decoupling capacitor is
fitted between the 5V and 0V lines to prevent spurious changes in the signal out.

The PRESSURE SENSOR transducer is a diaphragm actuated strain gauge that vents to atmosphere, and
which contains voltage to frequency conversion circuitry. It is supplied from 0V and 12V and provides a
square wave signal that oscillates between 0V and 5V. The square wave frequency is proportional to the
pressure of the pneumatic system, relative to atmosphere. The pressure transducer signal is directly
monitored on the microprocessor timer input.

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Pressure is calculated as P(mbar) = (Frequency -3000) x 0.667
[atmospheric pressure is assumed to be 1000mBar]

3.4 THE ROTARY VALVE

The multi-way rotary valve comprises a main body assembly in three principal sections. The upper section
carries a 24VDC motor and gearbox that drive the selector mechanism of the central section; the central
section contains a delryn or carbon filled PTFE central port to radial port seal/channel, an opto encoder disc,
and opto transmitter / receiver disc optos. The lower section carries the connectors for the pneumatic tubes
to the reagent bottles and wax baths. Two 120VAC cartridge heaters are installed in the bottom section to
heat the whole assembly and ensure that only hot air passes to the wax baths. This prevents solidification of
wax in the tubes.

The DC motor is controlled by the Electronics Box and indexes the valve through 32 port positions that
alternate between blind and open such that there are 16 open port positions for selection. Normal
advancement is to the next closed port position, and involves a three stage movement as follows:

i to the next closed position;

ii next open position,
iii one index position back to the closed position in i.

Control of the cartridge heaters is also via the Electronics Box. The heaters are mains fed and connect in
series for 230VAC installations, and in parallel for 115VAC installations.

The opto disc contains 6 opto devices to facilitate decoding of the valve positions. Four of these (A0, A1, A2
and A3) provide decoding information for 16 port positions in the form of a gray code. The remaining two
optos provide port open and port closed information. These six signals are all read by the microprocessor
through its xilinks I/O lines via the Interface PCB and the Motherboard. The status of the signals is displayed
by LED on the Interface PCB, and also on the PRODUCTION SERVICES SCREEN of the Command
Console.

Fault diagnosis is assisted by the LED indications derived from the disc optos as shown in TABLE 3.1 -
INTERFACE BOARD LED INDICATION SIGNIFICANCES: (Next Page).

Note:
1 The Rotary Valve can only be serviced by the replacement of the opto device, the opto disc drive
coupling and the motor

3.5 MINIATURE CONTROL PANEL

The Miniature Control Panel, or Unit Control Panel, comprises a three pad keyboard and a seven segment
digital display. The key pads are designated STOP, RESET and LID and on being pressed each key pulls
the logic Hi output to ground potential to provide the key-pressed signal. There are thus three outputs from
this panel. There are six inputs to the panel: three of the inputs drive the keypad LED via TR1, TR2 and
TR3; the remaining three inputs are used to drive the display driver chip. All the signals are
coupled to and from the microchip via a 14-way ribbon cable and eventually through the xilinks
programmable port.

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3.4.5 TABLE 3.1 - INTERFACE BOARD LED INDICATION SIGNIFICANCES

(Lit = logic 0)

LED5 LED4 LED9 LED8 LED7 LED6 VALVE

N P A0 A1 A2 A3 POSITION FUNCTION
Off Lit Off Off Off Off 15 Flush 1
Off Lit Lit Off Off Off 16 Flush 2
Off Lit Lit Off Off Off 1 Reagent 1
Off Lit Off Lit Off Off 2 Reagent 2
Off Lit Off Lit Lit Off 3 Reagent 3
Off Lit Lit Lit Lit Off 4 Reagent 4
Off Lit Lit Off Lit Off 5 Reagent 5
Off Lit Off Off Lit Off 6 Reagent 6
Off Lit Off Off Lit Lit 7 Reagent 7
Off Lit Lit Off Lit Lit 8 Reagent 8
Off Lit Lit Lit Lit Lit 9 Reagent 9
Off Lit Lit Lit Lit Lit 10 Reagent 10
Off Lit Off Lit Off Lit 11 Wax 'D'
Off Lit Lit Lit Off Lit 12 Wax 'C'
Off Lit Lit Off Off Lit 13 Wax 'B'
Off Lit Off Off Off Lit 14 Wax 'A'
Lit Off x x x x Undetermined

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1PES03GB Iss 03
3.6 AIR PUMP

A small uni-directional diaphragm pump at the bottom left hand side of the main chassis powers the pneumatic
system. It is driven by a nominal 50 W AC motor that operates at 240 V or 110V depending on the
instrument specification. Applied power to the motor is controlled by the Electronics Box.

3.7 AGITATE MECHANISM

Agitation of the specimens is achieved by a bell crank mechanism that acts on the tissue basket support
in the centre column of the Reaction Chamber. The bell crank is driven by a small synchronous motor (375
r.p.m 3.5 W) through a reduction gearbox to which the motor is fastened. The complete assembly of motor,
gearbox, and crank mechanism is suspended on a frame beneath the Reaction Chamber.

The agitate motor operates from 240 Volt or 110 Volt mains dependent on the specification of the
instrument. Control is from the Electronics Box.

3.8 HEATERS

The wax reservoirs are mounted on a cast manifold with four cartridge heaters installed - one for each
reservoir. Control of the heaters is effected by software that uses inputs from temperature sensors mounted
on the sidewalls of the wax reservoirs. Protection is provided by bi-metal cut-outs that are monitored by
the software to remove power from the heaters if the bi-metal switches go open circuit.

Additional protection for the instrument is provided by hard-wired resettable thermal cut-outs in the neutral
line to each heater.

IF THE MANUALLY RESET CUT-OUTS OPERATE, BE AWARE THAT THE ASSOCIATED

HEATER, WIRING, AND BI-METAL CUT-OUT ARE LIVE, UNLESS THE SOFTWARE HAS
ALSO DETECTED AN OVER-TEMPERATURE AND SWITCHED THE HEATER OFF.

3.9 PNEUMATIC VALVES

Three 12V DC 3 W solenoid valves sit on a manifold at the bottom rear of the instrument. They switch the
direction of air flow from the uni-directional air pump. An LED in the cap of each valve lights when the valve
coil is energised to show that the valve has switched, or is trying to switch. This provides useful diagnostic
information as indicated in TABLE 3.2 - SOLENOID VALVE LED SIGNIFICANCES.

3.11
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TABLE 3.2 - SOLENOID VALVE LED SIGNIFICANCES

SV1 SV2 SV3 PUMP VALVE PORT RESULTANT ACTION

OPEN

OFF ON OFF ON 3 Pumping from Reaction Chamber to Bottle 3

ON OFF OFF ON 3 Pumping from Bottle 3 to Reaction Chamber
X X ON X X Equalising System Pressure
OFF ON OFF ON 11 Pumping from Reaction Chamber to Wax Bath D
ON OFF OFF ON 11 Pumping from Wax Bath D to Reaction Chamber

3.10 COMMAND CONSOLE

The Command Console is the user interface to input commands to the control electronics, and to display the
current status of the instrument. It comprises membrane keypads that translate mechanical operation into
logic signals for the main Controller PCB, and a Densitron LCD.

The most significant PCB within the Command Console is the

DBC02 board that drives the display screen. Logically the
DBC02 sits between

i the system I/O that contains the registers that

configure the DBC02 to drive the screen
hardware, and

ii the system memory RAM that contains

information for the screen display.

LCD synchronisation pulses, byte clocking pulses, the bit shifting clock pulse, 8 data bits, and power rails for
the LCD are generated by the DBC02 and passed to the controller board expansion bus via 34 signal lines
through the Command Interface Board within the Command Console. This Command Interface Board also
connects the screen to the DBC02 via a 15 way cable.

Although potentiometers VR1 and VR2 are present on the DBC02 board, neither has any
significance as VR1 is overridden by the contrast control (VR2) of the Command Interface Board.
Potentiometer VR2 of the DBC02 is by-passed and has no effect.

3.12
1PES03GB Iss 03
 To January 1998

After January 1998

COMMAND CONSOLE COMPONENT LAYOUT

The Command Interface Board of the Command Console provides six functions:

i it performs impedance matching for the high speed data signals between the Controller PCB (of
the main chassis), and DBC02 (C16 - C47)
ii it sets the contrast for the display (VR2)
iii it sets the brightness for the display (VR1)
iv it provides the parallel interface for the printer (PL2)
v decodes the signals from the keypads (PL3)
vi it allows the LCD to be connected (PL10)

Termination for the 10 MHz data stream is achieved by 100pF capacitors and 100 ohm resistor networks.

Illumination for the LCD is provided by a 2 W fluorescent tube at the side of the screen. Power for this tube
is supplied by the 12V rail. Brightness is controlled by an Inverter Board which limits the power available,
with the level set by potentiometer VR1 of the Command Interface Board. Access to VR1 for adjustment
is by a knob in the rear panel of the Command Console. A second knob controls contrast via VR2 which
sets the level for an emitter follower configuration using TR1 to supply a low impedance negative supply
rail to the LCD via PL10.

3.13
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Power to the tube can be cut by TR2 of the Command Interface Board under the control of the CNT line from
the main chassis Controller PCB.

The LCD matrix takes 1 W from the 5 Volt power rail and has its own dedicated electronics. It is a relatively
fragile device and should not be physically abused nor have the electronics or connectors interfered with in any
way while power is on.

The 15 way and 5 way connectors that connect to the screen and the Inverter Board
WARNING are extremely fragile. Try to not disconnect them. Detach from the Command
Interface Board. DO NOT PULL THE WIRES.

The parallel printer port on PL2 has a low rate data stream. It is used to log the progress of the instrument
and to print out programs and service data on demand. Driver microchips U2 and U3 drive this port and are
themselves driven by serial clocked read and write bus (llC) from the main chassis Controller PCB via PL1.
Drivers U1 and U2 are additional parallel driven by llC. They are used to support the keypad matrix of the
Command Console.

The printer cable must be properly screened and terminated and must not be more than 3m long e.g.Inmac 1964-1.

3.11 SOFTWARE DESCRIPTION

3.11.1 Overview

The software developed for Pathcentre provides for continuous control and monitoring of routine instrument
operations, and also the means to control of specific, non-routine, tasks. Routine operations are as follows:

i to control the rotary valve.

ii to monitor the temperatures and to control the heaters.
iii to control the pressure.
iv to control the communications system.
v quality control.

3.11.2 Routine Operations

To Control the Rotary Valve the controller is able to detect an error in the position of the valve, or a failure of
the valve drive system. If a valve position error occurs during a processing cycle, the valve controller
attempts to rotate the valve to the last correctly reported position. Simultaneously, the controller also
attempts to draw the applicable reagent for the last reported good position of the valve. This is to protect the
tissue samples from drying out. The corrective action occurs before the error is reported to the user.

To Monitor the Temperatures and To Control the Heaters seven temperature sensors are distributed
throughout the instrument. Each sensor is monitored constantly and a new set of temperature readings is
obtained at intervals of between 4 and 10 seconds. The temperature readings are input to the heater controller
which compares them with the applicable target temperatures. The heater controller then calculates the
demand for heat, and uses PWM to vary the total current in each heater. The algorithm for the Rotary Valve,
Reaction Chamber and Inlet Heater ramps any change in target to prevent a large overshoot in temperature
if an attempt is made to heat an empty Reaction Chamber.

3.14
1PES03GB Iss 03
Note
1 The heater PWM algorithms limit the maximum current drawn when the instrument is operated from
110V supplies. This results in a slower rate of rise of temperature than for instruments that operate
from 240V supplies.

The software uses the pump and the air solenoids (SV1, SV2 and SV3) to control the pressure. The
software runs in an active or a passive mode. In active mode the pump is used to raise or lower the
pressure; in passive mode the majority of control is performed using only SV3.

To Control the Communications System the Processing Module has a communication link to each attached
Extension, and has facility for a remote PC to monitor or access data by a remote diagnostic PC. The
communications software operates with the RS232 and RS485 communications ports of the Processing
Module. The algorithms that detect and communicate with Extensions make the response rate of the
Pathcentre appear constant - irrespective of the number of Extensions attached. The same software also
controls the diagnostic link.

A Quality Control counter sums the passage of weeks so that a datum is available to calculate service
intervals with respect to user preferences. The software resets the counter for each parameter, on receipt of
a manual input, and produces a warning when the set time for each parameter times out. Typical of the
parameters is the replacement interval for the charcoal filter.

3.11.3 Non-Routine Tasks

The Process Cycle involves start up and stop actions that run in conjunction with a reagent cycle for each
step in the program. Before the processing cycle starts the instrument initialises the rotary valve, and performs
a lid test to ensure that the lid seal is effective. The lid is not tested again during the entire processing cycle,
unless the program is stopped and the lid opened.

After the lid test is completed, the rotary valve is indexed to connect the Reaction Chamber to the reagent
bottle applicable for that step in the program. The pressure controller then draws a vacuum in the Reaction
Chamber. The vacuum, and the connection to the reagent bottle, causes the selected reagent to transfer
into the Reaction Chamber. A ‘bubble detect’ algorithm runs while the fluid transfer takes place to look for a
continuous rise in pressure, in the Reaction Chamber, when all the reagent has been transferred. Detection
of this rise in pressure signals the end of the transfer. If the ‘bubble detect’ algorithm is triggered correctly,
then the transfer is considered to have taken place correctly and the rotary valve closes. The instrument
then waits for the programmed immersion time to expire.

Any agitation, heating, pressurisation or vacuum that is programmed to take place at that immersion step is
now applied for the pre-set time or frequency.

3.15
1PES03GB Iss 03
When the processing steps are completed, the instrument performs fluid transfer ‘confidence checks’ before
an attempt is made to blow the reagent from the Reaction Chamber back into the applicable reagent bottle.
The ‘confidence checks’ are to make sure that the instruument can release any residual vacuum or pressure,
and that it can draw vacuum and raise pressure. If successful, the ‘confidence checks’ ensure that fluid can
be drawn back into the Reaction Chamber, to keep the tissue samples covered, when the current contents
of the Reaction Chamber have been blown out.

When the confidence checks are concluded, for any step other than for the last step in a program, the rotary
valve opens and the reagent is blown back into the applicable reagent bottle. If, for some reason, the
reagent is not successfully blown back into its reagent bottle, the instrument attempts to draw the same
reagent back into the Reaction Chamber in order to protect the samples.

The rotary valve closes when all the reagent is blown out, and the programmed ‘Drain’ period starts. The
drain period allows the maximum volume of reagent to return to the reagent bottle before the next reagent is
drawn in. This ensures minimum carry over of reagent from one bottle to the next.

The operations that follow the Drain period depend on whether reagent or wax is the subject of the last
transfer. The Reaction Chamber is lightly pressurised while the Reaction Chamber drains. Any fluid that has
drained to the bottom of the Reaction Chamber is blown out when the rotary valve opens again. This cycle is
repeated if more steps in the program follow.

‘Underfill’ recovery algorithms are used. The selection of which of four algorithms is employed depends on
the type of underfill. If the underfill occurs on the first step, the Reaction Chamber is emptied and the alarm is
reported immediately. No automatic recovery is possible. If an underfill occurs on a wax step the instrument
attempts to draw the next wax, and continue. If this fails, the instrument uses a simple timed method to
attempt to draw the last wax back into the Reaction Chamber.

Other recovery actions depend on how the user sets the recovery options. If an underfill occurs while
BACKUP is selected, the instrument attempts to blow the fluid that has underfilled back into its reagent
bottle and then indexes back to and draws in the last reagent that was successfully used. The instrument
then indicates an alarm and waits for intervention by the operator.

If an underfill occurs while RECOVER is selected, the instrument searches forward to find a reagent that has
the same name as the reagent that underfilled. If the forward search is successful the reagent just found is
used to substitute for the underfill. If the forward search is unsuccessful, a backward search is used to find a
previously used reagent to substitute for the reagent that underfilled. If this search is successful, the
instrument draws the substitute reagent and continues with the program, avoiding the faulty bottle. If no
substitute reagent is found, the instrument operates as if BACKUP was selected.

Drain transfers the last reagent or wax from a processing cycle. If the program finished in a reagent step the
last of the reagent is blown out of the Reaction Chamber so that the instrument is immediately available for
the next processing cycle

3.16
1PES03GB Iss 03
If the program finished with wax, the wax is blown back into the wax tank. An audible warning then sounds
to warn the operator that the tissue samples are not immersed. All the heaters associated with the Reaction
Chamber are then switched off, with the exception of the heaters for the inlet manifold. The inlet manifold
heaters remain energised to prevent wax from solidifying in the pipes. A flush cycle must be performed after
each wax cycle. The operator removes the tissue samples before the flush is started.

The Flush cycle is selectable as Standard or Extended. Each flush is an identical sequence except for the
duration of each step. The first step is normally a transfer of Xylene from reagent bottle position 15 to the
Reaction Chamber. Heat is applied to the Reaction Chamber for the duration of the immersion time and is
only controlled after a target temperature of 60°C is attained. In the second half of the immersion time, the
reagent is agitated vigorously to improve cleaning. Agitation is effected by creating a vacuum in the Reaction
Chamber, and then opening the valve. Air at ambient temperature then rushes into the Reaction Chamber to
splash the flush reagent comprehensively throughout the Reaction Chamber. Agitation is used in the second
half of the immersion period only so that the rush of cool air does not delay heating of the reagent. The
rotary valve closes when the vacuum that caused agitation collapses.

Note
1 A preheat stage is run before an attempt is made to draw in the first flush reagent if the instrument
has been left with a drained wax bath for more than 10 minutes.

When the first flush cycle is completed the ‘First Flush’ reagent is pumped back into the bottle in position 15
and the second flush reagent is drawn in. The second flush reagent is usually alcohol from reagent bottle
position 16. The flush cycle is the same as before but without heat applied, and for a shorter duration.

After the second flush cycle is completed the operator may do a ‘Rinse’ cycle. The normal procedure is to
exchange the bottle in position 16 with a bottle that contains the requisite rinse reagent - usually water - and
to select ‘Rinse’ from the soft key options. A rinse cycle takes approximately five minutes, including fluid
transfer times, and may be repeated as often as desired.

Note
1 The unit will not be available for use following a flush cycle until ‘COMPLETE’ is pressed.

Abort is a simple and straightforward cycle. If a program is aborted the instrument determines whether the
Reaction Chamber is empty or not. If the Reaction Chamber is not empty, fluid is blown out of the Reaction
Chamber using a timed method rather than the process cycle method that tries to minimise bubbling.

Another program can be started after the ‘Abort’ is completed if the abort occured before wax is drawn into
the Reaction Chamber. However, if Abort occurs after wax has been drawn the instrument MUST be flushed
before the next program will run.

3.17
1PES03GB Iss 03
3.11.4 Software Issues and Up-Dates

The software releases are in the format “752-0D09 Issue ‘x’ - Date”. The history of software issues and
up-dates is briefly as follows:

Issue No Date Description

1 16/08/95 Test purposes only

2 25/09/95 Multi-language; new temperature measurement; No-Load pump start
3 20/10/95 Drawer Switch reversed; Event Log timing to 1 second.
4 30/10/95 Heater gains (110V) adjusted; Pressure transducer Start-Up.
5 07/11/95 Support for new pump and rotary valves.
6 22/11/95 Force (pump) Lid open; Production Services changes.
7 16/02/96 Rinse; Flush error handling.
8 12/04/96 New temperature control cut-outs/algorithms.
Test 07/02/97
9 20/03/97 Multi-module; Remote Access; Shadow Reagents; new Set End time.
10 16/12/97 New PCB support for Reaction Chamber Interface; new UK phone no.
11 21/05/98 Supports removal of Pressure Relief Valve; Cold Processing;
Extended Valve Error continues (not useable in shallow tank units)
12 27/08/98 Low Bubbling Software to ease wax blockages’ improve fluid transfer
error recovery

3.11.5 To Load the Software

The disc contains the download utility to program Pathcentre from a computer (either a portable or a PC).
You can either download a complete set of software e.g. when a new Pathcentre is installed, or just parts of
the software e.g. a correction to a single language. The sequence for a full install is as follows:

1 Select the applicable floppy disc “752 0D09 Iss ‘x’ - Date
2 Switch the Pathcentre OFF
3 Connect the cable 75220418 from COM1 of the computer to the 1010101 port of the
Pathcentre.
4 Switch ON the computer. Make sure the computer is in DOS (you will see a c:\> prompt on the
screen).
5 Insert the Floppy disc into the applicable disc drive.
6 Type ‘a:’ (or the relevant disc drive letter) then press ENTER (Carriage Return) (you will see
the a:\> prompt on the screen).
7 Type “PRCU Install” then press ENTER (Carriage Return).
8 Switch the Pathcentre ON.
9 Wait for all the files to download and the Successful Completion report.
10 Remove the disc from the computer, switch off the computer and disconnect the cable
75220418 from COM1 of the computer and the 1010101 port of the Pathcentre.

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4.0 INSTALLATION INSTRUCTIONS
4.1 INTRODUCTION

THE TRANSPORT CRATE IS 1160mm HIGH, 1260mm WIDE, AND 780mm DEEP AND WEIGHS
APPROXIMATELY 200kg (440 lbs). USE MECHANICAL AIDS AND GET HELP BEFORE YOU TRY
TO MOVE OR TO LIFT THE TRANSPORT CRATE OR YOU MAY INJURE YOURSELF. MAKE
SURE THAT YOU HAVE ADEQUATE SPACE TO MANOEUVRE.

4.1.1 Check that the label on the crate conforms with the order. Inform Shandon immediately if there are
any breakage or shortages. Quote the Order Number, Invoice Number, Delivery Note number, and the date.

4.2 TO UNPACK
4.2.1 The Pathcentre unit is mounted on its side on a wooden pallet inside the crate. An accessories box
is fitted on top. Keep the wooden pallet between the crate and the floor. Open the crate from the top.
Remove the accessories box and check that the contents are as listed in Table 4.1.

THE BINDING STRIPS ARE IN TENSION - WEAR PROTECTIVE GOGGLES AND GLOVES
BEFORE YOU CUT THE STRAPS. USE A PIECE OF HEAVY CLOTH TO PROTECT
AGAINST WHIPLASH.

i ii iii iv

4.2.2 With the help of assistants lift the shell of the crate vertically and remove it to a safe place.

4.2.3 Slide the unit on its spine along the pallet until its base projects beyond the pallet. Stand on the free
end of the pallet. Get assistance to lift the top end of the instrument vertically and pivot the instrument until it
rests on its wheels. Press down on the (red) brake actuators to lock the wheels.

Note
1 The instrument is heaviest at the top before it is loaded with reagents.

4.2.4 Undo and remove the four bolts that attach the transport spine to the unit. Remove the spine.
Insert the four bolts into the captive nuts provided on the spine. Retain the spine in a safe place for future
transportation of the Pathcentre.

4.1
1PES05GB Iss 03
 4.2.4

4.2.5

4.2.6

4.2
1PES05GB Iss 03
4.2.5 Remove the right hand side panel from the packaging. Connect the earth (ground) cable from the
frame of the Pathcentre to the earth connection on the right hand side panel. Secure with the nut and wash-
er.

4.2.6 Insert the lugs at the bottom of the right hand panel into the slots at the bottom of the frame. Push
the panel in until it fits flush in the frame. Turn the two catches a quarter-turn clockwise to secure.

4.3
1PES05GB Iss 03
 4.3.2

4.3.3

4.3.1

4.4.1 4.5.1

4.4
1PES05GB Iss 03
4.3 TO ASSEMBLE THE PROCESSING MODULE

Note
1 Instructions preceded by two asterisks ( ) apply only to Processing Modules that have an integral
Command Console.
**

** Hold electrical connectors by the body only. Some components in the Electronics
Module are sensitive to static electricity. You may cause damage if you touch the pins or
terminals.

Note
1 The Console has keyhole fasteners that locate over two fixed studs. Locate the holes over the studs
and push the Console away from you to secure, then fit the screws.

4.3.1 ** Position the Command Console above the aperture. Fit the two plugs on the flying leads to their
corresponding sockets underneath the Command Console. Use the captive locking screws to secure the
metal multi-way connector in position. Use the screw and washer to attach the tag of the green and yellow
coloured earth (ground) wire to the terminal. Push the Console on to the snap fasteners. Fit the two screws
at the front of the Console.

4.3.2 ** Align the hinge box above the snap fasteners. Push down on the hinge box to secure.

4.3.3 Press the O of the ON/OFF ( l / O ) switch to make sure that the instrument is switched off. The
switch is at the rear of the unit. Select the applicable mains lead and attach it to the socket next to the
ON/OFF switch. Plug the supply end of the mains lead into the wall socket.

Note
1 A proprietary Ground Fault Circuit interruption (earth leak detection) device may be fitted
at the wall socket as an additional electrical safeguard.

4.4 TO CONNECT AN EXTENSION

4.4.1 Connect a Communications Link from the Processing Module (that has the Command Console) to
the first Extension Unit. A second Communications Link is 'daisy chained' from the first Extension Unit.
Similarly, connect the third Extension to the second. Do not connect more than three Extension Units.

4.5 TO CONNECT A PRINTER

4.5.1 Connect the data input cable of an appropriate line printer to the Centronix connector on the rear of
the Command Console. Any dot matrix, ink jet, or laser printer that typically connects to the LPT1 Centronix
printer port of an IBM* compatible computer is suitable. The printer cable must be properly screened and
terminated, and should be not exceed 3m in length (e.g. Inmac 1964-1).

4.5
1PES05GB Iss 03
4.6 THE I/O CONNECTORS

4.6.1 The lOlOl connector provides facility to load and to down load software
between Pathcentre and a portable computer or IBM compatible Personal
Computer.

4.6.2 The Left Arrow and Right Arrow connectors are for Communication
Links to the Extension Units

4.6.3 The lower connector is a switch for a Remote Alarm annunciator. The
switch rating is 250V 3A a.c.

4.6.1
Note
1 There is no output power from the Remote Alarm connector. Normally Closed / Normally Open switch
contacts change state when an alarm exists. This change of state can be detected to, operate a
remote alarm annunciator.

4.7 TO LEVEL THE INSTRUMENT

4.7.1 Pathcentre is set level at the factory. Further attention should only be
necessary to compensate for local on-site irregularities in the floor level. It is
important that the instrument is made level before it is loaded with reagents and
wax (paraffin).. It is extremely difficult to adjust the castors afterwards, due to
the additional weight. The instrument is considered level when all four castors
support equal loads, the Reaction Chamber drains correctly, and spills of fluid
on the top deck do not run.

4.7.2 Make sure that all the wax baths are drained and that all the Reagent
bottles are removed before you attempt to adjust the castors:

i Decide which of the castors requires adjustment. Use the movable

wrench to turn the top locking nut clockwise (viewed from above) to
loosen it. It is necessary to remove the accessory drawer if the front 4.7.1
castors are to be adjusted.

ii Get help and use chocks between the instrument and the floor to take the weight off the castors you
require to adjust.

iii Use the movable wrench to screw the castor shaft into or out of the frame of the instrument. Screw
clockwise (viewed from above) to screw in the castor and lower Pathcentre; screw anti-clockwise to
screw out the castor and raise the Pathcentre.

4.6
1PES05GB Iss 03
 iv Make sure that the two front castors are correctly aligned - front to back - so that the Accessories
drawer is free to open. Use the movable wrench to turn the locking nut firmly anti-clockwise (viewed
from above) to lock the threaded shaft of each castor.

4.8 TO LOAD THE SOFTWARE

Application software for running Pathcentre is supplied on a 3½ inch floppy disc suitable for use with an IBM
compatible computer (either PC or portable).

To load the software proceed as follows:

1 Make sure that you have the correct version of software on the floppy disc.

2 Switch the Pathcentre OFF

3 Connect the cable 75220418 from COM1 of the computer to the IOIOI port of the Pathcentre.

4 Switch ON the computer. Make sure the computer is in DOS (you will see a c:\> prompt on the
screen).

5 Insert the Floppy disc into the applicable disc drive.

6 Type ‘a:’ (or the relevant disc drive letter) then press ENTER (Carriage Return) (you will see the
a:\> prompt on the screen).

7 Type “PRCU Install” then press ENTER (Carriage Return).

8 Switch the Pathcentre ON.

9 Wait for all the files to download and the Successful Completion report.

10 Remove the disc from the portable (or PC), switch off the portable (or PC) and disconnect the
cable 75220418 from COM1 of the PC and the IOIOI port of the Pathcentre.

4.7
1PES05GB Iss 03
4.8
1PES05GB Iss 03
5.0 FUNCTIONAL TESTS

5.1 INTRODUCTION

5.1.1 These tests are designed to enable service personnel to test a Pathcentre Tissue Processor after
service or repair.

It is essential that service personnel are familiar with the use of the Production Service
WARNING facility before any work is carried out on the Pathcentre.

5.1.2 The range of tests is restricted to operation of the complete instrument. It is not possible to bench
test individual parts or sub-assemblies without extensive specialist test equipment. It is essential that only
factory issue spares and replacements are used to do a repair or considerable and costly damage can result.
Similarly, proprietary items such as motors and transducers are supplied against rigid specifications. Any
variation from these specifications could cause a malfunction.

5.1.3 The Electronics Unit is designed for continuous operation for the lifetime of the product . It should
not normally require any service attention. There are no standard tests for the Electronics Unit. Use the
Flowcharts in Chapter 6 to assess its suitablity for use. If an Electronics Unit proves to be faulty, you must fit
a factory supplied 'Service Exchange' replacement unit.

5.1.4 The effects of common malfunctions are shown, as they occur, in the banner heading of the display.
The Production Services facility enables Service Engineers to run tests to establish the cause or causes of a
malfunction. The Production Service facility is a very powerful tool for manipulating individual components
within the instrument. Misuse of this facility can result in expensive and time consuming rectification.

IT IS VERY IMPORTANT THAT YOU FULLY UNDERSTAND THE RESULTS OF YOUR

ACTIONS WHEN YOU USE THE PRODUCTION SERVICES FACILITY. CHECK AND
RE-CHECK THE SYSTEM SETTINGS AFTER YOU HAVE OPERATED THE INSTRUMENT
FROM THE PRODUCTION SERVICES SCREEN.

5.1
1PES05GB Iss 03
5.2 PRODUCTION SERVICES

5.2.1 Fault diagnosis is assisted by the PRODUCTION

SERVICES display. This display allows you to control significant
software functions, and to perform individual tasks, independant
of the automatic control system. Press and hold [RESTART] and
[LID] for 2 seconds to produce the display.

5.2.2 The Production Services Screen

8 April 1999
UIF = 0.f.m. BIOS = 0068 PRODUCTION SERVICES SCREEN

Temperature control Single Port Outputs Sequenced Actions For Display Only
Set Wax A temp 57 57 Valve 1 V is Off Close Rotary valve Drawer is closed
Set Wax B temp 57 57 Valve 2 P is Off Open Rotary valve Lid latch closed
Set Wax C temp 57 57 Valve 3 EQU is Off Pressurise chamber Overfill: OK
Set Wax D temp 57 56 Valve 4 WC1 is Off Evacuate chamber Overtemp: O.K.
Set valve temp 67 Valve 5 WC2 is Off Release RC P or V 110V - 0
Set RC temp 32 Fast pump is Off Draw fluid into RC 240V - 1
Set Inlet temp 32 Slow pump is Off Blow fluid from RC Buttons: 0
Reset Memory Agitate motor is Off Valve to Reagent 1 Last key: 186
Force open lid Start LED is Off Valve to Flush 1 Valve is closed
Kill running program Stop LED is Off Index Valve 1 Port Valve at port 15
Exit to Pathcentre Lid LED is Off Valve to first wax Pressure 1035mBar

Select Printouts Exit

KEY

UIF = User Inter Face BIOS = Basic Input Output Source

O.f.m = Number (Variable) 0068 = Version (Variable)

The significance of selections in the four columns are as follows:

i Temperature Control. The top seven rows in the first (left hand) column of figures show the SET
temperatures for the components indicated (Max = 80°C). The second (right hand) column shows
the ACTUAL temperature attained. Use the number keys to set the desired temperature Press
[Select], or use the arrow keys to move the cursor, to enter the new figure in memory.

5.2
1PES05GB Iss 03
Note
1 When you work with ‘Temperature Control’ selections you must press ‘Select’ before the new
parameters can take effect e.g. if you change 'Set Wax D temp' from 57 to 60 you must press
‘Select’, (or a cursor arrow key), before the new command is recognised.

The entries in the four remaining rows are self-explanatory:

RESET MEMORY
FORCE LID OPEN
KILL RUNNING PROGRAM, and
EXIT TO PATHCENTRE

RESET MEMORY wipes all user entered parameters, such as programs, reagent location
WARNING
data, Quality Control data, and the capability for remote access, from the battery backed
RAM . Use this facility with discretion.

ii Single Port Outputs. The ‘Select’ soft key changes to ‘Start’ when you cursor to the Single Ports
Output column. You can move the cursor up or down the status indicator for each device. Press
‘Start’ to change an OFF state to ON. The ‘Start’ softkey changes to ‘Stop’ when the cursor
highlights an ON selection. Press ‘Stop’ to change an ON state to OFF. You can only make one
selection at a time. When you press ‘Start’ with the cursor at the Start LED, Stop LED or Lid LED
selection, the result is a transitory change of state for lamp testing purposes. Cursor to the desired
station then watch the Unit Control Panel then press ‘Start’. The applicable LED should flash ON,
then return to unlit almost immediately.

It is important to know the effects that all driven actions might have on the status of the
WARNING Pathcentre when you use the Sequenced Actions facility. When Production Services are
entered while a program is running, the program is put on hold while Production Services are
selected. Adjustments made in the Sequenced Actions column kill the running program or flush
cycle at its current state. Make sure that you return the status of reagents etc to their 'Start of
Program' state before processing is resumed. OVERFILLS and serious spillage may result if you
simply 'Exit to Pathcentre'.

iii Sequenced Actions. The ‘Select’ soft key changes to ‘Start’ when you cursor to the Sequenced
Actions columnn. The Sequenced Actions column enables you to drive the listed devices to a desired
state for test and evaluation purposes. The options are as follows:

The current status of the valve is shown by a “Valve is closed” or “Valve is open” statement in
the For Display Only column. Similarly, the “Valve at port ‘n’” statement in the For Display Only
column shows the current Port selected.

The rotary valve is a 32 position indexing selector valve with 16 Port positions, and 16 Blank
positions. There is one blank position between each Port.

1 CLOSE ROTARY VALVE This command will move the valve from an open position to a
closed position at any port.

Note
1 Allow sufficient time for the valve to complete the move before you select the next command. Always

5.3
1PES05GB Iss 03
 check the actual status of the valve in the For Display Only column before you send the next
command . (If you cursor out of the selected position before the valve completes its move it may move
to the last position entered in memory). When the valve completes a move, the left softkey will change
back to ‘START’.

2 OPEN ROTARY VALVE This command rotates the closed rotary valve from a blank
position to the open Port. The status of the valve, and the Port selected, is shown in For
Display Only column.

3 PRESSURISE CHAMBER This command starts the pump and energises SV2 to pass air into
the Reaction Chamber. You must see “Valve is closed” in the For Display Only column before
you select PRESSURISE CHAMBER. The pressure obtained shows in the “Pressure ‘n’mBar”
statement in the For Display Only column.

Care must be taken: the pressure to the chamber will exceed normal operating
WARNING
pressures. Manual stop should be used.

4 EVACUATE CHAMBER This command starts the pump and energises SV1 to draw air
from the Reaction Chamber. You must see “Valve is closed” in the For Display Only column
before you select EVACUATE CHAMBER. The vacuum obtained shows in the “Pressure
‘n’mBar” statement in the For Display Only column. The pump stops when the system
vacuum reaches 500mBar.

5 RELEASE RC P or V This command energises SV3 which effectively equalises the

pressure in the pneumatic system.

6 DRAW FLUID INTO RC This command opens the rotary valve, starts the pump and
energises SV1.

Note
1 With the rotary valve set to the applicable port, fluid is transferred from the source bottle (or wax bath)
to the Reaction Chamber. The detection of bubbles signifies the completion of transfer. The pump and
SV2 are stopped and the rotary valve is closed.

7 BLOW FLUID FROM RC This command opens the rotary valve, starts the pump and
energises SV2.

Note
1 With the rotary valve set to the applicable port, fluid is transferred from the Reaction Chamber to the
source bottle (or wax bath). The detection of bubbles signifies the completion of transfer. The pump
and SV2 are stopped and the rotary valve is closed.

8 VALVE TO REAGENT 1 This command rotates the rotary valve to the first Port position i.e.
for Reagent Bottle 1. VALVE TO REAGENT 1 is inoperative if the rotary valve has previously
been set to a Port associated with a wax bath.
Note
1 It is mandatory that a Flush operation is completed after a Wax Bath position is selected, irrespective
of whether or not wax has been introduced into the Reaction Chamber. If you wish to proceed with
another Port selection, but do not want to enter a wax bath position, select “Valve to Reagent 1” and
INDEX THE VALVE 1 PORT at a time from there.

5.4
1PES05GB Iss 03
 9 VALVE TO FLUSH 1 This command rotates the rotary valve to the Port associated with
the reagent bottle in position 15.

Note
1 To avoid an unnecessary flush cycle, the value will run back through the reagents if wax has not been
selected.

10 INDEX VALVE 1 PORT This command rotates the Selector Valve to the next port position
with the valve closed. In practice the valve indexes 3 positions - the first indexed move is to the
blank (closed) position after the current Port; the second indexed move is to the next higher
port (open) position counting from Port 1. The third index is a reverse back to the blank
(closed) port just passed.

Note
1 These moves only occur in Production Services, and provide port width data for the log.

If you wish to select a lower numbered port, use 'VALVE TO REAGENT 1' then sequentially
press INDEX VALVE 1 PORT until the desired port is selected. This by-passes the flush stages
that are mandatory after a wax position is selected.

11 VALVE TO FIRST WAX This command rotates the rotary valve from whichever port
position is currently selected to the Port that connects to the rearmost Wax Bath ( BATH D).
Note
1 You must do a flush, or at least draw and blow bottle 15, after the rotary valve has been set to a wax
bath Port. To flush, insert a bottle that contains flush reagent (xylene) in position 15 then press:
“Valve to Flush 1”
“Draw fluid Into RC” - wait for the pump to stop then press -
“Blow fluid from RC” - wait for the pump to stop then proceed with other functions.
2 To avoid xylene contamination to bottle 1, draw and blow bottle 16 before running normal reagents

iv For Display Only. This column shows the current status of software controlled devices in the instrument.
Many of the devices in the instrument are electro-mechanical in construction and require time to
respond to a command. It is important that you allow each command to complete before you proceed to
enter a new command. Watch the screen, and especially the For Display Only column, to make sure
that the instrument is in a condition to accept, and to respond to, the new command.

5.3 WARNINGS

5.3.1 Warnings replace the SHANDON Pathcentre title header if the conditions that follow apply:

Lid Open
Drawer Open
Quality Control
Power fail has occurred
Underfill

5.3.2 The warning is removed after the applicable action is taken. The “Quality Control” warning
shows if one or more of the criteria set up in the Quality Control menu is breached. Refer to the Quality
Control Checklist.

5.5
1PES05GB Iss 03
Note
1 Power Fail messages will remain on the display until a flush has been completed. Power fails are not
displayed if the unit is in the ‘available’ mode - i.e. not running a program or flushing.

5.4 FAULTS

5.4.1 Faults are in dicated by an on-screen error message and an audible sounder. Each error
message starts with the introduction:

The following error has occurred: (number)

a description of the error

the remedial action to be taken.

Silence Alarm Continue Printouts

5.5 SPECIFICATIONS

5.5.1 The following results should be obtained during test:

Air pump outlet pressure (dead end) 2 Bar (29.4 p.s.i) max.

Wax Bath heater resistance 60 W each

Indexing selector valve heater resistance 280 W

Inlet heater resistance 140 W

Reaction Chamber side heater resistance 44 W

Reaction Chamber bottom heater resistance 44 W

Pipe heater 58 W

5.6
1PES05GB Iss 03
5.6 RESETS

5.6.1 A Reset enables the service engineer to return the software in the instrument to a known datum
point. Three such datum points exist:
RESET 5
RESET 6, and
RESET 7.

5.6.2 RESET 5 - General Reset A General Reset is used if the instrument 'locks up' or shows an error
from which it fails to recover. A General Reset breaks the control loop at any step in a program and prevents
further automatic operation until the instrument is restarted. The instrument restarts from the step at which it
stopped when the reset is terminated.

To do a General Reset press and hold pressed the [STOP] push-

button and the [RESTART] push-button of the Unit Control Panel
simultaneously. Keep the push-buttons pressed and switch the
instrument OFF then ON again by use of the mains switch at the
rear of the instrument. The 7 segment display of the Unit Control
Panel shows the number '5'.

To restart the instrument from the step at which it stopped, make

sure that a '5' shows in the display of the Unit Control Panel, then
press the [RESTART] push-button at the Unit Control panel.

Note
1 It is preferable to kill a running program from the Production Services facility. A General Reset resets
all the Quality Control counters.

5.6.3 RESET 6 kills all running programs and causes the WELCOME screen to show in the display.

To do a Reset 6 press and hold pressed the [STOP] push-button and the [RESTART] push-button of the
Unit Control Panel simultaneously. Keep the push-buttons pressed and switch the instrument OFF then ON
again by use of the mains switch at the rear of the instrument. Press [STOP] when the number '5'.shows in
the display of the Unit Control Panel. The display changes to show a number '6'.

Press [RESTART] at the Unit Control panel to perform the reset. This restarts the instrument in the normal
manner. If you have used the Production Services facility, make sure that conditions are satisfactory for the
resumption by automatic control.

5.6.4 RESET 7 completely clears the memory of user defined selections and sets the status of a newly
installed instrument.

To do a Reset 7 press and hold pressed the [STOP] push-button and the [RESTART] push-button of the
Unit Control Panel simultaneously. Keep the push-buttons pressed and switch the instrument OFF then ON
again by use of the mains switch at the rear of the instrument. Press [STOP] when the number '5'.shows in
the display of the Unit Control Panel. Press [STOP] again when ’6’ shows in the display. The display
changes to show a number '7'.

Press [RESTART] at the Unit Control panel to perform the reset. The instrument reverts to default settings
and requires re-programming.

5.7
1PES05GB Iss 03
5.7 PRINTOUTS

5.7.1 Pathcentre maintains a database that comprises a chronological record of all instrument activity,
including individual keystrokes. Specific items from this database can be reproduced as a printed report.

5.7.2 To obtain a printed report connect a printer to the Command Console (see Page 4.5 - To Connect
a Printer). Select the Production Services facility and press the PRINTOUTS soft key. A display of print
options appears. Use the number keys to make your selection.

BRIEF USER TEMP. SERVICE FULL

REPORT REPORT REPORT REPORT LOG

LAST PROGRAM TO RUN 9 1 90 93 99

2ND LAST PROGRAM 9 2
3RD LAST PROGRAM 9 3
4TH LAST PROGRAM 9 4
5TH LAST PROGRAM 9 5
LAST 7 DAYS OF PROGRAMS 9 6 91 94 96
FULL LOG CONTENTS 9 7 92 95 97
AS IT HAPPENS. 8 98

5.7.3 Definitions of Printout Clasifications

BRIEF REPORT List of Temperatures; Power Ups; Errors; Starts; Stops; and Resets
performed during the selected period

USER REPORT

TEMP. REPORT A listing of the temperature history and including Start/Stops; Fluid
Transfers, and Errors.

SERVICE REPORTS A performance monitoring report of the last program.

FULL LOG Full print out of the contents of the event log memory.

LAST PROGRAM TO RUN This may be the current running program.

nTH LAST PROGRAM Sequence of programs available for printing in latest first format.

LAST 7 DAYS OF PROGRAMS Data is written to memory in eight hour blocks and this selection prints
out the last 21 blocks of data i.e. one week.

FULL LOG CONTENTS All information contained in the event log memory is printed in the
selected format.

AS IT HAPPENS Printout concurrent with the activity. Requires a dedicated printer.

5.8
1PES05GB Iss 03
5.8 ADDITIONAL GUIDANCE TO USE PRODUCTION SERVICES

5.8.1 The mains fed heaters are energised by pulses of mains voltage. The Mark-To-Space ratio of the
pulse stream is determined by the software (as a % of demand) .from data provided by the temperature
sensors. The amount of heat called for can be displayed in the banner of the PRODUCTION SERVICES
SCREEN, and held there while in the PROCESS or other screens. This enables the performance of the
heaters to be monitored while on-line processing takes place. The complete display comprises ACTUAL
TEMP; SET TEMP; and % DEMAND for all mains fed heaters i.e. Wax Baths D, C, B, A, Valve, RC
(Reaction Chamber), and Inlet. (The Inlet Tube heater is 24V d.c. and is always on).

5.8.2 Press [RESTART ]and [LID ] simultaneously on the Unit Control Panel for two seconds (until the
tone) to display the PRODUCTION SERVICES SCREEN. Press [RESTART] and [LID] again for another
two seconds and the Temperature Monitoring Display appears in the banner space. You can now select
EXIT TO PATHCENTRE. The temperature display will restore in the other PROCESS and other screens.

5.8.3 To Delete the Temperature Monitoring Display from the PROCESS and other screens, press
[RESTART] and [LID] simultaneously on the Unit Control Panel for two seconds (until the tone) to display
the PRODUCTION SERVICES SCREEN. Press [RESTART] and [LID] again for another two seconds - and
then again for another two seconds. Select EXIT TO PATHCENTRE. The Temperature Monitoring Display
is not now accessible to the other screens.

(Wax Bath/Item) (D) (C) (B) (A) (V) (R) (I)

(Actual temp) 0056 0057 0057 0057 0000 0000 0000
(Set Temp). 0057 0057 0057 0057 0067 0032 0032
(% Demand) 0005 0000 0000 0000 0100 0100 0100
8 April 1999
UIF = 0.f.m. BIOS = 0068 PRODUCTION SERVICES SCREEN

Temperature control Single Port Outputs Sequenced Actions For Display Only
Set Wax A temp 57 57 Valve 1 V is Off Close Rotary valve Drawer is closed
Set Wax B temp 57 57 Valve 2 P is Off Open Rotary valve Lid latch closed
Set Wax C temp 57 57 Valve 3 EQU is Off Pressurise chamber Overfill: OK
Set Wax D temp 57 56 Valve 4 WC1 is Off Evacuate chamber Overtemp: O.K.
Set valve temp 67 Valve 5 WC2 is Off Release RC P or V 110V - 0
Set RC temp 32 Fast pump is Off Draw fluid into RC 240V - 1
Set Inlet temp 32 Slow pump is Off Blow fluid from RC Buttons: 0
Reset Memory Agitate motor is Off Valve to Reagent 1 Last key: 186
Force open lid Start LED is Off Valve to Flush 1 Valve is closed
Kill running program Stop LED is Off Index Valve 1 Port Valve at port 15
Exit to Pathcentre Lid LED is Off Valve to first wax Pressure 1035mBar

Select Printouts Exit

5.9
1PES05GB Iss 03
5.9 PROCEDURE 1 - AIR PUMP AND REACTION CHAMBER SEALS TEST

Object
To confirm that the air pump operates to specification, and that the Reaction Chamber seals correctly. It
differs from Procedure 2 in that the solenoid valve air circuit is isolated in this test.

Equipment
i 2m length length of nylon pneumatic tube (M03681).

ii Timer (0-300 seconds).

iii Paper wipes.

iv Notebook and pen/pencil.

Note
1 You need to know if the subject Pathcentre has a deep or shallow Reaction Chamber:

Deep = 190mm (approx.)

Shallow = 150mm (approx.)

Set Up
i Remove the Rear and the Left-hand Side Panel

ii Undo the two-pin plug / socket connection to the orange wires of the Inlet Pipe Heater. The plug./ socket
is located in the approximate centre of the space enclosed by the Rear Panel, and behind the air pipes.

iii Reattach the mains lead and switch the instrument ON.

iv Enter the Production Services menu (section 5.2.1).

v Make a note of the ‘Start of Processing‘ conditions with respect to the settings in the ‘Temperature
Control’ column, and the ‘Valve is ..’ and ‘Valve at port’ reports in the ‘For Display Only’ column.

vi In the ‘Temperature control ’ column of the display select ‘Set RC temp’ and use the number keys
to set the value to ‘0’.

vii Make sure that the indicated pressure in the ‘For Display Only’ column is 1000mBar ± 15mBar.

viii If applicable, remove the white PTFE lid seal and fit a Viton seal, then close the lid.

ix Make sure that the Reaction Chamber and the Inlet Pipe are at an ambient temperature of between
15°C and 25°C (NB. Residual heat in the Reaction Chamber will adversely affect the results).

x Disconnect the tube from the ‘T’-piece that attaches to the metal pipe that goes to the vapour trap jar
in the back of the unit.

xi Disconnect both the pneumatic tubes from the air pump in the bottom left corner
(do not disturb the connectors in the head of the pump).

5.10
1PES05GB Iss 03
 xii Connect one end of the 2m long pneumatic tube (equipment item (i)) to the left-hand port (suction)
side of the pump.

xiii Connect the free end of the 2m long pneumatic tube (equipment item (i)) to the third port of the
“Festo” T-piece.

Note
1 The pneumatic valves are out of circuit. Use the manual Emergency Vacuum Release (under the Lid
Lock) to relieve any residual pressure or vacuum.

Procedure
i Move the cursor to 'Close Rotary Valve' in the ‘Sequenced Actions’ column, then press ‘Start’.

ii When the valve is closed, move the cursor to 'Fast Pump' in the ‘Single Port Outputs’ column,
then press ‘Start’.

iii Draw a vacuum in the Reaction Chamber until the indicated pressure is 600mBar’ and press
‘Stop’.

Note
1 If the pressure fails to fall to 600 mBar in (iii) above, select ‘Pressurise Chamber’ in the ‘Sequenced
Actions’ column, then press ‘Start’. Then go to ‘Error 9: Failure to Pull Vacuum’ (Page 6.40).

iv Start the Timer (equipment item (ii)).

v At the end of 5 minutes the indicated pressure must not exceed 620mBar.

Note
1 If the indicated pressure is greater than 620mBar you must investigate and cure the source of leakage
before you continue with this test.

vi Disconnect the 2m long tube (equipment item (1)) from the left-hand (suction) port of the air pump.
Allow the Reaction Chamber to return to atmospheric pressure

vii Connect the free end of the 2m long tube (equipment item (1)) to the right-hand (pressure) side of
the air pump.

viii. With the cursor at the ‘Fast Pump’ selection press ‘Start’.

ix When the indicated pressure is 1300mBar press ‘Stop’ and , start the timer (equipment item (ii)).

x At the end of 5 minutes the indicated pressure must not be less than 1280mBar.

Notes
1 If the pressure fails to rise to 1300 mBar.in instruments with software up to and including Issue 10,
monitor the indicated pressure and adjust the Pressure Relief Valve to give a steadystate reading of
1300mBar ± 5mBar. Note the actual pressure reading. Then go to ‘Error 1: Failure to Pressurise the
Reaction Chamber’ (Page 6.33)

5.11
1PES05GB Iss 03
 2 If the indicated pressure is less than 1280mBar you must investigate and cure the source of leakage
before you continue with the test.

xi Disconnect the 2m long pneumatic tube (equipment item (i)) from the right-hand (pressure) side of
the air pump. Allow the pressure to equalise to 1000mBar ± 15%. Connect the tube to the left hand
(vacuum) side of the pump.

xii With ‘Fast Pump’ selected press ‘Start’ and monitor the fall in pressure indicated in the ‘For
Display Only’ column.

xiii When the indicated pressure is 900mBar start the timer.

xiv When the indicated pressure is 500mBar stop the timer and press ‘Stop’. Note the elapsed time.

xv Relieve the vacuum by removing the hose from the pump. When the pressure is 1000mBar ± 15%,
reattach the hose. Repeat tests xii and xiv above three times.

xvi The elapsed time for each test must be the same within ± 3sec. The average time for the three tests
must be within the range:
Deep Reaction Chamber 70 to 88 seconds
Shallow Reaction Chamber 58 to 74 seconds

To Conclude
i If the results do not meet the criteria set out above you must service the air pump. Refer to Chart
13A - ‘Pneumatic Circuit Diagnostics’.

ii Disconnect the pneumatic tubes and allow the indicated pressure to recover to 1000mBar ±15mBar.

iii Make good the original connections to the Pressure Transducer (PTX), the Reaction Chamber and
the Air pump heater wiring. Remove the Reagent Bottle from position 1and discard the contents.
Replace the original reagent into bottle position 1.

iv Restore the instrument to the Start of Processing condition as observed in ‘Set Up’ (step (v), then
move cursor to ‘Exit to Pathcentre’ and press ‘Select’.

v If applicable, remove the Viton lid seal and fit the white PTFE seal removed in Set Up step (vi). Close
and lock the lid.

Make sure that all earth leads are correctly reconnected if they have been disconnected
WARNING
during servicing

vi Replace the Rear and the Left-hand Side panels.

5.12
1PES05GB Iss 03
5.10 PROCEDURE 2 - FLUID CONNECTOR AND PIPE LEAK TEST

Object
To test the fluid system for leaks.

Equipment
i Spare reagent bottle.

Set Up
i Remove the Rear and Side panels.

ii Enter the Production Services menu (section 5.2.1).

iii Make a note of the ‘Start of Processing ‘ conditions with respect to the ‘Valve is ..’ and the ‘Valve at
port’ status reported in the ‘For Display Only’ column.

iv Move the cursor to ‘Release RC P or V’ in the ‘Sequenced Actions’ column and press ‘Start’.
Make sure that the ‘Pressure ‘ indicated in the ‘For Display Only’ column is 1000mBar ±15mBar.

Procedure
i Move the cursor to ‘Valve to Reagent 1’ in the ‘Sequenced Actions’ column and press ‘Start’.
Wait for the valve to complete the move.

Note
1 If you suspect leakage at one specific bottle position do and repeat Step (vii) until the ‘Valve at port
...’ position in the ‘For Display Only’ column is the same as the suspect position, then do Steps (ii) to
(v).

ii Move the cursor to the 'Draw Fluid into RC' selection in the ‘Sequenced Actions’ column of the
display, then press ‘Start’.
iii Wait for the fluid transfer to complete then check the pipes and connections for leakage. Do the
repair if you find a leak.

iv Move the cursor to the 'Blow Fluid from RC' selection in the ‘Sequenced Actions’ column of the
display, then press ‘Start’.

v Wait for the fluid transfer to complete then check the pipes and connections for leakage. Do the
repair if you find a leak.

vi Move the cursor to ‘Index Valve 1 Port ’ in the ‘Sequenced Actions’ column and press ‘Start’.
Wait for the valve to complete the move.

vii Repeat the Steps (vi) to (xi) for each bottle position.

viii Remove the spare bottle from the last bottle position.

ix Replace the Rear Panel and the Side Panels.

x Refer to ‘Set Up’ (iii). Re-establish the ‘Start of Processing ‘ conditions with respect to the ‘Valve is ..’

5.13
1PES05GB Iss 03
 and the ‘Valve at port’ status reported in the ‘For Display Only’ column.

To Conclude
i Make sure that there are no drips or discharge of fluid from any part of the system.

Make sure that all earth leads are correctly reconnected if they have been disconnected
WARNING
during servicing

ii Replace the Rear and the Side panels.

5.11 PROCEDURE 3 - AGITATE MOTOR AND LINKAGE TEST

Object
To confirm the action of the Agitation motor, and its linkages.

Equipment
i three cassette baskets.

Set Up
i Remove the left-hand side panel.
ii Enter the Production Services menu (section 5.2.1).

Procedure
i Move the cursor to the ‘Agitate Motor’ selection in the ‘Single Port Outputs’ column, then press
‘Start’.

ii Make sure that the top section of the centre column rotates slowly and steadily, backward and for-
ward.

iii Press ‘Stop’.

iv Install the cassette baskets in the Reaction Chamber.

v Press ‘Start’.

vi Make sure that the cassette baskets do not touch the overfill sensor, the air inlet, or the side-walls of
the Reaction Chamber.

5.14
1PES05GB Iss 03
 DO NOT INSERT FINGERS INSIDE THE AREA DEFINED BY THE FRAME WHILE THE
PATHCENTRE IS SWITCHED ON. THE AGITATE MOTOR IS POWERFUL AND MAY
CAUSE INJURY WHEN IT OPERATES.

vii From the side, view the agitate motor linkage. Make sure that that the agitate motor linkage does not
touch or wear any wires, pneumatic tube or hardware inside the instrument.

viii Press ‘Stop’ to switch the Agitate motor Off.

ix Press 'Exit’, then ‘Select’.

x Switch off the Pathcentre at the mains.

xi Make sure that all wires and tubes are correctly anchored with tie wraps and cannot tangle with the
agitate mechanism.

Make sure that all earth leads are correctly reconnected if they have been disconnected
WARNING
during servicing

xii Replace the left-hand side panel.

To Conclude
i The Agitate mechanism operates freely and without jerks.

ii The cassette baskets fit centrally within the Reaction Chamber and do not touch the sides, or the
overfill sensor.

5.12 PROCEDURE 4 - TEMPERATURE CONTROL TESTS

Object
To confirm that the heaters respond to ‘Set temperature’ commands.

Equipment
i No special equipment is required.

Set Up
i Remove the Rear and the Side Panels

ii Enter the Production Services menu (section 5.2.1).

iii Press and hold for two seconds the [RESTART] and [LID] push-buttons of the Miniature Control
Panel to obtain the Temperature Monitoring screen in the banner section of the display.

iv Make a note of the ‘Start of Processing ‘ conditions with respect to all the parameters.

5.15
1PES05GB Iss 03
Procedure

(Wax Bath/Item) ( D ) (C) ( B) ( A) (V) (R) (l)

(Actual Temp) 0056 0057 0057 0056 0000 0000 0000
(Set Temp) 0057 0057 0057 0060 0067 0032 0032
(% Demand) 0005 0000 0000 0000 0100 0100 0100

8 April 1995
UIF = 0.f.m. BIOS = 0068 PRODUCTION SERVICES SCREEN

Temperature control Single Port Outputs Sequenced Actions For Display Only
Set Wax A temp 60 56 Valve 1 V is Off Close Rotary valve Drawer is closed
Set Wax B temp 57 57 Valve 2 P is Off Open Rotary valve Lid latch closed
Set Wax C temp 57 57 Valve 3 EQU is Off Pressurise chamber Overfill: OK
Set Wax D temp 57 56 Valve 4 WC1 is Off Evacuate chamber Overtemp: O.K.
Set valve temp 67 Valve 5 WC2 is Off Release RC P or V 110V - 0
Set RC temp 32 Fast pump is Off Draw fluid into RC 240V - 1
Set Inlet temp 32 Slow pump is Off Blow fluid from RC Buttons: 0
Reset Memory Agitate motor is Off Valve to Reagent 1 Last key: 186
Force open lid Start LED is Off Valve to Flush 1 Valve is closed
Kill running program Stop LED is Off Index Valve 1 Port Valve at port 15
Exit to Pathcentre Lid LED is Off Valve to first wax Pressure 1035mBar

Select Printouts Exit

The Temperature Monitoring Display

i Set Wax A, Wax B, Wax C, Wax D, Valve, RC and Inlet to a temperature higher than the displayed
‘actual’ temperature and verify that the Temperature Monitoring display changes for each.
To Conclude
i Confirm that the desired responses were obtained.

ii Restore the temperature settings in the Temperature Control column to the ‘Start of Processing’
conditions observed in Set Up (iv).

iii Press ‘Exit’, then ‘Select’.

Make sure that all earth leads are correctly reconnected if they have been disconnected
WARNING
during servicing

iv Replace the left-hand side panel.

5.16
1PES05GB Iss 03
5.13 PROCEDURE 5 - ELECTRONICS MODULE SYSTEMS CHECKS

Object
To confirm that the hardware responds to command.

Equipment
i No special equipment is required.

Set Up
i Remove the Rear and the Side Panels.

ii Enter the Production Services menu (section 5.2.1).

iii Make a note of the ‘Start of Processing ‘ conditions with respect to all the parameters.

iv Move the cursor to the 'Kill Running Program', in the ‘Temperature Control’ column then press
‘Select’.

v Fit a reagent bottle that contains Xylene in the Flush 1 bottle position (bottle position 15).

vi Fit a reagent bottle that contains Alcohol in the Flush 2 bottle position (bottle position 16).

Procedure

Move the cursor in the Single Port Outputs’ Column

i Move the cursor to the 'Valve 1 V is ...' selection, then press ‘Start' and make sure that the display
changes to 'Valve 1 V is On'.

ii Listen for the 'click' as the valve operates, and make sure that SV1 energises* (the LED is lit**).

iii Press ‘Stop’. Make sure that the display changes to 'Valve 1 V is Off' and that valve SV1 de-
energises* (the LED is not lit**).
iv Repeat steps i to iii for ‘Valve 2 P is ...’ and ‘Valve 3 EQU is ...’

v Move the cursor to the 'Fast Pump is ...' selection, then press ‘Start'. Make sure that the display
shows 'Fast Pump is On'. Listen for the pump to start.

vi Press ‘Stop’. Listen for the pump to stop. Make sure that the display shows 'Fast Pump is Off'.

vii Move the cursor to the 'Agitate motor is ...' selection, then press ‘Start’. Observe that the top of the cen-
tre column in the Reaction Chamber rotates backward and forward and that the display shows 'Agitate
motor is On'.

viii Press ‘Stop’. Observe that the top of the centre column in the Reaction Chamber stops. Make sure
that the display shows 'Agitate motor is Off'.

ix Move the cursor to the 'Start LED is Off' selection.

x Watch the [RESTART] push-button of the Miniature Control Panel carefully, then press ‘Start’.

5.17
1PES05GB Iss 03
 xi Observe that the [RESTART] push-button LED flashes briefly, and that the display is 'Start LED is .Off’.

xii Move the cursor to the 'Stop LED is ...' selection.

xiii Watch the [STOP] push-button of the Miniature Control Panel carefully, then press ‘Start’.

xiv Observe that the [STOP] push-button LED flashes briefly, and that the display is 'Stop LED is .Off’.

xv Move the cursor to the 'Lid LED is ...' selection.

xvi Watch the [LID] push-button of the Miniature Control Panel carefully, then press ‘Start’.

xvii Observe that [LID] push-button LED flashes briefly, and that the display is 'Lid LED is Off’.

Move the cursor in the Sequenced Actions’ Column

i Move the cursor to the ‘Close Rotary valve’ selection, then press ‘Start’. Make sure that ‘Valve is
closed’ is displayed.

ii Move the cursor to the ‘Open Rotary valve’ selection, then press ‘Start’.. Make sure that ‘Valve is
Open’ is displayed.

iii Move the cursor to the ‘Close Rotary valve’ selection, then press ‘Start’.. Make sure that ‘Valve is
Closed’ is displayed.

iv Move the cursor to the ‘Pressurise Chamber’ selection, then press ‘Start’. Make sure that the
Pressure indication rises above 1200mBar and press ‘Stop’.

v Move the cursor to the ‘Evacuate Chamber’ selection, then press ‘Start’. Make sure that the
Pressure indication falls below 900mBar.

vi Move the cursor to the ‘Release RC P or V.' selection, then press ‘Start’. Make sure that the
Pressure indication returns to 1000mBar (±15mBar).

vii Move the cursor to the ‘Valve to Reagent 1’ selection, then press ‘Start’. Make sure that Valve
displays ‘Valve at port 1’.

viii Move the cursor to the ‘Valve to first wax’ selection , then press ‘Start’. Make sure that ‘Valve at
port 11’ is displayed.

ix Move the cursor to the ‘Index Valve 1 Port’ selection , then press ‘Start’. Make sure that the display
shows ‘Valve at port 12’.

Note
1 Tests (vii )to (ix ) confirm that the valve operates through all wax positions. The software demands that
a flush cycle is always performed after a wax position is selected, at any time, irrespective of whether

5.18
1PES05GB Iss 03
 or not wax is actually drawn into the Reaction Chamber. This ensures total cleanliness of the system.
It also lengthens the useful life of reagents, and minimises the danger wax contamination in the event
of a power failure.

2 It is necessary to do Flush 2 (alcohol) after Flush 1 to ensure that there is no carry over of Xylene into
the first processing stage after the tests are completed.

x Move the cursor to the ‘Valve to Flush 1’ selection, then press ‘Start’.

Note
1 Make sure that the Flush 1 bottle is filled with clean Xylene and correctly loaded in position 15.

xi Move the cursor to the ‘Draw fluid into RC’ selection, then press ‘Start’.

xii Wait for the transfer of fluid to complete.and make sure that all the fluid is drawn from bottle 15.

xiii Move the cursor to the ‘Blow fluid from RC’ selection and press ‘Start’.

xiv Wait for the transfer of fluid to complete.

Note
1 Make sure that the Flush 2 bottle is filled with clean alcohol and correctly loaded in position 16.

xv Move the cursor to the ‘Index Valve 1 Port’ selection, then press ‘Start’. Make sure that ‘Valve at
port 16’ is displayed.

xvi Move the cursor to the 'Draw fluid into RC' selection, then press ‘Start’.

xvii Wait for the transfer of fluid to complete.and make sure that all the fluid is drawn from bottle 16.

xviii Move the cursor to the 'Blow fluid from RC' selection and press ‘Start’.

xix Wait for the transfer of fluid to complete.

Checks in the ‘For Display Only’ Column

i Pull open the Accessories drawer. Make sure that the top row shows 'Drawer is Open'.

ii Push closed the Accessories drawer. Make sure that the top row shows 'Drawer is Closed'.

iii Press the [LID] push-button of the Miniature Control Panel. Make sure that the second row shows 'Lid
latch open'.

iv Close and latch the lid. Make sure that the second row shows 'Lid latch closed'.

To Conclude

i Investigate the cause of any malfunction. Use the Fault Finding Charts as necessary to locate a
fault.

5.19
1PES05GB Iss 03
 ii Restore the original ‘Start of Processing’ conditions as established in ‘Set Up’ step (iii).

iii Press ‘Exit’, then ‘Select’.

Make sure that all earth leads are correctly reconnected if they have been disconnected
WARNING during servicing

iv Replace the rear and side panels.

5.20
1PES05GB Iss 03
6.0 FAULT FINDING
6.1 INTRODUCTION
The charts that follow are designed to simplify the location and repair of faults. They are intended for use in
conjunction with the Production Services facility. Only those engineers who are familiar with the concept
and construction of Pathcentre, and who have attended a Shandon course of instruction, should attempt to
use the Production Services facility.

THE MANUALLY RESET SAFETY THERMAL CUT-OUT SWITCHES ARE HARD-

WIRED INTO THE NEUTRAL RETURN OF THE HEATER CIRCUIT.
BE AWARE THAT THE HEATER SYSTEM IS LIVE WHEN THESE MANUAL
RESET SAFETY SWITCHES INTERRUPT POWER SUPPLY TO THE HEATERS.

FUSES Two 20 mm fuses are fitted in the mains inlet filter assembly. You can replace them from outside the
Electronics Module. Use only F10A Fast Blow replacement fuses. (A T5A 1¼ in fuse is fitted in the SPIPS
inside the Electronics Module and is only accessible with the Electronics Box cover removed.)

Note
1 Some instruments have a 10 second power-up delay that makes the instrument appear dead when
first switched on. Other instruments have a three second power up delay before the LCD lights up.
These delays protect the integrity of the software on power-up in the event of a sporadic shut-down.

6.1 NEW BIOS (Changes to the Rotary Valve Controller for BIOS 201 Onwards)

The open and close commands now tie the valve position to a specific bottle or wax bath. Previously these
commands would not produce an error signal if the valve stopped at any open or closed position. The new
BIOS dictates that the valve can only stop at an open or closed position, at the correct bottle or wax bath.
With the old controller it was possible for the valve to skip a position, and cause an overfill. When the valve
now indexes from position to position, each intermediate position must be seen to match with the expected
intermediate positions. Previously, the valve indexed until it found the target position. In the event that an
in-between position was missing, the old controller drove the valve backward and forward indefinitely.

The timeout periods for the valve to successfully complete an operation are shortened. This minimises the
chance that the valve runs on too far if the opto system fails to detect the next position. All of the changes
now allow attempts to retry any valve errors.

For the software to calculate the next expected valve position, it must always know the current valve
position. After a 'reset', that information is lost. To make sure that the software always knows the position of
the valve before it starts, a synchronisation step is performed when a program cycle, drain cycle, or flush
cycle, starts.

The valve position commands from Production Services have some detail changes. These are to gather
information for the valve serviceability test, compared to the normal process versions. These routines do not
update the calculated position, or result in an error, if the position they stop at is not the next expected
position. Consequently, movement of the valve in PS can confuse the software that runs the processes
when you exit PS. It is essential to use the correct procedures when you use PS to move the valve, or
Error 30 or 39 will occur when the valve is next moved under programmed (rather than manual) control.

6.1
1PES06GB Iss 03
It is also important to note that the PS screen does not display errors. If a valve movement fails, the
ABORT touch key remains visible. Valve movement must be aborted, and then OPEN and CLOSE used to
re-synchronise the actual position of the valve with respect to the position calculated by the software. It is
possible that some hardware failures make it impossible to move the valve without an error occurring.

If 'MOVING' is always displayed in PS, you must OPEN and CLOSE the valve before you can do any other
movement of the valve. The same applies after a 'reset', otherwise the software uses the reported position
(often 15 moving) as the starting point for its calculations. This results in the valve moving into a wax
position.

You must always run a flush after the valve has entered a wax position. You cannot index the valve again
until the flush is completed. You must always run a Flush 2 (alcohol) after Flush 1 (Xylene) to prevent cross-
contamination of reagent 1 (usually formalin).

6.1.2 Obsolete Errors, and Errors Not Supported

From BIOS 0201 onwards the following errors are obsolete:

5: non-continuable fluid transfer problem

11: software fault on rotary valve control
12: failure to open rotary valve correctly
13: failure to close rotary valve
14: failure to open rotary valve
24: power failure
26: failure to release vacuum on lid open
27: failure to release pressure on lid open
34: initialisation test failed

The highest numbered error is error 40 although errors 36 and 38 cannot occur.

6.1.3 Pressure and Vacuum Rates

Pressure test:

Pressurise a dry, empty Reaction Chamber from 1000mBar to 1250mBar.

Below 37 seconds is OK.
Above 41 seconds is not OK.
37 – 41 seconds is marginal pass/fail and is thus a cause for concern.
Typical results around 30 seconds for current issue Pathcentres.

Vacuum test:

Evacuate a dry, empty Reaction Chamber from 1000mBar to 500mBar.

Below 150 seconds is OK.
Above 160 seconds is not OK.
150 – 160 seconds is marginal pass/fail and is thus a cause for concern.
Typical results 140 – 150 seconds.

6.2
1PES06GB Iss 03
 Chart 1: Solenoid Valve Checks

Solenoid valve 1: used to draw vacuum into the Reaction Chamber.

Solenoid valve 2: used apply pressure to the Reaction Chamber..
Start Solenoid valve 3: used to equalise the pressure in the Reaction Chamber.

Note
Enter Production The quickest way to test the cable is to swap the valve at the
Services. spade connector with another valve. If the new valve (on the
suspect cable) lights, then the previous valve must be faulty
- otherwise the fault lies in the cable, or higher in the system.

Is valve
No Change gold box. Retry.
LED unlit ?

Yes

Operate valve.
(1) Change cables.

No

Is valve
LED lit ?
No

(2) Change gold box.

Toggle valve,
listen for click.

Does the
Change
valve click No click
solenoid valve.
when operated?

Click

Clean valve seat.

6.3
1PES06GB Iss 03
 Chart 2: Air Pump Checks

Start

Is motor free Goto chart 13

No Retry.
to rotate ? (service pump)

Yes

Early instrument Goto chart 2a

No
with external SSR? (new pump test)

Yes

Enter P S

Volts
@ pins 3&4 No Change gold box.
of SSR = 0V
(pump off)?

Yes

Mains at SSR
No Change cables.
pin2 to neutral ?

Yes

Select 'Fast Pump' ON

(1) Change cables.

Volts @ No
SSR pins 3&4 now
24Vdc ? No
(2) Change gold box.
Yes

Pump Runs ? No Change pump.

Yes

Change SSR assembly.

6.4
1PES06GB Iss 03
 Chart 2a: Air Pump Checks - continuation (1)

Start

Enter P S.
Make sure
pump is OFF.

Mains at pump
Yes Change gold box. Retry
terminals ?

No

Select fast pump on.

Mains at pump
No Change gold box.
terminals?

Yes

Change pump.
 Chart 3: Wax Baseplate Over-Temperature Cut-Out

The wax base over-temperature cut-out comprises two temperature switches connected in series. The
switch goes open circuit when its case exceeds 110°C. If either cut-out opens, the whole circuit goes open
circuit and 'Error' appears in the Overtemp display of the Production Services screen. The software will not
drive any wax heater when this circuit is open circuit. Removing the connector from the switches provides a
quick and easy method of disabling the wax heaters.

If the circuit is closed the only way to check the switch operation is allow the wax base to exceed 110°C. To
do this, drain off the molten wax and re-fill all the wax baths with pellets. The wax base will exceed 110°C for
the time it takes to melt the wax. This is normal. The event log will contain a number of "Null event 85..."
entries that show the operation of the switches.

Start Enter PS. Observe the

"Overtemp:" indication.

Check connection,
or disconnect then Disconnect 2 pin
reconnect 2 pin Overtemp:
Error OK Trident connector
Trident connector at OK or Error ?
at rear of wax bath.
rear of wax bath.

Overtemp: Overtemp:
OK Done Error
OK or Error ? OK or Error ?

Error OK

OK OK
Short out female Disconnect PL7
connector. on gold box.

Change
Overtemp: Change Overtemp:
OK switches and Error
OK or Error ? cable. OK or Error ?
cable loom.

Error OK

Change cable Overtemp:

Error Change gold box.
to gold box. OK or Error ?

6.6
1PES06GB Iss 03
 Chart 4: Overfill Sensor

The overfill sensor is a thermistor that is driven sufficiently hard so that it self heats to approximately 80°C.
When immersed in fluid, the temperature of the thermistor drops and this results in a change in the flow of
current through the thermistor. The change in current flow is detected by the electronics and software. To be
effective, the thermistor must run hotter than any fluid with which it is likely to come into contact.

Start

Disconnect sensor and

measure resistance.

Is resistance
2.3k @ 25C ? No Change sensor. Retry.
(approx.)

Yes

(1) Change cables.

Voltage No
@ cable connector
= 12Vdc (approx)
No

(2) Change gold box.

Yes Yes

(1) Change sensor. (2) Change gold box.

6.7
1PES06GB Iss 03
 Chart 5: Battery Checks

The batteries power the RAM and the clock when mains power is removed. User programs, and reagent
setups, are stored in Flash ROM that does not need permanent power. The RAM holds data on the current
state of the instrument (such as program running, drawing fluid etc.) as well as the reagent life data and the
event log. To make sure that an instrument always recovers from power interruptions, a number of RAM
integrity checks are performed when the instrument is powered on or off.

On power off, the RAM integrity data is saved in a number of locations throughout the RAM - just before the
voltage drops too low to operate the instrument. On power up these values are recalculated and compared
with the versions saved at the time of power off. If they match the RAM is assumed to have remained valid
and the normal startup sequences occur. However, if there is a difference the memory is reinitialised and an
Error 23 is displayed.

It is essential that the batteries are only removed while the instrument is powered up. Failure to
observe this will results in an Error 23 and loss of essential user information.

Start Retry

Make sure that the

instrument is powered up.
Remove each battery and
measure the voltage.

Voltage
>1.35Vdc No Replace batteries.
& <1.6Vdc ?

Yes

Make sure that

the batteries are
correctly oriented.
Refit the batteries.

6.8
1PES06GB Iss 03
 Chart 6: Heated Tube Checks

The heated inlet pipe is powered continuously from a 24V dc supply. The resistance of the heater, when
cold, is 45 Ohms. The resistance increases when the heater is hot. Allow the heater to cool for at least 10
minutes before you measure the resistance.

Start

(1) Change
Retry.
cables.
No

24Vdc on
connector?
No

(2) Change
gold box.

Yes

Heater
Change
current. >360mA No
heated pipe.
and <400mA ?

Yes

Intermittent fault.

6.9
1PES06GB Iss 03
 Chart 7: Heaters (part i)
Heater faults fall into 3 categories:-
1 Heater permanently on; - results in the operation of the manually resetable thermal cut-out.
2 Failure to heat; - possibly because of the above condition.
3 Poor control of temperature; - often due to a fault in the temperature sensors, or low wax levels.

The heater system cannot function correctly if the temperatures monitored are incorrect. Use Chart 9 to
make sure that the temperature sensors operate correctly.

The band heater of the Reaction Chamber, the inlet cartridge heater, and the cartridge heater of the Rotary
Valve have individual, manually reset, cut-outs. Also, the front two wax baths share one manually reset cut-out,
and the rear two wax baths share another. To reset a cut-out, press the centre firmly. A slight 'click' will be felt
when the cut-out resets. The cut-out will not reset, or will trip when the reset is released, if the cut-out is too hot.

THE SSR ASSOCIATED WITH EACH HEATER IS IN THE LIVE FEED TO THAT HEATER.
THE MANUALLY RESET THERMAL CUT-OUT IS IN THE NEUTRAL RETURN.
CONSEQUENTLY, THE HEATER, AND ONE SIDE OF THE CUT-OUT, REMAIN LIVE, EVEN
THOUGH THE HEATER IS OFF. TAKE CARE WHEN YOU WORK ON THE HEATERS.

An instrument that fails to heat on one or more channels after transportation probably has a tripped cut-out.
This may occur on brand new machines just delivered from the factory.

Two thermal switches of the self-reset type are included to limit the maximum temperature of the base of the
wax baths to 115°C-120°C. (approx.). These thermal switches are monitored by the heater control software.
When the switches become active the signal switches off the heaters of the wax baths until the temperature
of the base falls to below 110°C. You can monitor the state of the switches in the 'Overtemp' heading in the
‘For Display Only’ column of the of the Production Services screen. The display changes from ‘OK’ to
‘Error’ when active. Unlike the cut-outs, these switches do not switch the heater current on or off.

The manually reset cut-outs operate if:

- the temperature is too high.
- a device is faulty.
- subjected to mechanical shock, or vibration.

Each chamber has an effect on, and is affected by, its neighbour. If a wax bath heater fails when a wax bath
contains molten wax, heat acquired from adjacent baths is sufficient to maintain the wax in a molten state.
The temperature will probably be about 1°C less than the set point. The temperature of the adjacent baths
will be 1°C or 2°C more because they run hotter to make up for the heat loss. It is possible that this fault is
undetected for some time because the wax behaves and transfers normally. However, there will be
insufficient heat to melt new wax, and the fault becomes apparent

Observe that the temperature sensors are approximately two thirds up the wax baths. The sidewall material
of the baths is not a good conductor of heat. The selected position gives the best compromise between
speed of melt, and control of temperature. The level of melted wax is above the height of the sensor so that
the true temperature of the wax is monitored - not the temperature of the sidewall. If the melted wax is much
lower than the height of the sensor, the sensor receives heat from the sidewall only. This can lead to wax in
the tank becoming too hot. Always make sure that the wax baths are filled to the correct level.

When wax is transferred to the Reaction Chamber, the temperature of its bath is reduced by 10°C (i.e. to
10°C below the set temperature). This prevents the temperature of the base rising too high while the sensor
is not covered with wax.

6.10
1PES06GB Iss 03
 Chart 7: Heaters (part ii) - Continuation 1

The voltage applied to the heaters is pulse width modulated. Unless the PWM rate is 100% the voltage
displayed on a DVM is not steady.

Gross Wax Fault

Start

(1)
Change
cables
Remove plug No
Overtemp and short out Overtemp
No
tripped ? connector to now OK ?
gold box. No
(2)
Change
Yes gold box.

2 or more wax
Yes
heaters permanently
Both cutouts
Yes on, follow single
tripped ?
channel fault,
channel too hot.

No Change
Retry.
overtemp sensors.
Follow single
channel fault,
channel not
working.

Twin Channel Wax Fault

Start

1 or more heaters
permanently on,
Cutout tripped ? Yes follow single
channel fault for
both channels.

No

Follow single
channel fault,
channel not
working.

6.11
1PES06GB Iss 03
 Chart 7: Heaters (part iii) - Continuation 2.
Single Channel Fault: temperature too high.

A channel gets too hot when the heaters do not switch off, or are maintained switched on for too long. This
may be due to a fault in the electronic switches, or because the reported temperature is incorrect.

Start Retry

Use Chart 9 to
confirm operation
of temperature
sensor

Enter PS.
Reset cut- out for
this channel. Set
heater demand
to zero.

Change
Heater drive off? No
gold box.

Yes

Mains volts Set switches to

same as No same as local
switches ? mains.

Yes

Is the fluid Fill to correct

No
level correct? level

Yes

Check log for sudden

jumps in temperature,
suspect cables and
sensors, then gold box
for intermittent fault.

6.12
1PES06GB Iss 03
 Chart 7: Heaters (part iv) - Continuation 3
Single Channel Fault: temperature too low.

Start

Follow the chart for

single channel faults for
temperature too high.

Fault found ? Fault was found Retry

No fault found

Set demand and check (1)

heater drive voltage. Change cables.

No

(2)
Disconnect cutout,
Drive volts is a No check cutout continuity,
PWM wave ? change cutout if open
circuit.

No
Yes

Disconnect heater and (3)

measure resistance. Change gold box.
Resistance is xxx
@25°C

Suspect intermittent
fault in cables,
Resistance OK ? No
sensors or
gold box.

Yes

Change heater.

6.13
1PES06GB Iss 03
 Chart 8: Accessories Drawer Switch

Start

Adjust switch
Does drawer No mechanism so drawer Retry.
operate switch?
operates switch.

Remove the cables Yes

then measure the
resistance at the
switch Pressed
resistance < 1ohm No Change switch.
o/c when free?

Measure the resistance

at the gold box end of
the cables.
Pressed
resistance < 1ohm No Change cables.
o/c when free?

Yes

Change gold box.

6.14
1PES06GB Iss 03
 Chart 9: Temperature Sensors.
A temperature of 99°C with all other channels showing 69°C indicates a missing signal due to a faulty
sensor, cable or gold box. The channel that shows 99°C is the channel at fault. Note that if all channels fail,
then the channel that shows 99°C was the channel measured at the time of failure.

Start

Displayed
Display shows Connect test sensor Change original
Yes temperature Yes
69,99,69 pattern ? to faulty channel. faulty sensor.
correct?

No

Disconnect sensor.
Connect test sensor.

Displayed
temperature No
correct ?

No No

Yes

Fit replacement (1) (2)

sensor. Change Change
cables. gold box.

Retry

A thermal lag between the
actual temperature and the
reported temperature
results from poorly mounted
sensors. This produces
errors between the true
temperature and the
displayed temperature.
The temperature sensor produces a square wave output of 5V amplitude
at 4kHz (nominal). The duty cycle varies in line with temperature. The
hotter the sensor, the longer the 'on' period. You can observe the
operation of a transducer with a DVM. The cable to each transducer is
clearly labelled, with 5Vdc supplied to power each sensor. The output
signal depends on the DVM and the temperature. The nominal output is
2.5V at room temperature. A DVM that can measure frequency is useful
to verify the operation of the sensor.
Note
1 Sensor frequency varies with temperature,
2 Any frequency between 1.5kHz and 6kHz is acceptable.

6.15
1PES06GB Iss 03
 Chart 10a: RC Lid (electrical)
The lid release mechanism is controlled by software that ensures that it only activates when it is safe to do so.
The algorithm ensures that any residual vacuum or pressure is released before the release solenoid is driven.
The software only permits the lid to open when the LED is lit in the [LID] push-button of the Miniature Control
Panel. If the emergency lid release is pulled at any other timer then an Error 10 "Lid no longer appears locked"
is reported. The algorithm for software up to Issue 10 is different to that for Issue 11 software, and later.

Software up to Issue 10 produced a timed release of pressure or vacuum. If the vacuum/pressure is not
released in 45 seconds, then 10 seconds of active relief occurs. Active release causes the pump to run to try
to pump away the residual vacuum/pressure. If this is unsuccessful, Errors 7 and 8 may show. The
solenoid is driven when the pressure decreases to within the range 950mB to 1035mBar.

Software from Issue 11 controls algorithms to relieve any residual vacuum/pressure. Failure to equalise in
time causes Errors 7 or 8 to show.

The PSU 24V does not connect directly to the solenoid. To limit the current in the release mechanism, a
capacitor, connected to the release solenoid by a relay, is charged to 24V. When the relay switches, the
release mechanism operates to allow the lid to open. A switch on the mechanism signals to the software that
the lid is released. If the lid release fails, the software switches the relay to charge the capacitor again then
switch it back to the release solenoid. This repeats with a 6 second charge time until the lid opens. The LED
in the [LID] push-button flashes approximately twice a second while vacuum/pressure is released and the
while the capacitor charges up.

N.B. The cable to the emegency lid open switch on the lid release mechanism is designed to report that the
lid is closed even if the cable is disconnected or broken. This ensures that a processing run can complete
without a false ‘Lid Open’ alarm signalled.

Lid open detect switch

Enter production services
Confirm the RC pressure is 950mB to 1035mB.
Start Check that the lid is closed.

Does banner Disconnect cable Does banner

show lid open Yes from release show lid open Yes
warning? mechanism. warning?

No No

Pull emergency Change

Change cable.
release cable. gold box.

Does banner
show lid open Yes
warning?
Retry

No

Done
continued
on 10b

6.16
1PES06GB Iss 03
 Chart 10b: RC Lid (electrical)

continued
from 10a

Does lid physically Goto chart 10x

No Retry
open (lid: mechanical)

Yes

Close lid, then select

"Force open lid"

(1) Change cable.

No
Does lid solenoid
fire ?
No

(2) Change gold box

Yes

Does lid physically Goto chart 10c

No
open (lid: mechanical)

Yes

Done

6.17
1PES06GB Iss 03
 Chart 10c: RC Lid (mechanical)
Do Chart 10 to prove that the electrical/electronic operation is satisfactory. If the lid still fails to open the fault
must be mechanical.

Start

See Chart

With lid up,

10e

No
will latch close

Yes
Notes
1 The cable should pull the solenoid release arm fully
Pull emergency lid
release cable and over. Physically make sure that the arm moves fully.
observe lid latch
assembly in machine 2 Open and close the latch to check for interference,
particularly between the solenoid and the latching pin.

Does the
Adjust/replace
cable operate the
No emergency lid release Retry
solenoid.
cable
*1

Yes

Pull the lid release &

gently pull/push the front
latch panel

Solenoid is very jammed

and may require
Lid opens No breaking to allow Retry
removal - refit new
solenoid.

Yes
See Chart

Leave lid in the upright

open position & close
10d

Latch opens Yes

latch.
Pull lid release cable.

No

See Chart
10e

6.18
1PES06GB Iss 03
 Chart 10d: RC Lid (mechanical) - continuation 1

Retry

Latch
Close latch
opens Check lid
then use lid Yes
smoothly setting
release to open
*2

No

Remove front
cover plate from
front panel
latching
assembly

Hinge mounting
Secure and retry No screws(4) secured
correctly

Retry Yes

Adjust release
pin to give Slowly close front
smooth latch assembly
engagement

No

Remove lid latch &

Latch Solenoid release friction plate assy.
panel Yes pin catching on No Remove screws (2)
bent ? the solenoid ? from latch plate &
allow to swing freely.

Yes

Friction plate/lid
Fix/replace Latch
stay assembly
panel Yes swings
too tight ?
freely
Replace and retry.

No

See
Retry Chart
10f

6.19
1PES06GB Iss 03
 Chart 10e: RC Lid (mechanical) - continuation 2

Remove front
cover plate from
front panel
latching
assembly

Remove solenoid
release pin from
latching panel.
Hold panel clear
and insert pin only
into solenoid.
Pull the release
cable

Change pin

No

Pin fires out Retry

No

Change solenoid
Yes

Refit pin to latch

panel & adjust.
Close latch and
reopen using lid
release.

Latch opens ? Yes Rebuild and retry

No

See
Chart
10d

6.20
1PES06GB Iss 03
 Chart 10f: RC Lid (mechanical) - continuation 3

Remove front
cover plate from
front panel
latching
assembly

Remove solenoid
release pin from
latching panel.
Hold panel clear
and insert pin only
into solenoid.
Pull the release
cable

Change pin

No

Pin fires out Retry

No

Change solenoid
Yes

Refit pin to latch

panel & adjust.
Close latch and
reopen using lid
release.

Latch opens ? Yes Rebuild and retry

No

See
Chart
10d

6.21
1PES06GB Iss 03
 Chart 10g: RC Lid (mechanical) - continuation 4

Lid
release correctly
Readjust
adjusted ? No
and retry
(not in tension)

Yes

Remove lid
latch pin from
front panel

Change pin

Yes
Will lid latch
plate 'engage' to full
extent Retry

Yes

Change solenoid

No

Check latch plate

mounting and
straightness
(use Chart 10d)

6.22
1PES06GB Iss 03
 Chart 11: Pressure Transducer
The pressure transducer generates a 5V square wave output whose frequency varies linearly with pressure.
The outputs are within the range 3kHz at 0mB; 4.5kHz at 1000mBar (atmospheric) and 6kHz at 2000mBar
(pressures absolute).

Measure the voltage between the wires that follow to check the transducer cables:
Red - Yellow = 11.8 - 12.2V. Blue - Yellow = 2.5V (approx. dependent upon the type of DVM used).

Notes
1 To check the operation of the transducer, a frequency measuring DVM is preferred.
2 Unless a spare transducer is available for comparison with the suspect transducer, the only way to
test the transducer is on a known good Pathcentre.

Start

(1) Change
cables.
No
Open lid, Is
enter P S. Is pressure Disconnect pressure now
No
reading >985mB & transducer. 19642mB
<1015mB ?
No

(2) Change gold

box.

Yes Yes

Pressurise RC No Change transducer.

Is pressure
> 1250mB

Yes

Evacuate RC, check No

pressure < 650mB

Yes

Intermittent fault. Retry

6.23
1PES06GB Iss 03
 Chart 12a: Agitate Motor; to Locate Faults and To Check Serviceability

Start
Notes:
1 Use P&S - Agitate
2 Empty Chamber (No Baskets Installed)

Does the unit Is linkage

No No Fit correctly & retry
drive ? fitted ?

Yes

Change cable

No
Check volts
Yes on motor drive Retry
on load
No

Change gold box

Yes

While agitate
operates use Drive on motor
Remove linkage Chart
See

12a
tool T61168. Centre Yes torque > 1.8Nm. Yes
and spring
column stalls Use tool T61169
< 2Nm ?

No
No

Change motor
Insert
3 baskets/carriers
+ displacement
block in RC

Do the baskets/carriers
Does Unit drive No touch the sides or Yes Rectify & retry
bottom of the RC ?

Yes

Possible intermittent
fault: Inspect cables -
No
/Change cables
/Change gold box

6.24
1PES06GB Iss 03
 Chart 12b: Agitate Motor; to Locate Faults and To Check Serviceability
(continuation 1)
Notes
1 Motor drive is proven satisfactory.
2* Redo pump test to confirm no loss of
performance.

Start

Unlinked Linkage is set to

centre incorrect length or
No Retry
column torque seized.
> 1.5 Nm Rectify

Yes

Apply pump serviceability

test to determine
chamber integrity

Remove central
column, clean bearing,
grease with P13725
(Rocol ASP)

Centre column Rebuild and retry

No
torque > 1.5 (see note*)

Yes

Change whole
centre column
(see note 2*)

6.25
1PES06GB Iss 03
 Chart 13a: Pneumatic Circuit Diagnostics
The pneumatic circuit functions below specification; a flow restriction exists.
Note
1* Fitting instructions, ref 752-1010

Close Emergency
Start
Vacuum Release

No

Chart 13d

detection
Passes Emergency

- leak
production pressure/ No Vacuum Release Yes
vacuum test ? closed ?

Yes

Passes
production press/
vac test with solenoid 2 Pump head or pump
No Rectify and retry
(pres) or solenoid 1 pipe fittings leaking
(vac) open in
P&S

Yes

Remove pump head.

Pump passes
Check for debris on
serviceability No Pump passes test Yes Retry
diaphragm and valves
test * *see note

Yes No

Remove rear air

connector from Replace diaphragm
solenoid block (air and valves
return)

Problem lies in
Rate of pressure No restriction in air Pump passes test Yes Retry
rise too slow ?
return circuit

Yes No

See Chart
Problem lies in 13b Replace pump
restriction in
direct air circuit

See Chart
13c

6.26
1PES06GB Iss 03
 Chart 13b: Restriction in Air Return Circuit
Solenoid Valves to Bottles/Wax Bath

Start

Circuit intact,
drawer open
(re-reconnect
pipework)

Check the air connectors &

pipework of Accessories
Drawer for blockages.
Rate of pressure Yes Make sure the Vapour Trap Retry
rise correct ?.
& Air Bag are empty of fluid.
Make sure that the pressure &
vacuum valves are set correctly.

No

Fault lies in pipe from

solenoid valve to
drawer, or in the
drawer connector.
Rectify.

Retry

6.27
1PES06GB Iss 03
 Chart 13c: Restriction in Direct Air Circuit
Solenoid Valves to Reaction Chamber

Start

Pipe solenoid valve

outlet directly into 'T'-
piece that attaches the
pressure transducer to
the RC

Restriction is
Pressure rate O.K.? Yes in condensate pipe/jar Retry
line. Rectify or replace.

No

Fault is in solenoid valve.

Retry
Rework/replace

6.28
1PES06GB Iss 03
 Chart 13d: Leak Detection
Use this chart if the system fails the production pressure/vacuum test. A leak in the system that could
account for the loss in performance is indicated.

Note
1 Isolate the pump from the circuit when the required pressure/vacuum is reached.

Start
Retry

Leak lies in the air

Passes
system. Isolate PRV Faulty PRV.
pump serviceability Yes Passes test Yes
and repeat production Fix or replace
test *1
pressure/vacuum test

No No

Leak is in RC/
Isolate Condensate
pressure transducer
Jar and repeat test
pipework

Faulty
Check lid setting. Condensate Jar.
Passes test Yes
Remove & clean lid. Check/Replace
Seal and retest. Seal/Lid

No

Isolate solenoid
Passes valves after test Retry
production pressure/ Yes Retry pressure/vacuum
vacuum test ? achieved

No

Draw bottle of fluid Replace

Passes test ? Yes
(water) into RC. solenoid assembly
Apply pressure.
Check for leaks at
valve, heated pipe, No
or base of RC

See
Retry
Chart
1. Valve - change valve. 13e
2. Pipe - loosen & retighten
Leak seen Yes fittings - replace pipe.
3. RC base - tighten clamp
in gauge - change seal.

No

See Chart
13e Retry

6.29
1PES06GB Iss 03
 Chart 13e: Leak Detection - Continuation 1

Leak Passes
Seen Test
(Refer to (Refer to
Chart 13d) Chart 13d)

No No

Remove centre
column drive spindle Check pipework and
(agitate drive). Seal fittings common to all
with rubber bung. above tests.
Repeat test.

Leak was on agitate

centre column - replace
Leak? No Retry
PTFE seal on column
and refit.

Yes

Check fitting/sealing
integrity of:-
1. Overfill sensor fitting.
2. Air supply fitting.
3. Pipework to pressure
transducer.

Retry Retry

6.30
1PES06GB Iss 03
 Chart 14: Rotary Valve

Start

Retry

Measure
motor current
while valve is
attempting to move.

Valve is siezed.
Current > 0.62A Yes
Replace valve.

No

Remove
motor/gearbox
from valve.

Does output Motor/gearbox.

No
shaft rotate? faulty. Replace
motor/gearbox.

Yes

Is valve Replace coupling

coupling Yes with stainless
broken? steel version.

No

Intermittent Fault.

6.31
1PES06GB Iss 03
 Error 1: Failure to Pressurise the Reaction Chamber

Use this chart to confirm that the lid is closed and sealed.
The pressure must reach 1050mB in 15secs, and 1200mB in 45secs.
Solenoid valve 2 and the pump are active, and the rotary valve is closed ,while pressure is applied to the
Reaction Chamber.

Start Use production services

"Pressurise Chamber".

Lid
No Close the lid. Retry
closed ?

Yes

Pump Goto chart 2

No
operates ? (pump)

Yes

Solenoids Goto chart 1

No
operate ? (solenoids)

Yes

Pressure Sensor Faulty

rising ? No Goto chart 11
(Screen display) (pressure sensor)

Yes Sensor OK

Rate of
pressure rise slow, Intermittent electrical
No
or rise stops before or pneumatic fault.
limit.

Goto chart 13a

(check pneumatics)

6.32
1PES06GB Iss 03
 Error 2: Failed to Release Pressure

Use this chart as part of lid the check.

The pressure must decay from 1200mB to 1050mB in 45 secs.

Solenoid 3 is active while pressure is released.

Use production services

Start "Release RC P or V".

Do the solenoids Goto chart 1

No Retry.
operate ? (solenoids)

Yes

Does the pressure fall to

Sensor Faulty
Goto chart 11
below 1050mB or does the No
pressure fall very slowly ? (Pressure sensor)

Sensor OK
Yes

Goto chart 13a

(check pneumatics)

6.33
1PES06GB Iss 03
 Error 3: Failed to Draw Fluid (Bottle Empty)
The draw takes 180 seconds: there are no bubble checks in the first 75 seconds; bubbles are detected in
the last 105 seconds. Bubbles are defined as 8 successive increases in pressure. If no bubbles are detected
in 180 seconds the bottle is declared empty. The lowest pressure seen is >850mB and the last pressure
value seen is >850mB.

To draw vacuum Solenoid 1 is open, the pump is active, and the selector valve is open at the correct port.
When wax is transferred, the wax baths, selector valve, inlet pipe and the RC inlet must be hot to keep the
wax molten.

Start Use production services

"Draw fluid into RC".

Fill bottle and fit

Bottle full and fitted
No correctly. Visually check Retry
correctly ?
seals are OK.

Yes

Does the pump Goto chart 2

No
operate ? (pump)

Yes

Do the solenoids Goto chart 1

No
operate ? (solenoids)

Yes

Sensor Faulty
Pressure falling; or Goto chart 11
No
chamber fills slowly ? (pressure sensor)

Yes Sensor OK

Goto chart 13a

(check pneumatics)

6.34
1PES06GB Iss 03
 Error 4: Failed to Draw Fluid (Bottle Blocked)
The draw takes 180 seconds: there are no bubble checks in the first 75 seconds; bubbles are detected in
the last 105 seconds. Bubbles are defined as 8 successive increases in pressure. If no bubbles are detected
in 180 seconds the bottle is declared empty. The pressure seen < 900mB. The conditions for error 3 are
checked before those for error 4.

To draw vacuum Solenoid 1 is open, the pump is active, and the selector valve is open at the correct port.
When wax is transferred, the wax baths, selector valve, inlet pipe and the RC inlet must be hot to keep the
wax molten.

Use production services

Start "Draw fluid into RC".

Is the bottle full of Clean out bottle, refill

No Retry
fluid (note 1) ? and fit correctly.

Yes

Does the pump No

Goto chart 2
operate ? (pump)

Yes

Do the solenoids Goto chart 1

No
operate ? (solenoids)

Yes

Sensor Faulty
Pressure falling; or Goto chart 11
No
chamber fills slowly? (pressure sensor)

Sensor OK
Yes
Note 1
If inadequate quality control is applied to the flush
reagents the 1st flush reagent can become too
viscous to be drawn in when cold. The wax
dissolved in the flush reagent virtually solidifies.
Goto chart 13a
(check pneumatics)

6.35
1PES06GB Iss 03
 Error 6: Failed to Release Vacuum

This error results from either:

1) an attempt to release vacuum during processing (i.e. after drawing a fluid). In this case the pressure
should rise to > 950mB after 75 secs. If the pressure is still too low, the system should pressurise for
10 secs. The error occurs if the pressure is still < 950mB.

2) an air system confidence check before fluid is blown out. The pressure should be > 950mB or should
have increased by 100mB after 20 seconds. (n.b. the conditions at the start are different to 1 above) .

Solenoid 3 is active while vacuum is released . The pump and solenoid 2 are active to apply pressure to
release vacuum.

Use production services

Start "Release RC P or V".

Do the solenoids Goto chart 1

No No Retry
operate ? (solenoids)

Yes

Open the emergency

relief valve.

Yes

Displayed pressure Goto chart 11

No
rises to >950mB ? (pressure sensor)

Yes

Goto chart 13a

(check pneumatics)

6.36
1PES06GB Iss 03
 Error 7: Failed to Release Pressure

The pressure should drop to <1035mB within 45 seconds or 10 seconds of vacuum is applied. The error
occurs if the pressure is still > 1035mB.

Solenoid 3 is active while pressure is released. The pump and solenoid 1 are active while vacuum is drawn

Use production services

Start "Release RC P or V".

Do the solenoids Goto chart 1

No No Retry
operate ? (solenoids)

Yes

Open the emergency

relief valve.

Yes

Displayed pressure Goto chart 11

No
drops to <1050mB ? (pressure sensor)

Yes

Goto chart 13a

(check pneumatics)

6.37
1PES06GB Iss 03
 Error 8: Failure to Raise Pressure

This is part of the air system confidence check performed before fluid is blown out. The pressure should rise
by 100mB in 15 seconds.

The pump and solenoid 2 are active while pressure is applied.

Use production services

Start ""Pressurise chamber".

Do the solenoids Goto chart 1

No Retry
operate ? (solenoids)

Yes

Does the pump Goto chart 2

No
operate ? (pump)

Yes

Sensor Faulty
Goto chart 11
Pressure rising, or No
(pressure sensor)
rising very slowly ?

Yes Sensor OK

Goto chart 13a

(check pneumatics)

6.38
1PES06GB Iss 03
 Error 9: Failure to Draw Vacuum

This is part of the air system confidence check performed before fluid is blown out. The pressure should fall
by 100mB in 15 seconds.

The pump and solenoid 2 are active while vacuum is drawn.

Use production services

Start ""Evacuate chamber".

Do the solenoids Goto chart 1

No Retry
operate ? (solenoids)

Yes

Does the pump Goto chart 2

No
operate ? (pump)

Yes

Sensor Faulty
Pressure falling Goto chart 11
No
or falling very (pressure sensor)
slowly?

Yes Sensor OK

Goto chart 13a

(check pneumatics)

6.39
1PES06GB Iss 03
 Error 10: Lid No Longer Appears Locked
This error arises if the lid is opened manually while the machine is running a process/flush or drain
sequence.

Start

Latch
Goto
mechanism
No chart 10c Retry
free with lid
(lid)
closed ?

Yes

Incorrect
Inform user of
use of emergency Yes
correct procedure.
lid release?

No

Change
Check cables. Faulty
cables.

No Fault

Go to
24V pulse when
Yes chart 10a
operated?
(lid)

No

Change
gold box.

6.40
1PES06GB Iss 03
 Error 16: Timeout on Reagent Blowout
Software to Issue 10 (BIOS201a)
Blowout of fluid should finish successfully in 180 seconds: bubble detection checks are not applied for the
first 60 seconds. At the finish of the 60 seconds the software checks to make sure that the pressure
exceeded 1180 mBar in the 60 second period. This serves to confirm that fluid is in the Reaction Chamber.
Blowout is complete if the pressure drops below 1150mB for at least 6 seconds within the next 120 second
period. The error alarm occurs if the pressure does not drop below < 1150mBar for 6 seconds by the time
the 120 second period expires. If no fluid is detected then no error is generated. The error normally occurs if
the pneumatic performance is poor, or if there is some form of blockage. Repeated Error 16 leads to Error
17 if the cause is not rectified.

The pump and solenoid 2 are active, and the rotary valve is open, while reagent is blown out of the RC.

Start The RC must be full of fluid.

Use PC to "Blow fluid from RC".

Pump Goto chart 2

No Retry
operates ? (pump)

Yes

Solenoids No
Goto chart 1
operate ? (solenoids)

Yes

Sensor Faulty
Pressure Goto chart 11
No
increases ? (Pressure sensor)

Yes Sensor OK

Rate of
Goto chart 13a
pressure rise No
(check pneumatics)
OK ?

Yes

Check for fluid side

restriction or air return
side restrictions.

6.41
1PES06GB Iss 03
 Error 17: Failure to Empty Reaction Chamber
Software to Issue 10 (BIOS201a)
Blowout of fluid should finish successfully in 180 seconds: bubble detection checks are not applied for the
first 60 seconds. At the finish of the 60 seconds the software checks to make sure that the pressure
exceeded 1180 mBar in the 60 second period. This serves to confirm that fluid is in the Reaction Chamber.
Blowout is complete if the pressure drops below 1150mB for at least 6 seconds within the next 120 second
period. An Error 17 alarm occurs if the pressure is above 1150mBar for 6 seconds when the 120 second
period expires. If no fluid is detected then no error is generated. The error normally occurs if the pneumatic
performance is very poor, or if there is a blockage. Intermittent Error 17 is usually a result of particles or
debris in the fluid or air lines.

The pump and solenoid 2 are active, and the rotary valve is open, while reagent is blown out of the RC.

Start The RC must be full of fluid.

Use PS to "Blow fluid from RC".

Pump Goto chart 2

No Retry
operates ? (pump)

Yes

Solenoids Goto chart 1

No
operate ? (solenoids)

Yes

Pressure Goto chart 11 Sensor Faulty

No
increases ? (Pressure sensor)

Yes Sensor OK

Rate
Goto chart 13a
of pressure rise No
(check pneumatics)
OK ?

Yes

Check for gross fluid

bloackage or possible
air return side
restrictions.

6.42
1PES06GB Iss 03
 Error 16: Timeout on Reagent Blowout
Error 17: Failure to Empty Reaction Chamber

Software Issue 11 (BIOS313)

Amendments to the software - Issues 11 (BIOS313) onwards - facilitate the exclusion of the Pressure Relief
Valve (PRV) from all instruments with this software installed. The objective is to reduce the volume of
bubbles into the reagent bottles when fluid transfer is complete and obtain better control of pressure.

Software up to and inclusive of Issue 10 (BIOS201a) operated in conjunction with a mechanical PRV. The
PRV limited the maximum pressure that could build up in the Reaction Chamber, and opened at a preset
value, 1300mBar nominal , to discharge excess pressure into the air system.

With the introduction of the revised software, control of the pressure in the Reaction Chamber is by Solenoid
Valves SV1 and SV2. When SV2 opens while the air pump is on, air passes into the Reaction Chamber and
pressure increases: when SV1 opens while the air pump is on, air is drawn from the Reaction Chamber and
pressure falls. By control of the open and closed states of these valves the pressure in the Reaction
Chamber is accurately maintained at a new nominal pressure of 1250mBar for fluid blowout.

The full revised cycle for the software control of pressure in the Reaction Chamber is as follows.

The pump runs with solenoid SV2 open, and the rotary Selector Valve closed. The pressure in the Reaction
Chamber is allowed to increase to a nominal pressure of 1250mBar. The rate of increase in pressure up to
this value must not be less than 80mBar in 13 seconds. Failure to achieve this rate of rise in infers a fault in
the air system and causes Error 8 - ‘Failure to Reach Pressure’ to show. Similarly, Error 8 shows if the
target pressure of 1250mBar is not achieved within 30 seconds.

If the pressure rises to 1250mBar within the specified time, the software opens the rotary Selector Valve, at
the applicable port, to blow out the fluid. The pressure is maintained between 1225mBar and 1250mBar, by
control of SV2 and SV1, while blowout occurs. Successful completion of the blowout is detected by the
software when the pressure in the Reaction Chamber is seen as 1200mBar. Alternatively, successful
completion of the blowout is assumed when the pressure drops below 1218mBar with the pressure solenoid
valve (SV2 ) energised for more than 4 seconds.

A fault is indicated if the software detects a time-out condition whereby the requisite condition is not obtained
within the specified time, or SV2 remains de-energised for more than 25 seconds. Typically, this occurs if
fluid cannot flow easily - either because there is a problem in the air lines, or a blockage in the fluid pipes. If
the pressure fails to fall to 1200mBar, or is over 1218mBar for more than 4 seconds with SV2 open, then
Error 16 - ‘Timeout on Reagent Blowout’ shows.

If SV2 is off and the pressure remains high, the inference is that the fluid path is blocked. This results in
Error 17 - ‘Failure to Empty Reaction Chamber’.

The software always tries to protect the tissue samples. After an Error 16 or Error 17 is detected the
software tries to draw the current reagent back into the Reaction Chamber to cover the samples.

6.43
1PES06GB Iss 03
 Error 18: Wax Bath 'n' Failed to Reach Temperature
The temperature of the wax in the wax bath should be within 5°C of the target temperature before wax is
transferred into the Reaction Chamber. Error 18 is generated if the wax is not up to temperature when a
transfer of wax is requested.

Trying Advise user of wax

to use wax before Yes melt times and bath Retry
molten ? loading rules.

No

Are Goto chart 7

all the waxes Yes (heaters: gross
solid ? wax fault)

No

Goto chart 7
Are 2 waxes Yes (heaters: twin
solid ?
wax fault)

No

Goto chart 7
Is 1 wax Yes (heaters: single
solid ?
channel fault)

No

Are all Goto chart 7

waxes below set Yes (heaters: gross
temp ? wax fault)

No

Are 2 Goto chart 7

waxes below set Yes (heaters: twin
temp ? channel fault)

No

Is 1 Goto chart 7
wax below set Yes (heaters: single
temp ? channel fault)

No

Goto error
18a

6.44
1PES06GB Iss 03
 Error 18: Wax Bath 'n' Failed to Reach Temperature - Continuation 1

Continued
from error 18
Chart 18 (Part 1) indicates no
obvious heater fault, but overall
heater performance is poor.

Level of Wax Fill to

No Retry
Correct ? correct level.

Yes

Is corresponding
temperature Go to
No
sensor OK ? Chart 9

Yes

Heater Drive OK ? No
Go to
(Chart 7 iv) Chart 7 iv

Yes

Check event log for step

change in temperature.

Possible intermittent faults

with temperature sensor or
gold box and cables.

6.45
1PES06GB Iss 03
 Error 19: Rotary Valve Failed to Reach Temperature
Normally the Selector Valve is 10°C hotter than the set temperature of the wax baths. Error 19 is signalled if
the temperature of the Selector Valve is more than 10°C below the set temperature of the wax baths. The
temperature of the Selector Valve is only sampled when the wax baths are at the correct temperature. This is
because the Selector Valve runs cool, even when it works correctly, if the wax baths are not up to temperature.
Error 19 implies a fault on either the valve heater or the temperature sensor.

Start

Goto to chart 7
Valve temp
No (heaters: single Retry
correct ?
channel fault)

Yes

Goto chart 18 a
(heaters: intermittent
and poor
performance)

6.46
1PES06GB Iss 03
 Error 20: Temperature too High in the Reaction Chamber
If the sensors of the Reaction Chamber or the Inlet Pipe detect temperatures that are higher than 75°C an
Error 20 is signalled. If the sensor system is faulty, the software reports a channel at 99°C. Alternatively, the
fault may be due to a real over temperature that should cause the manually re-set cut-outs to operate. It is
essential that both the cut-outs are checked if this error is reported.

BE AWARE THAT THE HEATER CIRCUIT IS LIVE IF A CUT-OUT TRIPS.

Start

Reported Goto chart 9

temperature No (temperature Retry
accurate ? sensors)

Yes

Reset cutouts,
set temperature
demand to zero.
Yes

Heater Change
No
drive off ? gold box.

Yes

Mains Set switches inside

voltage selectors No gold box for correct
set correctly ? supply voltage.

Yes

Fluid level Fill to

No
correct ? correct level.

Yes

Check event log for step

change in temperature.

Possible intermittent faults

with temperature sensor or
gold box and cables.

6.47
1PES06GB Iss 03
 Error 21: Temperature too High on 'n'
Error 21 is generated if the Temperature of the Wax Baths exceeds 75°C, or if the temperature of the
Selector Valve exceeds 98°C. In both circumstances the resultant error signal is Error 21: ‘Temperature too
High on ‘n’. The number of the Wax Bath signalled for a Selector Valve over temperature is not significant.

Be aware that the Wax Baths, the Inlet Pipe, the Selector Valve and the Reaction Chamber are all linked
mechanically by heat conductive material. Consequently, a malfunction of one item affects adjacent
components. You must make sure that all the components operate correctly before you can assume that
the cause of an Error 21 is repaired.

Start

Follow methods for

error 20.

6.48
1PES06GB Iss 03
 Error 22: Accessories Drawer Open
This alarm is currently suppressed in all versions of software but it may be activated at a later date. If the
drawer is open a message is displayed on the Pathcentre banner. A process cannot be started if the drawer
is open, but once started, the drawer maybe opened without stopping the process.

Start

Adjust position
Closed drawer
No of drawer closed Retry.
hits switch ?.
switch.

Yes

Switch o/c
with drawer open, No Change switch
s/c when
closed ?

Yes

Switch
contacts at
No Change cables.
gold box same as
above ?

Yes

Change gold box.

6.49
1PES06GB Iss 03
 Error 23: Non-continuable Memory Error
This error has four possible causes: 1) Failure to complete a flash memory write cycle; 2) Incorrect software
update. 3) Software failure watchdog. 4) Failure of the internal confidence check after a power cycle.

Premature chip failure, or failure of the internal 12V programming supply, results in Error 23 a few seconds
after the screen message "Please wait, saving data..." appears. Failure on power-up suggests failure of the
battery backup circuitry. Failure after a software update is now normal operation. Check for errors reported
on the PC / laptop to see if the update procedure failed. Often, no obvious cause for the error will be found.
If the software is older than BIOS 330, then that BIOS should be fitted. If the fault persists, check for loose
cables in the command module, and between the command module and the gold box. The only certain cure
is to replace both the command module and the gold box.

To clear this error, select “Reset Memory” from Production Services.

Start

Updating
Yes Change gold box. Retry
flash memory ?

No

Battery change Advise user of the

Yes
with power off ? correct procedure.

No

Batteries fitted
No Fit correctly.
correctly ?

Yes

Each
battery No Fit new batteries.
1.3V - 1.5V ?

Yes

Change gold box and

command display.

6.50
1PES06GB Iss 03
 Error 25: Non-continuable Error Combination.
Error 25 occurs if a new and unrelated error occurs while the instrument is processing a different error, or
while an error recovery procedure is performed. Most frequently this error occurs if the lid is opened by use
of the Emergency Lid Release pull-cord, instead of by operation of the lid release button, while the machine
is in error.

The instrument may stop with a full or dirty Reaction Chamber in the course of error recovery. Empty the
Reaction Chamber by use of Production Services routines. Make sure that you flush the instrument before
the next program is run, irrespective of whether or not a wax was the last reagent.

Start

Enter PS. Select

"kill running program".

If necessary,
use functions
to empty RC.

Exit PS and
flush if needed.

Study the Event Log to find the cause of

Address original error
and re-run process.
the original error. The original error will
be recorded in the entry for Error 25.
Previous entries in the Event Log should
provide clues to the cause of the error.

6.51
1PES06GB Iss 03
 Error 28: Overfill on Wax
If a wax bath overfill occurs the surplus wax is forced into the air system and serious blockage results.
Consequently, automatic recovery is not possible after an overfill on wax.

The most usual reasons for wax overfill are 1) failure of the instrument to fully evacuate the Reaction
Chamber before wax is drawn in, 2) misuse of the Production Services facility, or 3) too many pellets in the
wax bath before melt (especially Wax Bath D).

The repair after Error 28 is invariably a complete strip out of all the pneumatic system, and a thorough clean
out odf the hardware.

Start

Is this
Goto chart 4
a real No Retry
(overfill sensor)
overfill ?

Yes

Open lid.
Remove samples.
Make sure that
all the wax drain
valves are closed.

The use of PS may fail

at this point because of
Bail out the RC fault conditions or
manually, errors as yet
or use PS to unreported.
evacuate
chamber.

The flush cycle may

fail at this point
because of fault
conditions or errors as
Flush the yet unreported.
instrument

Check
pneumatics for wax
contamination.

6.52
1PES06GB Iss 03
 Error 29: Overfill Sensor Triggered When Not Running
The overfill sensor is active at all times unless there is a possibility that splashes could cause an
unnecessary error indication i.e. in ‘flush’ or tidal agitation.

Start

Fit sensor cap

Sensor No with slot at Retry
cap fitted ?
45 degrees.

Yes

Lid covered with Clean lid of

Yes
condensation ? condensation.

No

Goto chart 4
(overfill sensor)

6.53
1PES06GB Iss 03
 Error 30: Opto Detector Failure
If the actual position of the rotary valve is not the same as the expected position, then Error 30 is signalled.
The absolute value detected by the optos is reported in the error message and can assist in diagnosis.

Note
1 See notes on the new valve controller.

Under some circumstances the valve assembly

may be opened, and the encoder disk checked
Start and cleaned. Discuss with your distributor
before you attempt this operation.

Run valve
serviceability Passes Retry
check

Fails

(1)
Replace
ribbon cable

Retry
Fails

(2)
Replace
opto block

Retry
Fails

(3)
Replace
gold box

Retry
Fails

(4)
Replace valve

6.54
1PES06GB Iss 03
 Error 31: D.C. Motor Failure
Error 31 is indicated if the position of the rotary Selector Valve does not appear to have changed for xx
seconds, despite commands to rotate.

Start

Enter PS
Open valve,
then close valve.

Check cables
24Vdc No
Motor on motor terminals Retry
No
operates ? while valve
No
moving ?
Change gold box.

Yes

Yes Goto chart 14a

(valve jammed)

Goto chart 14b

Valve shaft
No (gearbox /coupling
rotates ?
fault)

Yes

Examine
Event Log for Slow Change valve.
valve times ?

OK
Follow
procedures
for error 30.

6.55
1PES06GB Iss 03
 Error 32: Overfill from Reagent 'n' (1)
This is the first of 3 error messages concerned with overfill. The errors that follow (33, 34) are not true
errors, but are a controlled method to guide the user to complete the overfill recovery procedure.

Start

Put empty bottle

in position for
reagent 'n'.

Follow on screen
instructions.

Wait for error 33.

6.56
1PES06GB Iss 03
 Error 33: Overfill from Reagent 'n' (2)
This is the second of 3 error messages to do with overfill. The following error (34) is not a true error but a
controlled method of guiding the user to complete the overfill recovery procedure.

Start

Remove half
filled bottle from
reagent 'n'.

Put empty bottle

in position for
reagent 'n'.

Follow on screen
instructions.

Wait for error 34.

6.57
1PES06GB Iss 03
 Error 34: Overfill from Reagent 'n' (3)
This is the third of 3 error messages to do with overfill. This is not a true error but a controlled method of
guiding the user to complete the overfill recovery procedure.

Start

Remove half
filled bottle from
reagent 'n'.

Put correctly filled

bottle of reagent
in position 'n'.

Follow on screen
instructions.

6.58
1PES06GB Iss 03
 Error 35: Program Held For More Than 5 Mins
If the instrument is left on ‘Hold’ for 5 minutes or more, then Error 35 shows as a reminder for the operator.
The options available are to continue on ‘Hold’, or to clear the message and to restart processing. Error 35 is
not strictly an error, and the escape route is as follows:

1 Press 'CONTINUE' to extend the hold for a further 5 minutes.

2 The alarm sounds at the finish of the extended hold period.
3 Processing cycle does not restart when 'CONTINUE' is pressed.
4 Press 'CONTINUE' to clear the error, followed by 'RESTART' to continue processing.

Start

Program placed
on hold by user.

5 mins elapsed,
machine errors.

CONTINUE pressed,
machine returns CONTINUE only
to hold state.

CONTINUE + RESTART

Processing
continues.

6.59
1PES06GB Iss 03
 Error 37: Communications Failure
Error 37 occurs if a Pathcentre is connected to an Extension with which it cannot communicate.

Start

Comms
cable fitted No Refit cable. Retry
correctly ?.

Yes
Detach Extension
module from
software, then
Follow the procedure -Section 3.6 of the User Guide reattach.
- To Add and To Remove Extension Units

Change cable.

Change Extension
gold box.

Change Processor
gold box.

6.60
1PES06GB Iss 03
 Error 39: Opto Detector Failure (1)
Error 39 is effectively the same as Error 30 but for an Error 39 the valve is indexed from a wax position to a
reagent position. A previous opto detector failure may have allowed the valve into a wax position, or the
current reported position appears to be a wax position. In all circumstances, you must flush the instrument
before further use.

Under some circumstances the valve assembly

may be opened, and the encoder disk checked
and cleaned. Discuss with your distributor
Start before you attempt this operation.

Run valve
serviceability Passes Retry
check

Fails

(1)
Replace
ribbon cable

Retry
Fails

(2)
Replace
opto block

Retry
Fails

(3)
Replace
gold box

Retry
Fails

(4)
Replace valve

6.61
1PES06GB Iss 03
 Error 40: Opto Detector Failure (2)
Error 40 is similar to Error 30 and Error 39 but in this case the valve is indexed from a wax position to a
reagent position. This is probably due to a previous opto detector failure that allowed the valve into wax, or
because the reported position now appears to be a wax position. In all circumstances, you must flush the
instrument before further use.

Start

Drain the RC
manually.

Follow the recovery

procedures for
errors 30 and 39.

6.62
1PES06GB Iss 03
7.0 PARTS REMOVAL AND REPLACEMENT

7.1 GENERAL INTRODUCTION

Minimum maintenance is required to keep the Pathcentre operational. Access to the inside of the main
frame or to the inside of the Electronics Module should only be required if a fault is diagnosed. The instrument
is designed to accept guaranteed, new, tested, replacement assemblies or modules to maintain the integrity
of the instrument. There are no service repairable items in the instrument. Faulty assemblies should be
returned to Shandon for service. Make sure that earth/ground connections are maintained - especially on the
side and rear panels.

When solvent lines, pneumatic tubes and/or electrical connectors have been re-connected you must do the
applicable functional test to ensure that the repair is good. This should involve pressurisation and evacuation
of the Reaction Chamber. If there is any leakage you must re do the connection. If there is any leakage from
the lid seal you must re-adjust the lid hinges and the lock mechanism until the see-through lid engages cor-
rectly as per section 8.4.4. Make sure that you do not drop small components into the instrument when you
do repairs, and always re-do tie wraps.

Use the torque settings that follow unless instructed to do otherwise:

Screw Size Torque N/m (Brass/Steel) (Aluminium/Copper)
3 0.5 0.3
4 1.8 1.2
5 3 2
6 7 5.5
To gain access to any serviceable parts of the Pathcentre it is necessary to remove the left-hand side panel
(viewed from the front), and the rear panel. It is only necessary to remove the right-hand side panel if you
need to do work on the Wax Baths.

7.1.1 To Remove a Panel

i Rotate each of the slot headed screws one quarter turn anti-clockwise to undo.
ii Tilt the top of the panel outward.
iii Lift the panel clear of the slots on the base rail.
iv Withdraw the panel. Do not undo the earth/ground connection. Pivot the panel to the side or the front
of the instrument as applicable.

7.1.2 To Fit a Panel

i Locate the tabs on the bottom of the panel in the slots of the base rail.
ii Make sure that the earth/ground wire is not trapped then pivot the panel until it is level with the frame.
iii Rotate each of the slot headed screws one quarter turn clockwise to fasten.

7.1
1PES07GB Iss 03
 connectors

screws

7.2.2 To Remove the Electronics Module

7.2
1PES07GB Iss 03
7.2 ELECTRONICS MODULE

7.2.1 To Remove the Electronics Module - Complete

i Disconnect the mains input power from the instrument.

ii Remove the left-hand and the rear panel (7.1.1 ).

iii Disconnect all nine plugged connections at the back of the Electronics Module, and the earth connection.

iv Undo and remove the six screws that hold the Electronics Module box in the frame.

v Withdraw the Electronics Module carefully as a complete assembly.

7.2.2 To Fit the Electronics Module - Complete

Note
1 When you install a modified Electronics Module you must remove the SSR from the air pump.

To remove the SSR from the air pump :

ii Locate the air pump. Identify the SSR assembly that is mounted on top of the pump, and a three-way
terminal block attached to the SSR.

iii Disconnect and remove the brown coloured wire that connects between L1 of the terminal block and
the SSR. Discard the brown wire.

iv Disconnect the white wire from the other ‘mains’ connection of the SSR.

v Connect the white wire (removed from the SSR) to terminal L1 of the terminal block.

To fit the replacement Electronics Module:

vi Align the replacement Electronics Module with the aperture, then slide it carefully into position.

ii Use the six screws to secure the Electronics Module in position.

iii Connect all nine plugged connectors into their corresponding sockets and secure them, and remake
the earth connection.

iv Refit the left hand side panel, and the rear panel.

v Re-connect and restore the mains supply.

7.2.3 To Test

i Do the tests: Test Procedure 3 (5.11); Test Procedure 5 (5.13).; Test Procedure 6 (5.14).

7.3
1PES07GB Iss 03
 7.3.1 To Remove the Command Console

7.4
1PES07GB Iss 03
7.3 COMMAND CONSOLE (If fitted)

7.3.1 To Remove the Command Console

i Disconnect the mains input power from the instrument.

ii Disconnect the printer cable (if fitted) from the connector at the rear of the Console.

iii Lift the hinge cover box vertically to remove (if necessary lever upward with a plastic spatula).

iv Undo and remove the two screws that hold the front tabs of the Console to the top deck. Lift the rear
of the plinth off the spring clips (or slide the plinth towards you to release the keyhole tabs).

HOLD ELECTRICAL CONNECTORS BY THE BODY ONLY. SOME ELECTRONIC

COMPONENTS ARE SENSITIV E TO STATIC ELECTRICITY AND MAY BE DAMAGED IF
YOU TOUCH PINS OR TERMINALS.

v Lift up the Console carefully and decouple the connectors from the underside.

vi Undo the Earth (Ground) connection to the top deck Remove the Console to a safe place.

7.3.2 To Fit the Command Console

i Couple the electrical connectors to the corresponding sockets on the underside of the Command
Console. Make sure to make the Earth (Ground) connection with the Green/Yellow wire to the top
deck using the screws and washers removed in 7.3.1 v above.

ii Insert the two screws in the front tabs of the Command Console. Tighten the screws.

iii Put the hinge cover box in position. Press down to snap it into place.

iv Re-connect and restore the mains supply.

7.3.3 To Test

i Do the tests: Test Procedure 5 (5.13); Test Procedure 6 (5.14). (Use all keys).

7.4 REACTION CHAMBER

7.4.1 To Remove the Reaction Chamber

i Disconnect mains input power from the instrument.

ii Open the lid and remove the lid seal. Store the seal in a safe place.

iii Remove the left hand side panel.

7.5
1PES07GB Iss 03
 lid seal
nut

air inlet

overfill sensor
fixing screws

7.4.1 To Remove the Reaction Chamber

7.6
1PES07GB Iss 03
 iv Disconnect the heated Inlet Pipe from the bottom of the Reaction Chamber.

v Make a note of the electrical connections.

vi Disconnect all electrical connections (7off) to the Reaction Chamber assembly and Agitation motor.

vii Disconnect the plastic air tube from the blue Festo connector at the top rear of the Reaction Chamber.

viii Undo and remove to a safe place the securing nut (18mm) of the air inlet connector.

ix Push the air inlet connector into the Reaction Chamber to allow clearance when lifting the Reaction
Chamber through the aperture in the deck.

x Use wax crayon to draw an alignment mark on the deck and on the rim of the Reaction Chamber.

xi Undo and remove the (8) Allen screws that secure the Reaction Chamber to the deck.

xii Lift the Reaction Chamber out of the deck.

xiii Invert the Reaction Chamber and place it on a bench in a safe place.

xiv Remove and discard the PTFE seal from the underside of the Reaction Chamber.

7.4.2 To Fit the Reaction Chamber

i Fit a replacement PTFE seal.

ii Lift the Reaction Chamber and turn it over so that the Agitate assembly is underneath.

iii Carefully insert the Reaction Chamber into the deck aperture.

iv Rotate the Reaction Chamber about the axis of the centre column until the crayon marks line up.

v Insert and tighten the (8) Allen screws to secure the Reaction Chamber to the deck.

vi Insert the air inlet connector into its aperture in the side-wall of the Reaction Chamber.

vii Change the PTFE 'O' ring of the air inlet connector and then use the 18mm nut to secure the air inlet
connector to the side-wall of the Reaction Chamber.

viii Attach the plastic air tube to the Festo connector and screw finger tight.

ix Attach the electrical connectors and make good the electrical connections to the Reaction Chamber.

7.7
1PES07GB Iss 03
 insulation pad

heating pad

second hole

7.5.1 The Reaction Chamber Bottom Heater

7.8
1PES07GB Iss 03
 x Re-connect the Reagent Tube to the bottom of the Reaction Chamber and tighten firmly.

xi Replace the left hand side panel, and refit the lid seal removed in 7.1.1 ii.

xii Re-connect and restore the mains supply.

7.4.3 To Test

i Do the tests: Test Procedure 2 (5.10); Test Procedure 3 (5.11);

Test Procedure 4.(5.12); Test Procedure 5 (5.13) Test Procedure 6 (5.14).

7.5 BOTTOM HEATER - REACTION CHAMBER

7.5.1 To Remove the Bottom Heater

i Remove the Reaction Chamber (7.4.1).

ii Cut the aluminium tape that secures the insulation pad to the bottom of the Reaction Cham ber.

iii Remove the insulation pad and discard it safely.

iv Remove the heater pad, and discard it safely.

v The heater pad is self adhesive. Remove all traces of the adhesive and clean the area with alcohol
before the heater pad is replaced.

7.5.2 To Fit the Bottom Heater

i Fit the replacement Reaction Chamber heating mat. Take care to align the heater correctly before
fully pressing down.

ii Make sure that the slot lines up with the 2nd hole to the right of the studs (as viewed).

iii Cover the heating mat with the Reaction Chamber base insulating mat.

iv Align the insulating mat with the 2nd slot to the right of the studs (as viewed).

v Use aluminium foil tape and fasten the insulating mat in position.

vi Refit the Reaction chamber (7.4.2).

7.5.3 To Test

i Do the tests: As 7.4.3 and Test Procedure 5 (5.13); Test Procedure 6 (5.14) (Omit Wax Baths)

7.9
1PES07GB Iss 03
 50 mm

7.6.2 The Reaction Chamber Side Wall Heater

overfill sensor

7.7.1 The Overfill Sensor

7.10
1PES07GB Iss 03
7.6 SIDE-WALL HEATER - REACTION CHAMBER

7.6.1 To Remove the Side-wall Heater

i Remove the Reaction Chamber (7.4.1).

ii Cut the aluminium tape and undo the straps that secure the insulation to the side walls of the
Reaction Chamber.

iii Remove the insulation and discard it safely.

iv Remove the side wall heater band and discard it safely.

7.6.2 To Fit the Side-wall Heater

i Fit the replacement Reaction Chamber heater band in position. Set the lower edge at a height of
50mm as shown.

ii Cut insulation to size and shape and fit it to cover the heater band and temperature sensor.

WARNING M A K E S U R E T H A T S I L V E R F O I L T A P E D O E S N O T T O U C H E L E C T R I C A L
CONNECTIONS OR COMPONENTS.

iii Set aluminium band to a height of 50 mm as shown to hold the insulation in position.

iv Use aluminium foil tape to secure the aluminium band in position .

v Refit the Reaction chamber (7.4.2).

7.6.3 To Test

i Do the tests: As 7.4.3 and Test Procedure 5 (5.13); Test Procedure 6 (5.14) (Omit Wax Baths).

7.7 OVERFILL SENSOR

7.7.1 To Remove the Overfill Sensor

i Disconnect the mains input power from the instrument.

ii Remove the left hand side panel.

iii Disconnect the electrical cabling to the overfill sensor.

iv Loosen and undo the nut that secures the sensor in the side wall of the Reaction Chamber.

7.11
1PES07GB Iss 03
 motor

allen screws

spring

set screws

7.8.1 The Agitation Assembly

7.12
1PES07GB Iss 03
7.7.2 To Fit the Overfill Sensor

i Hold the replacement Overfill sensor in position. Carefully fit the securing nut.

ii Tighten the securing nut carefully. DO NOT OVER TIGHTEN.

iii Re-make the electrical connections to the Overfill sensor.

iv Replace the left hand side panel.

v Re-connect and restore the mains supply.

7.7.3 To Test

i Do the tests: Test Procedure 1 ( 5.9), and a functional sensor test.

7.8 AGITATION MOTOR

7.8.1 To Remove the Agitation Motor

i Disconnect mains input power from the instrument.

ii Remove the left hand side panel.

iii Undo the connector to the Red and Blue, or Blue and White, electrical wires for the agitation
motor/gearbox assembly.

iv Locate the link arm that connects between the motor/gearbox assembly and the agitation actuator arm.

v Loosen the two set screw at the back of the block that holds the link arm on the drive shaft of the
motor. DO NOT LOSE THE SPRING.

vi Remove the block for the link arm from the motor drive shaft and note the position of the ‘flat’ with
respect to the set screws.

vii Undo and remove the four Allen screws (4mm) that secure the motor/gearbox to the bracket.

vii Lift the motor/gearbox assembly upwards to remove.

7.8.2 To Fit the Agitiation Motor

i Make sure that the replacement motor/gearbox assembly is correctly orientated for installation.

ii Fit the replacement motor/gearbox assembly on the bracket. Use the four 4 mm Allen screws to secure.

iii Fit the connector to the Red and Blue, or Blue and White, electrical wires for the agitation motor /
gearbox assembly. Connect the mains supply to the instrument.

7.13
1PES07GB Iss 03
 10mm nuts

Heated Inlet Pipe Rotary Selector Valve Bracket

Heater Manifold PTFE Seals Connector Panel Nylon Retaining Scews

7.9.1 To Remove the Rotary Selector Valve.

7.14
1PES07GB Iss 03
 iv Use Production Services to energise the Agitation motor. Stop the motor when the ‘flat’ of the motor
drive shaft is nominally in the position noted in (vi) above.

v Disconnect mains input power from the instrument.

vi Fit the spring and washer, and then fit the block of the link arm, on to the motor drive shaft.

vii Rotate the link arm so that the set screw sits on the ‘flat’ of the motor shaft. Unscrew the set screws
sufficiently to apply 'pink Loctite 222' to the threads, then tighten the set screws.

viii Fit the side panel and connect the mains supply to the instrument.

7.8.3 To Test

i Fit baskets in the Reaction Chamber and select Agitate. Make sure that the baskets do not touch the
obverfill detector cap.

ii Do the tests: Test Procedure 4 (5.12).

7.9 THE ROTARY SELECTOR VALVE

7.9.1 To Remove the Rotary Selector Valve

i Drain the Wax Baths and allow them to cool, then remove the Electronics Module (7.2.1).

ii Disconnect the heated Inlet Pipe from the bottom of the Reaction Chamber (7.16.1).

iii Disconnect the electrical connectors (3) and tie wraps associated with the cables to the Selector Valve.

iv Disengage all the bottles in the reagent store from their connectors, then undo the lock nuts of the four
nylon screws that hold the two connector retaining panels in position.

v Rotate clockwise the nylon screws that hold the connector panels. Push the right and left edges of the
panels to release them. Allow the panels to slide downward.

vi Release all the bottle connectors from the rear wall plate of the reagent bottle store.

vii Undo and remove the (2x)10mm nuts that hold the valve bracket to the wax bath heater manifold.

viii Carefully withdraw the bracket and Selector Valve from the instrument.

ix Carefully lift out and discard the four PTFE seals from the wax bath heater manifold.

Note
1 Most repairs to the rotary valve are possible with the valve still attached to the connector tubes. If you
have to remove the valve completely, note the positions of the connector tubes before disconnecting.

7.15
1PES07GB Iss 03
 cartridge heaters

7.10.1 To Remove the Cartridge Heaters from the Rotary Selector Valve

7.16
1PES07GB Iss 03
7.9.2 To Fit the Rotary Selector Valve

i Insert replacement PTFE seals in the four outlet orifices of the wax bath heater manifold.

ii Carefully slide the bracket and the Selector Valve on to the two studs on the wax bath manifold.
Secure with the washers and 10mm nuts. Tighten securely, but do not over tighten.

iii Make the three electrical connections to the Selector Valve, and fit tie wraps to the wiring.

iv Re-connect the heated pipe to the bottom of the Reaction Chamber (7.16.2).

v Put the bottle connectors in their correct positions in the rear wall plate of the reagent bottle store. Lift
and position the connector retaining plates into the retaining slots. Use the bottles to hold the
connectors in position before the retaining plates are fitted.

vi Screw in the four nylon retaining screws that hold the two connector retaining panels in position. Use
the lock-nuts to secure. DO NOT OVER TIGHTEN. Remove the outer bottles and make sure that the
connectors are free to move in their slots.

viii Push all the bottles fully home in their corresponding connectors.

ix Fit the Electronics Module (7.2.2).

7.9.3 To Test

i Do the tests: Test Procedure 2; (5.10); Test Procedure 3; (5.11);

Test Procedure 5; (5.13); Test Procedure 6 (5.14) (Omit Wax Baths).

7.10 CARTRIDGE HEATERS - ROTARY SELECTOR VALVE

7.10.1 To Remove the Cartridge Heaters from the Rotary Selector Valve

i Remove the rotary Selector Valve (7.8.1).

ii Undo and remove the six Allen screws that hold the rotary Selector Valve on the mounting bracket.

iii Undo the heater connecting wires from the manual reset thermal switch. Use long-nose pliers to
withdraw the cartridge heaters from the body of the rotary Selector Valve. Secure the valve to prevent
the fluid pipes becoming kinked or otherwise damaged.

iv Use methylated spirit and cotton buds to clean the orifice of each cartridge heater.

7.10.2 To Fit the Cartridge Heaters into the Rotary Selector Valve

i Use heat transfer compound. Fit the replacement heater cartridge into the orifice.

ii Connect the heater wires to the manual reset thermal switch.

7.17
1PES07GB Iss 03
 M4 nuts

7.11.1 To Remove the Air Pump

7.18
1PES07GB Iss 03
 iii Fit new seals then fit the mounting bracket to the rotary Selector Valve. Secure with the six Allen
screws (7.7.1 ii).

iv Fit the rotary Selector Valve (7.8.2).

7.10.3 To Test

i Do the tests: Test Procedure 6 (5.14) (Omit Wax Baths).

7.11 THE AIR PUMP

7.11.1 To Remove the Air Pump

i Disconnect the mains input power from the instrument.

ii Remove the back panel, and disconnect the electrical wiring to the pump.

iii Note the positions of the air lines with respect to the pump. Disconnect the air lines from the pump.

iv Undo and remove the M4 nuts that secure the pump to the mounting plate.

v Remove the anti-vibration bushes. Lift the pump off the mounting plate.

7.11.2 To Fit the Air Pump

i Check that the anti-vibration mounting bushes are in good condition Replace if necessary.

ii Fit the pump on the mounting plate. Fit the anti-vibration bushes, the washers, and the nuts and
secure with the M4 nuts (7.10.1 iv). Use replacement Nyloc nuts if necessary.
DO NOT OVERTIGHTEN.

iii Make the electrical wiring connections to the pump.

iv Note the positions of the two air tubes. Attach the two air tubes to the correct Festo connectors. Screw
the Festo connector nuts finger tight.

v Fit the back panel.

vi Attach the air lines to the pump.

vii Re-connect and restore the mains supply.

7.11.3 To Test

i Do the test: Test Procedure 1 (5.9).

7.19
1PES07GB Iss 03
 solenoids

air pipes

base block

7.12.1 To Remove the Complete Solenoid Valve Assembly

housing

screws (2)

block

switchover

7.13.1 To Remove an Individual Solenoid Valve

7.20
1PES07GB Iss 03
7.12 THE SOLENOID ASSEMBLY - COMPLETE

7.12.1 To Remove the Solenoid Assembly

i Disconnect the mains input power from the instrument, and remove the rear panel. (Do not
disconnect the earth (ground) wires - move the panels to one side to obtain access).

ii Disconnect the electrical wiring to the solenoid assembly.

iii Make a note of the relative positions of the air tubes. Undo the nuts of the connectors
associated with those air tubes. Disconnect the air tubes from the solenoid assembly.

iv Undo the four screws that hold the solenoid manifold on the mounting plate.

7.12.2 To Fit the Solenoid Assembly

i Fit the replacement solenoid assembly and manifold, in the correct orientation, on the mounting plate.
Use the four screws (7.11.1 iv) to secure the assembly on the mounting plate.

ii Refer to your note of the positions for the air tubes. Fit the air tubes on the connectors. Screw the nuts
of the connectors finger tight.

iii Make the electrical wiring connections to the solenoid assembly.

iv Fit the rear panel, and re-connect and restore the mains supply.

7.12.3 To Test
i Do the tests: Test Procedure 5 (5.13) (Valves only); Test Procedure 2 (5.9).

7.13 SOLENOIDS - INDIVIDUAL

7.13.1 To Remove an Individual Solenoid Valve

i Disconnect the mains input power from the instrument.

ii Remove the rear panel. (Do not disconnect the earth (ground) wires - move the panels to one side to
obtain access).

iii Disconnect the electrical wiring to the solenoid assembly.

iv Undo the screw in the centre of the connector housing. Lift off the connector housing.

v Undo, but do not remove, the two screws that hold the solenoid block.

vi Lift the black solenoid block (1), with the switchover instrument (2) attached, from the manifold block.

7.21
1PES07GB Iss 03
 Heater and Sensor Connectors Concealed screws under Lid Lock

Wax Drain Cover Screws Top Deck Fixings

7.14.1 To Remove the Wax Baths

7.22
1PES07GB Iss 03
Note
Replace the solenoid as a unit, complete with switchover unit.

7.13.2 To Fit an Individual Solenoid Valve

i Orientate the replacement solenoid block on the manifold block.

ii Tighten the two screws in the corners of the solenoid block to 0.5Nm torque.

iii Fit the connector housing on the connectors. and tighten the central screw.

iv Carefully connect the electrical wiring to the solenoid assembly.

v Fit the rear panel.

vi Re-connect and restore the mains supply.

7.13.3 To Test

i Do the tests: Test Procedure 5 (5.13) (Valves only); Test Procedure 2 (5.9).

7.14 WAX BATHS

MAKE SURE THAT THE WAX BATHS ARE COOL AND ARE EMPTY BEFORE YOU START.

7.14.1 To Remove the Wax Baths

i Remove the Command Console (7.3.1); the Electronics Module (7.2.1), and the Reaction Chamber (7.4.1).

ii Remove the right-hand side, and the rear, panels.(Do not disconnect the earth (ground) wires).
iii Unscrew and remove the wax bath drain spout.

iv Undo the Festo connector for the air tube to the wax trap.

v Cut the tie-wraps for the main cableform and uncouple ALL the electrical connectors to the wax baths,
at the rear of wax bath 'D'.

vi Undo and remove the screws that hold both the lid lock door hinge blocks to the top deck.

vii Lower the lid lock door carefully. Let it to hang from the fixed stay.

viii Remove the two screws into the top deck that are revealed when the lid lock door is lowered.

ix Remove the five screws that hold the drain tap cover. Allow the plate to hang from the pull-ring.

x Remove the countersunk screw that holds the top deck to the frame, then close the door.

7.23
1PES07GB Iss 03
7.24
1PES07GB Iss 03
 xi Remove the three screws that hold the left hand side of the top deck to the frame (viewed from the
front). Repeat for the screws at the back and right-hand sides.

xii Use adhesive tape to secure the see-through lid in its closed position on the top deck.

GET HELP AND WEAR PROTECTIVE GLOVES BEFORE YOU LIFT THE TOP DECK
ASSEMBLY. IT IS VERY HEAVY AND AWKWARD TO MANOEUVRE.

xiii Lift off the top deck complete with wax bath assembly Place the top deck upside down on a strong bench.

7.14.2 To Fit the Wax Baths

Get help and wear protective gloves before you lift the top deck assembly. It is very heavy and
awkward to manoeuvre.

i Align the top deck carefully over the frame of the instrument then lower it into position.

ii Insert and tighten the nine screws that hold the top deck to the frame.

iii Remove the adhesive tape from the see-through lid then open the lid.

iv Put the lid latch door in position. Insert and tighten the two screws in each of the two hinge blocks.

v Close the see-through lid and latch it closed with the lid lock door.

vi Align the cover plate over the wax drain taps and secure in position with the five screws.

vii Tie-wrap the cableform to the centre of the middle deck.

viii Make good all the electrical connections to the wax baths. Fit new tie wraps to hold the cables in position.

ix Replace the right-hand side panel.

x Fasten the connector for the air tube to the wax trap.

xi Replace the wax bath drain spout.

xii Fit the Reaction Chamber (7.4.2).

xiiii Fit the Electronics Module (7.2.2).

xiv Fit the Command Console (7.3.2).

7.14.3 To Test

i Do the tests: As specified in 7.2.3; 7.3.3; 7.4.3.

7.25
1PES07GB Iss 03
 Heater
Cartridge
Locations

Underside View of the Wax Bath Heater Manifold

Right-hand Panel side

Heater
Cartridges
A B C D

FRONT REAR

Reaction Chamber Side

7.15.1 To Remove the Wax Bath Cartridge Heaters.

7.26
1PES07GB Iss 03
7.15 CARTRIDGE HEATERS - WAX BATHS

7.15.1 To Remove the Wax Bath Cartridge Heaters

i Disconnect the mains input power from the instrument.

ii Remove the right-hand side panel (Do not disconnect the earth (ground) wires - move the panels to
one side to obtain access).

iii Cut the tie wraps that hold the cables to the wax bath cartridge heaters.

iv Undo the electrical connector to the wax bath cartridge heaters.

v Use long-nosed pliers to slide the spade connectors off the terminals of the associated manual reset
safety cut-out switch.

vi Pull the connecting wire of the defective cartridge heater to withdraw the cartridge from the manifold.

vii Use a pin extractor to remove the old connecting pins from the connector.

viii Discard the faulty cartridge heater.

Note
1 If the cartridge heater of wax bath D sticks in the manifold, remove the rotary Selector Valve and use a
metal rod of a suitable sized to push the cartridge out from the opposite side.

7.15.2 To Fit the Wax Bath Cartridge Heaters

i Push new heater wiring pins into the connector.

ii Clear the hole of residual thermal grease.

iii Insert adequate thermal grease in the cartridge housing to ensure good heat conduction.

iv Smear the replacement cartridge heater with thermal grease. Insert the cartridge heater into the
housing. Make sure that cartridge heater is pushed fully home. Make sure that the front end of the
cartridge heater is flush with the inner edge of the manifold.

v Make sure that the rubber sleeves over the wire are pressed against the cartridge heater. Bend the
wires into position and fit the tie wraps.

vi Make the electrical wiring connections to the heater and the appropriate manual reset safety cut-out
switch.

vii Replace the right-hand side panel.

viii Re-connect and restore the mains supply.

7.27
1PES07GB Iss 03
 tie wraps

cartridge
heaters

heated inlet pipe

7.16.1 To Remove the Heater Cartridges from the Inlet Column

7.28
1PES07GB Iss 03
7.15.3 To Test

i Do the tests: Test Procedure 6 (5.14) ('Set Wax ....' only); also Test Procedure 2 if the selector
valve is removed (refer to Note 1 above).

7.16 INLET HEATERS - INLET COLUMN

7.16.1 To Remove the Inlet Column Cartridge Heaters

i Remove the Electronics Module (7.2.1).

ii Cut the tie wraps that hold the cables for the agitate column inlet heaters.

iii Undo the electrical connector for the agitate column inlet heaters.

iv Use long-nosed pliers to slide the spade connectors off the terminals of the appropriate manual
reset safety cut-out switch.

v Pull the connecting wire of the defective heater and withdraw the defective heater from the manifold. If
the the defective heater is stuck, undo the single screw that holds the temperature sensor support plate
on the opposite side of the column then remove the support plate. Use a metal rod to push the cartridge
out of its housing.

vi Use a pin extractor to remove the connecting pins from the connector. Discard the heater.

7.16.2 To Fit the Inlet Column Cartridge Heaters

i Push the pins of the replacement cartridge heater into the connector.

ii Insert adequate thermal grease in the cartridge housing to ensure good heat conduction.

iii Smear the replacement cartridge heater with thermal grease. Insert the replacement cartridge heater
into the housing. Make sure that the replacement cartridge heater is pushed fully home. Fit the
sensor support plate if applicable.

iv Make the electrical connections to the the replacement cartridge heater and associated manual reset
safety cut-out switch.

v Attach tie wraps to support the wiring.

vi Fit the Electronics Module (7.2.2).

7.16.3 To Test

i Do the tests: Test Procedure 6 (5.14).

7.29
1PES07GB Iss 03
 nut

tie wraps

iii
connectors
v
extension piece
for pipe to bottle 10

7.17.1 To Remove the Heated Inlet Pipe

7.30
1PES07GB Iss 03
7.17 INTERCONNECTING HEATED PIPE - REACTION CHAMBER FEED

7.17.1 To Remove the Interconnecting Heated Pipe

i Remove the Electronics Module (7.2.1).

ii Cut the tie wraps that hold the cable for the inlet column heaters.

iii Undo the electrical connectors for the heater of the inlet pipe and for the inlet column hea ters.

iv Use a special spanner to undo the bottle interconnecting pipe from the extension piece to port 10 of
the rotary selector valve.

v Use a shortened 22mm open ended spanner to undo the nut that attaches the heated pipe to the
rotary selector valve.

vi Use a shortened 22mm open ended spanner to undo the nut that attaches the heated pipe to the
agitate column, and remove the pipe.

7.17.2 To Fit the Interconnecting Heated Pipe

i Check that the replacement heated pipe is correctly orientated for the electrical connections.

ii Fit the nut on the threaded pipe of the agitate column and use a special shortened 22mm open ended
spanner to tighten the nut.

iii Make the electrical connection for the heater of the heated inlet pipe.

iv Fit the nut on the threaded centre port of the rotary selector valve and use a special shortened 22mm
open ended spanner to tighten the nut.

v Fit the bottle interconnecting pipe from bottle position 10 to the extension tube from port 10 of the
rotary selector valve. Use a special spanner to tighten the nut.

vi Install tie wraps to support the wires for the heated pipe and for the agitate column inlet heaters.

vii Fit the Electronics Module (7.2.2).

7.17.3 To Test

i Do the tests: Test Procedure 2 (5.10); Test Procedure 3 (5.11); Test Procedure 6 (5.14).

7.31
1PES07GB Iss 03
 nut

nylon screws
7.18.1 To Remove the Bottle Pipes

7.32
1PES07GB Iss 03
7.18 INTERCONNECTING PIPES - BOTTLES TO VALVE

7.18.1 To Remove the Interconnecting Pipes Between the Bottles and the Valve

i Remove the Electronics Module (7.2.1).

ii Remove the bottle from the reagent store position associated with the pipe to be removed. Leave all
the other bottles with their corresponding connectors engaged.

iii Undo the lock nuts of the nylon screws that hold the relevant connector retaining panel in position.

iv Turn the nylon screws that hold the retaining panel counter clockwise to loosen the panels.

v Push the right and left edges of the panel to release, and allow the panel to slide downward.

vi Release the relevant bottle connector from the connector panel.

vii Use a special spanner to loosen the interconnecting pipe at the valve, then turn the pipe counter
clockwise by hand to undo. Remove the interconnecting pipe. Remove the PTFE seal from the
bottom of the threaded aperture in the valve

7.18.2 To Fit the Interconnecting Pipes Between the Bottles and the Valve

i Fit the PTFE 'O' ring, (P9460) into the aperture in the valve that is to receive the interconnecting pipe.

ii Screw the connector of the interconnecting pipe to the valve and tighten.

iii Insert the bottle connector of the interconnecting pipe into the appropriate aperture in the connector
panel at the rear of the reagent store, and secure with the retaining panel.

iv Replace the reagent bottle in the appropriate position.

v Fit the Electronics Module. (7.2.2).

7.18.3 To Test

i Do the tests: Test Procedure 2 (5.10); Test Procedure 3 (5.11); Test Procedure 6 (5.14).

7.33
1PES07GB Iss 03
 connectors
insulation
‘windows’

7.19.1 To Remove the Temperature Sensing Transistor from a Wax Bath

stud

pad

bush

washers and
nut (M3)

7.19.2 To Assemble the Temperature Sensing Transistor from a Wax Bath

7.34
1PES07GB Iss 03
7.19 TEMPERATURE SENSING TRANSISTOR - INDIVIDUAL WAX BATHS

Notes
1 A digitising temperature sensing transistor is mounted on the right-hand sidewall (viewed from the
front) of each of the four wax baths.

7.19.1 To Remove the Temperature Sensing Transistor from a Wax Bath

i Disconnect the mains input power from the instrument. Remove the rear panel and the right-hand
panel (viewed from the front).

ii Undo the 12-way connector of the transistor cableform.

iii Remove the aluminium foil tape that secures the removable 'windows' in the insulation foam on the side
of the wax baths. Remove the foam 'windows'.

iv Remove the nut, spring washer, flat washer, bush, transistor, insulation and thermal washer of
faulty transistor. Cut tie wraps where appropriate.

v Make a note of the layout of the wiring at the 12-way connector. Use a pin extractor to remove the
wiring of the faulty transistor from the 12-way connector. Discard the transistor.

7.19.2 To Fit the Temperature Sensing Transistor from a Wax Bath

i Fit the wiring of the replacement transistor in place in the 12-way connector. Route the wiring from
the connector to the transistor location. Couple the connector to the 12-way socket.

ii Apply thermal grease around the appropriate stud then fit the thermal transfer washer.

iii Fit the insulation pad over its stud and against the thermal transfer washer.

iv Fit a 'Top Hat' section insulation bush into the hole of the replacement transistor from the 'stepped'
side of the transistor. Apply a small amount of Loctite 406 plastic adhesive on the large diameter side
of the bush. Secure the bush in position. Allow 1 or 2 seconds to cure, then fit the transistor on the
stud.

v Fit the flat washer, spring washer, and full M3 nut on the stud. Tighten to 0.5Nm torque. Hold the
transistor in position with gentle sideways pressure on the wires. Fit the nut and the washers.

vi Test that there is no short circuit between the top metal surface of the transistor and the wax bath.

vii Fit tie wraps where appropriate.

viii Replace the removable insulating foam 'window' panels. Make sure that the aluminised coating is
on the outside. Use heat resisting aluminium tape.

ix Replace the right-hand side and rear panels. Re-connect and restore the mains supply.

7.35
1PES07GB Iss 03
7.36
1PES07GB Iss 03
7.19.3 To Test

i Do the tests: Test Procedure 6 (5.14).

7.20 TEMPERATURE SENSING TRANSISTOR CABLEFORM - WAX BATHS

7.20.1 To Remove the Temperature Sensing Transistor Cableform (refer to figure 7.19.1)

i Disconnect the mains input power from the instrument.

ii Remove the rear panel and the right-hand panel (Do not disconnect the earth (ground) wires - move
the panels to one side to obtain access).

iii Decouple the 12-way connector of the transistor cableform.

iv Remove the aluminium foil tape that secures the two removable 'windows' in the insulation foam on the
side of the wax baths. Remove the foam windows.

v Remove the nut, spring washer, flat washer, bush, transistor, insulation pad and thermal washer of
each of the four transistors revealed. Cut tie wraps where appropriate.

vi Remove and discard the cableform with transistors.

7.20.2 To Replace the Temperature Sensing Transistor Cableform (refer to figure 7.19.2)

i Fit the replacement cableform in place. Route the wiring from the connector to the transistor
locations. Couple the connector to the 12-way socket.

ii Apply thermal grease around each stud on the wax bath. Fit the thermal transfer washers.

iii Fit an insulation pad over each stud, and push up against the thermal transfer washer.

iv Fit a 'Top Hat' section insulation bush into the hole of the replacement transistor from the 'stepped'
side of the transistor. Apply a small amount of Loctite 406 plastic adhesive on the large diameter side
of the bush. Secure the bush in position. Allow 1 or 2 seconds to cure, then fit the transistor on the
stud.

v Fit the flat washer, spring washer and full M3 nut on the stud at each location and tighten to 0.5Nm
torque. Gentle sideways pressure on the wires will hold the transistor in position while the nut and
washers are installed.

vi Test that there is no short circuit between the top metal surface of each transistor and the wax bath.

vii Fit tie wraps where appropriate.

viii Replace the removable insulating foam panels. Use heat resisting aluminium tape.

ix Replace the right-hand side and rear panels, and re-connect and restore the mains supply.

7.37
1PES07GB Iss 03
 cableform
connector

7.21.1 Access to the Thermal Cut-Outs and Cableform for the Wax Baths

Underside View of Manifold

DRAIN TAP END

front sensor

RIGHT HAND
PANEL SIDE

Ports (4) to
Selector Valve rear sensor
REAR

7.21.1 To Remove the Manual Reset Safety Switches of the Wax Bath Manifold

7.38
1PES07GB Iss 03
7.20.3 To Test

i Do the tests: Test Procedure 6 (5.14).

7.21 THERMAL CUT-OUT SWITCHES - WAX BATHS MANIFOLD

Notes
1 Two thermal cut-out switches on the heater manifold provide over-temperature protection while the Wax
Baths heat to the set temperature. Digitised control of the temperature then follows.

7.21.1 To Remove the Wax Bath Thermal Cut-Out Switches

i Disconnect the instrument from the mains supply, and remove reagent bottles 5 and 6

ii Remove the right-hand side and the rear panels. Undo the 2 - way connector for the thermal cut-out .

iii Pull the upper reagent bottle store door half way out to gain access to the aperture in the deck.

iv * Work upwards from reagent bottle positions 5 and 6. Use an M3 size nut driver to undo and remove
the nut, spring washer, the flat washer, and the front thermal cut-out switch.

v * Work upwards from reagent bottle positions 5 and 6. Use an M3 size nut driver to undo and remove
the nut, spring washer, the flat washer, and the rear thermal cut-out switch.

vi Use a pin removal tool to withdraw the pins associated with the thermal cut-out. Discard the
thermal cut-out switch.

7.21.2 To Fit the Wax Bath Thermal Cut-Out Switches

i Apply a thin film of grease around the stud for the cut-out switch. Fit an insulating pad.

ii Fit a 'Top Hat' section insulation bush into the hole of the replacement transistor from the 'stepped' side of the
transistor. Apply a small amount of Loctite 406 plastic adhesive on the large diameter side of the bush.
Secure the bush in position. Allow 1 or 2 seconds to cure, then fit the transistor on the stud.

iii Apply a thin film of grease over the insulating pad and fit the replacement thermal cut-out switch, with
insulating bush, in position on the stud.

iv Use an M3 nut driver and insert an M3 full nut followed by a trace of non-conducting silicone grease to
hold it in the tool. Insert the spring washer then flat washer into the tool and use a trace of silicone
grease to hold them in the tool.

v * Work upwards from reagent bottle positions 5 and 6. Fit the flat washer, spring washer and full M3
nut on the stud of the front thermal cut-out switch. Tighten to 0.5Nm torque.

vi * Work upwards from rear of the instrument. Use an M3 size nut driver. Fit the flat washer, spring
washer and full M3 nut on the stud of the rear thermal cut-out switch. Tighten to 0.5Nm torque.

vii Fit the pin of the cable for the replacement thermal cut-out switch in position in the connector.

7.39
1PES07GB Iss 03
 three way connector

pipe connector
to port 10

7.22.1 To Remove the Temperature Sensing Transistor of the Selector Valve

7.40
1PES07GB Iss 03
 Re-make the connections. Fit tie wraps where applicable.

viii Fit the right-hand side panel and replace the reagent bottles in positions 5 and 6. Re-connect and
restore the mains supply.

7.21.3 To Test

i Do the tests: Test Procedure 6 (5.14)

7.22 TEMPERATURE SENSING TRANSISTOR - ROTARY SELECTOR VALVE

7.22.1 To Remove the Temperature Sensing Transistor From the Rotary Selector Valve

i Disconnect the mains input power from the instrument.

ii Remove the rear panel and the left hand side panel. (Do not disconnect the earth (ground) wires -
move the panels to one side to obtain access).

iii Decouple the 3-way connector to the transistor.

iv Remove the pipe connector to Port 10 of the rotary valve, and the extension tube, to obtain access to the
transistor.

v Use an M3 size nut driver to undo and remove the nut that secures the transistor.

vi Remove the spring washer, flat washer, bush, transistor, insulation and thermal washer.

vii Cut tie wraps where appropriate, and remove and discard the cableform and transistor.

7.22.2 To Fit the Temperature Sensing Transistor in the Rotary Selector Valve

i Route the replacement cableform from the connector to the transistor site. Make the connection to
the 3-way socket.

ii Apply a thin film of silicone grease around the stud on the bottom of the rotary valve.

iii Fit a 'Top Hat' section insulation bush into the hole of the replacement transistor from the 'stepped' side of the
transistor. Apply a small amount of Loctite 406 plastic adhesive on the large diameter side of the bush.
Secure the bush in position. Allow 1 or 2 seconds to cure, then fit the transistor on the stud.

iv Use an M3 nut driver and insert an M3 full nut followed by a small amount of non-conducting silicone
grease to hold it in the tool. Insert the spring washer then flat washer into the tool and use a small
amount of silicone grease to hold them in the tool.

v Fit the flat washer, spring washer and full M3 nut on the stud and tighten to 0.5Nm torque. Use gentle
sideways pressure on the wires to hold the transistor in position.

7.41
1PES07GB Iss 03
 three way
connector

7.23.1 To Remove the Temperature Sensing Transistor from the Reaction Chamber

7.42
1PES07GB Iss 03
 vi Test that there is no short circuit between the plate of the transistor and the bottom of the rotary valve.

vii Replace the extension tube in Port 10 of the rotary valve. Refit the bottle connector to the extension
tube.

viii Replace the left hand side and rear panels.

ix Re-connect and restore the mains supply.

7.22.3 To Test

i Do the tests: Test Procedure 3 (5.11); Test Procedure 6 (5.14) (Set Valve temp...)

7.23 TEMPERATURE SENSING TRANSISTOR - REACTION CHAMBER

7.23.1 To Remove the Temperature Sensing Transistor from the Reaction Chamber

i Disconnect the mains input power from the instrument.

ii Remove the left hand side panel. (Do not disconnect the earth (ground) wires - move the panels to
one side to obtain access).

iii Decouple the 3-way connector to the transistor (Do not confuse with 3-way connector to the inlet
manifold that is also tie wrapped to the heat conducting plate).

iv Use an M3 size nut driver to undo and remove the nut that secures the transistor.

v Remove the spring washer, flat washer, insulating bush, transistor, and insulating pad.

vi Cut tie wraps where appropriate. Remove and discard the cableform and transistor.

7.23.2 To Fit the Temperature Sensing Transistor to the Reaction Chamber

i Route the replacement cableform from the connector to the transistor site, then make the connection
to the 3-way socket.

ii Apply a film of silicone grease round the stud and copper mounting plate, then fit the insulation.

iii Fit a 'Top Hat' section insulation bush into the hole of the replacement transistor from the 'stepped' side of the
transistor. Apply a small amount of Loctite 406 plastic adhesive on the large diameter side of the bush.
Secure the bush in position. Allow 1 or 2 seconds to cure, then fit the transistor on the stud.

iv Fit the flat washer, spring washer and full M3 nut on the stud. Tighten to 0.5Nm torque. Use gentle
sideways pressure on the wires to hold the transistor in position.

vi Test that there is no short circuit between the plate of the transistor and the copper mounting plate.

vii Replace the left hand side panel.

7.43
1PES07GB Iss 03
 7.24.1 To Remove the Temperature Sensing Transistor from the Inlet Manifold

7.44
Iss 03
1PES07GB
 viii Re-connect and restore the mains supply.

7.23.3 To Test

i Do the tests: Test Procedure 6 (5.14).(Set RC temp....)

7.24 TEMPERATURE SENSING TRANSISTOR - INLET MANIFOLD

7.24.1 To Remove the Temperature Sensing Transistor from the Inlet Manifold

i Disconnect the mains input power from the instrument.

ii Remove the left hand side panel. (Do not disconnect the earth (ground) wires - move the panels to
one side to obtain access).

iii Proceed as for 7.22.1 above but substitute Inlet Manifold for Reaction Chamber.

7.24.2 To Fit the Temperature Sensing Transistor to the Reaction Chamber

i Route the replacement cableform from the connector to the transistor site, then make the connection
to the 3-way socket.

ii Proceed as for 7.22.2 above but substitute 'Inlet Manifold' for 'Reaction Chamber'.

Note
1 Replace one cableform at a time or confusion may arise with respect to the connectors.

7.24.3 To Test

i Do the tests: Test Procedure 6 (5.14).(Set Inlet temp....).

7.25 MANUAL RESET SAFETY CUT-OUT SWITCHES - WAX BATHS MANIFOLD

Notes
1 The manual reset safety cut outs are hard-wired into the heater circuit to provide protection if for any
reason the temperature of the manifold becomes excessive.
2 Allow the temperature to fall within limits before the reset button of the switch is pressed.
3 The polarity of the wiring to the safety switch is not important.

THE MANUAL CUT-OUTS ARE WIRED IN THE NEUTRAL LINE TO THE HEATERS. THE
HEATERS ARE STILL LIVE WHEN THE SAFETY CUT-OUT OPERATES.

7.25.1 To Remove the Manual Safety Cut-Out Switches from the Wax Baths Heater Manifold

i Disconnect the mains input power from the instrument.

7.45
1PES07GB Iss 03
 cableform
connector

7.25.1 Access to the Cableform and Thermal Cut-Outs for the Wax Baths

Underside View of Manifold

FRONT (DRAIN TAP END)

Front Switch

RIGHT HAND
PANEL SIDE

Ports (4) to REAR

Selector Valve Rear Switch

7.25.2 To Replace the Manual Reset Safety Switches of the Wax Bath Manifold

7.46
ps01-07 1.03/96
 ii Remove the reagent bottles from positions 5 and 6,

iii Remove the right-hand side panel and the rear panel. (Do not disconnect the earth (ground) wires -
move the panels to one side to obtain access).

iv Make a note of the orientation of the switch and its connecting wires. Use long-nosed pliers to
carefully slide the spade connectors off the terminals of the switch (3 connectors per switch).

v Pull the upper reagent bottle store door half way out to gain access to the aperture in the deck.

vi [FRONT SWITCH] Work upwards from reagent bottle positions 5 and 6. Use an M3 size nut driver to
undo, then remove, both nuts spring washers, the flat washers, and the front switch.

[REAR SWITCH] Work upwards from rear of the instrument. Use an M3 size nut driver to undo,
then remove, both nuts, spring washers, the flat washers, and the rear switch.

vii Cut tie wraps where appropriate and remove and discard the cableform with the switch.

7.25.2 To Fit the Manual Safety Cut-Out Switches to the Wax Baths Heater Manifold

i Apply thermal grease to the face of the manual reset safety cut-out switch.

ii Carefully put the replacement switch in position on the studs.

iii Insert an M3 full nut followed by a a small amount of non-conducting silicone grease to hold the nut in
an M3 nut driver. Insert the spring washer then the flat washer in the tool. Use a small amount of
silicone grease to hold them in the tool.

iv [FRONT SWITCH] Work upwards from reagent bottle positions 5 and 6. Position the nut driver
over the stud and tighten to 0.5 Nm torque. Repeat for the second stud.

[REAR SWITCH] Work upwards from rear of the instrument. Position the nut driver over the stud and
tighten to 0.5 Nm torque. Repeat for the second stud.

v Carefully fit the 3 spade connectors on the appropriate terminals of the manual reset safety switch.

7.25.3 To Test

i Do the tests: Measure the resistance across the switch =<1 ohm.
Test Procedure 6 (5.14).(Set Wax (A-D) temp...).
ii Replace the right-hand panel and the rear panel.

iii Re-connect and restore the mains supply.

7.47
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7.26.1 To Remove the Manual Safety Cut-Out Switches from the Rotary Selector Valve

7.48
1PES07GB Iss 03
7.26 MANUAL RESET SAFETY CUT-OUT SWITCH - ROTARY VALVE

Notes
1 The manual reset safety cut outs are hard-wired into the heater circuit to provide protection if for any
reason the temperature of the Reaction Chamber becomes excessive.
2 Allow the temperature to fall within limits beforeyou press the switch reset button.
3 The polarity of the wiring to the safety switch is not important.

THE MANUAL CUT-OUTS ARE WIRED IN THE NEUTRAL LINE TO THE HEATERS. THE
HEATERS ARE STILL LIVE WHEN THE SAFETY CUT-OUT OPERATES.

7.26.1 To Remove the Manual Safety Cut-Out Switches from the rotary Selector Valve

i Disconnect the mains input power from the instrument.

ii Remove the rear panel and the left hand side panel.

iii Remove the pipe connector to Port 10 of the rotary valve, and the extension tube.

iv Carefully pull off the connectors to both spade terminals of the safety switch.

v Use an M3 size nut driver. Undo and remove both nuts that secure the switch.

vi Remove the spring washer, the flat washer, and the switch. The switch is stuck to the base of the
valve with thermal grease.

7.26.2 To Fit the Manual Safety Cut-Out Switches to the Rotary Selector Valve

i Apply thermal grease to the face of the safety cut-out switch.

ii Put the safety switch in position on the studs.

iii Insert an M3 full nut, and a small amount of non-conducting silicone grease, to hold the nut in an M3
nut driver. Insert the spring washer then the flat washer into the nut driver and use a small amount of
silicone grease to hold them in the tool.

iv Use the tool to fit the nuts and washers on the safety switch retaining studs. Tighten to 0.5Nm.

v Carefully fit the cableform connectors on the spade terminals of the safety switch.

vi Replace the pipe connector to Port 10 of the rotary valve, and the extension tube.

vii Replace the right-hand panel and the rear panel.

viii Re-connect and restore the mains supply.

7.49
1PES07GB Iss 03
 7.27.1 To Remove the Manual Reset Safety Switch from the Reaction Chamber

7.50
1PES07GB Iss 03
7.26.3 To Test

i Do the tests: Measure the resistance across the switch =<1 ohm.
Test procedure 3 (6.11); Test Procedure 6 (5.14).(Set valve temp...).

ii Replace the right-hand panel and the rear panel.

iii Re-connect and restore the mains supply.

7.27 MANUAL RESET SAFETY SWITCH - REACTION CHAMBER

Notes
1 The manual reset safety cut outs are hard-wired into the heater circuit to provide protection if for any
reason the temperature of the Reaction Chamber becomes excessive.
2 Allow the temperature to fall within limits before pressing the reset button of the switch.
3 The polarity of the wiring to the safety switch is not important.

THE MANUAL CUT-OUTS ARE WIRED IN THE NEUTRAL LINE TO THE HEATERS. THE
HEATERS ARE STILL LIVE WHEN THE SAFETY CUT-OUT OPERATES.

7.27.1 To Remove the Manual Reset Safety Switch from the Reaction Chamber

i Disconnect the mains input power from the instrument.

ii Remove the left hand side panel. (Do not disconnect the earth (ground) wires - move the panels to
one side to obtain access).

iii Carefully pull off the cableform connectors to both spade terminals of the safety switch.

iv Use an M3 size nut driver to undo and remove both nuts that secure the switch.

v Remove the spring washer, the flat washer, and the switch. The switch is stuck to the side of the
reaction chamber with thermal grease.

7.27.2 To Fit the Manual Reset Safety Switch to the Reaction Chamber

i Apply thermal grease to the replacement safety cut-out switch.

ii Put the safety switch in position on the studs.

iii Fit a flat washer, spring washer and an M3 nut on each stud and tighten to 0.5Nm.

iv Carefully fit the cableform connectors on the spade terminals of the safety switch.

vi Replace the left hand panel and the rear panel.

vii Re-connect and restore the mains supply.

7.51
1PES07GB Iss 03
 7.28.1 To Remove the Manual Reset Safety Switch from the Inlet Manifold

three way
connector

Air
connector

7.29.1 To Remove the Pressure Transducer

7.52
1PES07GB Iss 03
7.27.3 To Test

i Do the tests: Measure the resistance across the switch =<1 ohm.
Test Procedure 6 (5.14).(Set RC temp...).

ii Replace the right-hand panel and the rear panel.

iii Re-connect and restore the mains supply.

7.28 MANUAL RESET SAFETY SWITCH - INLET MANIFOLD

7.28.1 To Remove the Manual Reset Safety Switch from the Inlet Manifold

i Disconnect the mains input power from the instrument.

ii Remove the left hand side panel. (Do not disconnect the earth (ground) wires - move the panels to
one side to obtain access).

iii Proceed as for 7.26.1 above but substitute 'Inlet Manifold' for 'Reaction Chamber'.

7.28.2 To Fit the Manual Reset Safety Switch to the Reaction Chamber

i Proceed as for 7.26.2 above but substitute 'Inlet Manifold' for 'Reaction Chamber'. Test as above but
substitute 'Set Inlet temp...' for 'Set RC temp...'.

7.29 PRESSURE TRANSDUCER

Note
1 The pressure transducer is pre-calibrated and is not adjustable.

7.29.1 To Remove the Pressure Transducer

i Disconnect the mains input power from the instrument. Remove the left hand side panel.

ii Use firm pressure to pull the pressure transducer from the clips that hold it. Undo the 3-way connector.

ii Undo the Festo pneumatic connector at the nut end of the pressure transducer. Discard the
pressure transducer.

7.29.2 To Fit the Pressure Transducer

i Attach the Festo pneumatic connector to the replacement pressure transducer.

ii Make the electrical connection at the 3-way connector. Fit a tie wrap if necessary.

7.53
1PES07GB Iss 03
 rear securing
hinge retaining Hinge Support
screws (2)
screws (4) Plate (75220584)

Adjustable
Spacers (2)
Lock Nut (75230684)
(P11776)
Front securing
screws (2)

hinge tension
adjustment screw

7.30.1 The See-through Lid Hinge Assembly

7.54
1PES07GB Iss 03
 iii Use firm pressure to push the replacement pressure transducer into the clips.

iv Replace the left hand side panel.

v Re-connect and restore the mains supply.

7.29.3 To Test

i Do the tests: Test Procedure 2 (5.10); Test Procedure 3 (5.11).

7.30 TO REPLACE THE SEE-THROUGH LID

YOU MUST ALWAYS REPLACE THE GLASS WINDOW IF THERE ARE ANY CHIPS OR
SCRATCHES ON THE GLASS

7.30.1 To Remove the See-through Lid

i Make sure that the Reaction Chamber is at atmospheric pressure (loosen the Vacuum Release Tap if
applicable).

ii Disconnect the mains input power from the instrument. Remove the left hand side panel. Remove the
Electronics Module (7.2.1).

iii From the underside of the Top Deck undo and remove the front securing screw from both the
Adjustable Spacers of each hinge. Retain the front securing screws.

iv From the top undo and remove the two rear securing screws from the rear of each hinge. Retain the
rear securing screws

v Use the emergency release pull ring to unlatch the See-through Lid and release the catch of the
See-through Lid.

vi Remove the See-through Lid with the hinges attached.

7.30.2 To Fit the See-through Lid

i Place the See-through Lid in its correct position on the Top Deck of the instrument and locate the
hinges in their original positions.

ii Fit loosely the two rear securing screws in each of the two hinges. Do not tighten completely.

iii From the underside of the Top Deck loosen the four Lock Nuts and unscrew each of the two
Adjustable Spacers of both hinges at least two full revolutions.

iv Make sure that the four retaining screws of each hinge are tightened to 2Nm torque.

7.55
1PES07GB Iss 03
7.56
1PES07GB Iss 03
 v Fit loosely a front securing screw in each of the adjustable spacers of both hinges. Do not tighten
completely.

7.30.3 To Set and Adjust the See-through Lid after installation

Applicability: All instruments

Equipment: i Special Tool P01966.

ii Merck light green dye, ref CI 42095; 1% solution in water.

Method
i Open the See-through Lid. If necessary, pull the Emergency Release cord to release the catch.

ii Remove the Viton/PTFE Lid Seal from the Lid Seal Groove in the Top Deck of the instrument.

iii Put drops of the light green dye (equipment item ii) approximately 40mm apart around the perimeter
of the Lid Seal Groove.

iv Close the lid but do not engage the catch. View the dye through the glass window. There should be a
continuous ring of pale dye all around the rim of the Lid Seal Groove. Adjust the height of the hinge to
obtain this result.

To Adjust: (refer to figure 7.30.1)

a Adjust and tighten the outer Adjustable Spacer of each hinge before you adjust the inner
Adjustable Spacer of each hinge.

b Rotate clockwise the applicable Adjustable Spacer to lift the front of the hinge - rotate anti
clockwise the applicable Adjustable Spacer to lower the front of the hinge.

c Adjust the height of the front of each hinge in turn. Make sure that the dye is a continuous ring of
pale green around the perimeter of the Lid Seal Groove. Tighten the Lock Nut of each Adjustment
Spacer when done.

d Adjust the inner Adjustment Spacer of each hinge in turn to stabilise the set of each hinge. Tighten
the Lock Nut of each Adjustment Spacer when done.

e Open then close the See-through Lid. Make sure that there is a continuous ring of uniform pale
green dye around the perimeter of the Lid Seal Groove.

f Open the See-through Lid and wipe clean the Lid Seal Groove.

v Close the See-through Lid. Make sure that the front panel is parallel to the front vertical edge of the
instrument when the See-through Lid is in the closed position.

vi Fit a black Viton Lid Seal in the Lid Seal Groove. Make sure that the seal sits correctly in the groove.

vii Unscrew the 5mm, black, latch adjust set screw until two or three threads are visible.

7.57
1PES07GB Iss 03
 Roller mechanism
5mm, black,
‘height adjust’ latch adjust set
Allen screws screw.

Lid latch door

Cover retain
plates (3 off)

Cover retain
screws (6 off) ‘Seal Load’
screw (1)

Cover of Lid
The Lid Latch Door
Latch door (1)

Frame of the
See-through Lid
5mm, black,
latch adjust set
screw (1)
Roller mechanism (1)

‘Height adjust’
Allen screws (2)

Lid Latch door-

Hinged panel (1)

‘Seal Load’
screw (1)

Cover of Lid
Lid Latch Adjust Mechanism Latch door (1)

7.58
1PES07GB Iss 03
 viii Undo the two ‘Height Adjust’ Allen screws, then tighten them again by hand.

ix Use groove and check that the roller mechanism of the lid latch is free to rotate.

x Place a weight of approximately 5 Kg at the centre of the front edge of the frame of the see-through
lid.

xi Close the lid latch. Make sure that roller fully engages the catch on the frame of the see-through lid.

To Adjust:

a Loosen but do not remove the six countersunk head screws that hold the cover on the lid latch
door. Remove the cover.

b Use the Emergency Release cord to release the lid latch.

c Loosen the two ‘ height adjust’ Allen screws that secure the roller mechanism.

d Adjust the position of the roller mechanism, as necessary, to ensure that the roller engages with
the catch on the frame of the see-through lid.

e Tighten the two Allen screws, and test again.

f Repeat as necessary until engagement is satisfactory.

xii Remove the weight.

xiii Pull the Emergency Release cord. Make sure that the bottom edge of the Lid Latch Door springs
forward between 5 - 15 mm.

To Adjust:

a Use the Emergency Release cord to release the lid latch.

b Slightly loosen the two Allen screws that secure the roller mechanism ( make sure that you do not
change the position of the roller mechanism set in (iii) above).

c Rotate the 5mm, black, latch adjust Allen screw to adjust the roller mechanism in or out as
applicable.

d Tighten the two Allen screws, and re-test. Repeat a-c as necessary.

xiv Release the Lid Latch and open the See-through Lid.

xv Close the See-through Lid. Use your judgement to assess the downward force necessary to enable
the latch to engage and lock correctly. If necessary, repeat Step (iii).

xvi Open the see-through lid approximately 30° to the horizontal. Release the See-through Lid and allow
it to fall under its own weight.

7.59
1PES07GB Iss 03
 outlet pipe
securing plate

countersunk screws

cover plate

7.31.1 To Remove the Wax Bath Drain Taps

7.60
1PES07GB Iss 03
 xvii Make sure that the rate of descent is controlled and smooth. If the lid does not descend gently under
its own weight the hinge is too tight. If the lid descends too quickly the hinge is too slack. The lid is
heavy and could bruise or trap a finger. Adjust the hinge so that no discomfort is felt by a finger
trapped beneath the front edge of the see-through lid as it falls.

To Adjust:

a Open the See-through Lid

b Use the special tool P13509. From the front of the hinge insert the special tool into the hinge
tension adjust screw that compresses the Bellville washers.

c Rotate the special tool counter clockwise to tighten the hinge. Rotate the special tool
anti-clockwise to loosen the hinge.

ADJUST EACH HINGE IN AN IDENTICAL MANNER AND BY EQUAL AMOUNTS. MAKE ONLY
SMALL ADJUSTMENTS BEFORE YOU RE-TEST. DO NOT OVER-TIGHTEN THE HINGE OR YOU
WILL DAMAGE THE BELLVILLE WASHERS.

xviiiReplace the Console (if applicable), the hinge cover plate, and the cover to the lid latch door

xix Do the test 5.10 (PROCEDURE 2 - AIR SYSTEM TESTS; Page 5.15).

7.30.3 ToTest

i Do the tests: Test Procedure 2 (5.10); Test Procedure 3 (5.11).

7.31 WAX BATH DRAIN TAPS

Note
1 A Viton 'O' ring is used around the spindle of each wax drain tap to ensure a perfect seal against
seepage of hot wax. However, the seal can be ruptured if the tap is turned before the manifold is up to
temperature and solid wax fills the apertures.

TAKE CARE WHEN YOU REMOVE OR ADJUST THE WAX DRAIN TAPS AS ALL THE
HEATING MANIFOLD WILL BE HOT (60-65°C).

7.31.1 To Remove the Wax Bath Drain Taps

i Make sure that the wax bath associated with the tap to be removed is completely empty.

ii Make sure that the manifold is heated and that no solid wax is present in the area of the tap.

7.61
1PES07GB Iss 03
 rubber ‘O’ ring

7.31.2 To Fit the ‘O’ ring of the Wax Tap Spindle

7.62
1PES07GB Iss 03
 iii Make sure that the drain spout is not fitted on the drain orifice.

iv Undo and remove the four countersunk screws that hold the polished cover plate in position.

v Remove the cover plate.

vi Remove both Allen screws of the securing plate associated with the tap to be removed.

vii Turn the tap to be removed counter clockwise until completely unscrewed,. Remove the tap.

7.31.2 To Fit the Wax Bath Drain Taps

i Use a small screwdriver or similar tool to remove the old 'O' ring from the groove in the spindle of the tap.

ii Fit a replacement 12.81mm (Outside Diameter) Viton 'O' ring on the spindle. Make sure that it seats
correctly.

iii Locate the tap spindle in the aperture. Locate the securing plate in position.

iv Ease the tap forwards whilst rotating it clockwise to insert the ‘O’ ring into the aperture and engage
the threads.

v Turn the tap spindle clockwise until the tap is fully closed. Tighten the Allen screws that secure
plate.

vi Use the four countersunk screws to fit the polished cover plate.

v Check that the taps are accessible and that they operate smoothly.

vi Close all four taps. Re-fill the wax baths with wax. Set the wax baths temperature to 65°C until all the
wax is melted.

vii Set the wax baths to the correct temperature to process tissue.

7.31.3 To Test
i Do the tests: Test Procedure 2 (5.10); Test Procedure 3 (5.11).

MAKE SURE THAT EACH TAP IS CLOSED WHEN WORK IS COMPLETED OR WAX
WARNING WILL DISCHARGE AS IT MELTS WHEN THE INSTRUMENT IS SWITCHED ON.

7.63
1PES07GB Iss 03
7.64
1PES07GB Iss 03
8.0 SERVICE ADJUSTMENTS and AMENDMENTS
8.1 SERVICE HISTORY

8.1.1 Numerous modifications have been made since the introduction of Pathcentre™ to enhance the
performance of the instrument. Some of the software modifications improve temperature control and process
quality. Changes to the hardware improve reliability. To make sure that all the instruments in service benefit
from these amendments and improvements, it is suggested that the status of each instrument is checked
against the current standard. Please contact your Shandon dealer.

8.2 RECOMMENDED ROUTINE MAINTENANCE

Description Part No. Task

8.2.1 Every 12 months

i Viton lid Seal 75230645 Replace
ii Vent tubes 73930155 Check and clean
iii Overfill Sensor 75220170 Check Function
iv Batteries (AAA type) P12740 Replace
v Pressure & Vacuum Procedure 2 (Section 5.10 ; Page 5.15)
vi Agitation Motor Check Linkage
vii Pump Head, Diaphragm & seals Replace
viii Analysis Log 752-0D13 Check

8.2.2 Every 24 months

i Do the tasks 8.1.1 (i to x) above.
ii Reagent Bottle Seals Check
Reagent Bottle Seals Replace
iii Drawer Seals Check

8.2.3 Every 36 months

i Do the tasks 8.1.1 (i to x) above.

8.1
1PES08GB Iss 03
8.3 RECOMMENDED SPARES

Refurbished Parts Most of the more expensive assemblies are available on a service exchange basis.
Service exchange items comprise used assemblies that have been refurbished to current production
specifications and are fully warranted. Service exchange parts for Pathcentre are as follows:

Rotary Selector Valve 75210500

Command Module 75210501
Electronics Module 240V Processing Unit 75210502
Electronics Module 110V Processing Unit 75210503
Electronics Module 240V Extension Unit 75210504
Electronics Module 110V Extension Unit 75210505

8.2
1PES08GB Iss 03
9.0 SPECIFICATION, ACCESSORIES
AND SPARES LIST
9.1 SPECIFICATION

Physical
Height 1300mm (51¼ in)
Height (Wax Door Open) 1630mm (64¼ in)
Width 550mm (21¾ in)
Depth 600mm (23¾ in)
Weight (kg) 160 kg (352 lb)
Mounting 4 x Moveable Castors - Front 2 height adjustable

Electrical Note The correct voltage is set at the factory.

Power 2400 VA
Voltage 100V - 240V
Frequency 50/60 Hz
Fuse Europe 250V F10A - 5mm dia x 20mm long
U.S 250V F10A - 6.35mm dia x 25mm long
Switch Convention I = Power On
O = Power Off
Batteries Two; Size AA 1.5V
Insulation Category II
Pollution Degree 2

Indicator Panel All Models 7 segment display in RED Light Emitting Diodes
STOP push-button; RED when lit.
RESTART push-button; GREEN when lit.
LID push-button; YELLOW when lit.

Capacities All Models

Cassettes (No) 324 in Organised load.
Wax Chambers 4x 4.3 (litre)each
Fluid Reagent Bottles 12 x 4.3 (litre)each
Spillage Container 1x 4.3 (litre)

Environment
Temperature +5 °C to + 35 °C
Humidity 80% max for temperatures <31°C
50% max for temperatures >31°C <40°C
(Non condensing environment)

Standard Flush 20 mins Flush 1 @ 60 °C; Agitation 10 Wash + Stir;

5 mins Flush 2 @ <35 °C; Agitation 3 Wash + Stir.
Approximate duration 35 minutes

9.1
1PES9GB Iss 03
Extended Flush 40 mins Flush 1 @ 60 °C; Agitation 20 Wash + Stir
5 mins Flush2 @ <50 °C; Agitation 3 Wash.
Approximate duration 55 mins.

9.1 STANDARD ACCESSORIES

ITEM PART NUMBER DESCRIPTION

100A 75210145 Reagent Bottle - Pack of 3

101A 75210164 Organiser Basket - 3
102A 75210165 Random Basket - 1
103O 75210147 Wax Drain Container
104E 75210150xx Operator Manual (xx = language variant)
105E 75210151 Service Manual
106E 75210148 Bottle Connector Seals - 2 x Pack of 3
107E 75210149 Wax Reservoir Cap seals - Pack of 4
108E 75210152 Reagent Store shelf labels
109E 73910265 Reagent Bottle caps - Pack of 3
110E 73910136 Reaction Chamber Air Vent Sprung Cap - 3
111E 75210154 Filters - Reaction Chamber - 2 (machine version)
75210168 Filters - Reaction Chamber - 2 (machine version)
200E 75220419 Tissue Basket Handle - 3
300A 75230605 Displacement Block
303E 75210155 Rubber bottle guard - pack of 3
500C P12648 'T' Handle Box Spanner
502E P12736 Parallel Tip Screwdriver
503E 75210157 Reaction Vessel Seal (acetone)
504E 75210156 Charcoal Filter
505E 66110048 Airbags - pack of 4
506E P09046 Spatula/Scraper
507E P13442 Fast Blow Fuse 10A (5mm dia x 20 mm long) (110V)
......E P.......... Fuse ....230V Version
P09125 Adjustable spanner 200mm
75210161 Wax disposal bag - pack of 10
75220418 PRCU Lead
75220417 Wax drain spout
75230681 Viton lid seal
P12032 Mains lead (US style)
P12033 Mains lead (European style)
P12822 Mains lead (UK style)
P13433 Bottle pouring spout

9.2
1PES9GB Iss 03
9.3 SPARE PARTS LIST

PLEASE REFER TO THE ITEMISED EXPLODED VIEW DIAGRAM FOR PARTS IDENTIFICATION

ITEM PART No. DESCRIPTION

COMMAND MODULE

1 75230026 Plinth - Command (New Deck only)

1 752xxxxx
2 75220573
4 75220575
5 75230022
6 P12527
7 P12524
8 75220023
9 75230025
10 NOT USED
11 P12544
Plinth - Command (Old Deck only)
Main Body - Command
Interface PCB - Command
Back Plate - Command Bezel
Inverter
LCD
Bezel - Command
Touch Panel - Command
Latch Panel

DECK ASSEMBLY

12 75230091 Hinge - Reaction Vessel Lid

Not Shown P13288 Dowty Washers - where used?
13 75220202 Clutch Housing - Reaction Vessel Lid
14 Up to Serial No PC1189.06W
75220084 Hinge Support plate - Reaction Vessel Lid (Obsolete) Fit Support Plate Kit
75210167 (Instructions supplied)
After Serial No PC1189.06W, drill and tap the Top Deck (75220092) if applicable. Fit
75220584 Hinge Support plate - Reaction Vessel Lid
75230684 Spacer; Support Plate adjustment (4 off required)
P11776 Securing Nut for Spacer 75230684 (4 off required)
75230106 Pressure Pad (Spares only).
15 75230100 Hinge Pin - Reaction Vessel Lid
16 75210071 Lid - Reaction Vessel (includes Item 17)
* M03662 Gasket - PTFE - Reaction Vessel Lid
17 75230343 Glass - Reaction Vessel Lid - is this needed separately?
19 75230005 Locking Ramp - Reaction Vessel Lid
20 75210081 Wax Bath Lid Complete - comprises items 21, 22, 23, 24
21 P12623 Retainer- Wax Bath Lid (3 off)
22 P12622 Spring - Wax Bath Lid (3 off)
23 75230161 Locking Pin - Wax Bath Lid
24 P12624 Seal - Wax Bath Lid
25 75230158 Locating Ring
* 75230192 Backing washer
26 75220101 Wax Vent Assembly
* 73930376 Wax Vent gasket
27 NOT USED

9.3
1PES9GB Iss 03
ITEM PART No. DESCRIPTION (Continuation)

28 73930155 Wax Vent - Wax Trap

159 75220014 Condensing Pipe - Straight
161 75220092 Deck
176 75230677 Pivot Block - Wax Bath Outer Lid
177 75210082 Wax Bath Outer Lid
F 75230164 Clamp Plate (16)

REACTION VESSEL ASSEMBLY

* 75210065 Voltage Dependent complete Reaction Assembly

36 75220175 Temperature Sensor - required separately?
36A 75220083 Digital Temperature Sensor
75230272 Heat Transfer Washer - Reaction thermistor assembly?
37 P12711 Thermal Cut-out - Manual Reset
P13596 Thermal Cut-out, 80°C - Manual Reset after Serial No
PC1104.03W and Software disc 752-0D09 (V8); UIF=057B; BIOS=99E
P12705 Transistor insulating?
P11263 Transistor insulating?
90 P13495 Con Rod Ends (2 off)
91 75230266 Con Rod Studding
92 75220172 Agitation Motor - 230V
* 75220173 Agitation Motor - 110V
93 75230268 Motor Mounting Bracket - Agitation Motor
94 75230254 Locking Collar - Agitation Motor
95 75220155 Clamp Bolt
K P13569 Spring
P07109 Washer
96 75220154 Reaction Manifold Brazed
J 75220159 Temperature Sensor Mounting Plate (Reaction manifold)
97 75220167 Inlet Heater
98 P12600 Seal - Spring Energised
99 P09084 Seal - PTFE
100 75220177 Centre Column Pressed - check illustration?
101 75220176 Drive Unit (no seal) - NB 75220178 = 75220176 + P12600
N/S P12600 Seal - Drive Unit - Spring Energised - PTFE
* P13569 Spring
102/103 75230277 Reaction Vessel Bearing / Filter - Metric
104 75220171 Drive Arm
P05993 Retainer
105 75220169 Link Arm
131 75230256 Insulation - Reaction Vessel - Base - Items 131 - 135 - Do we sell electrical
132 75220165 Pad Heater - Reaction Vessel - Base assembly?
133 75230278 Insulation- Reaction Vessel - Side
134 75220166 Reaction Heater Band - Reaction Vessel
135 P12679 Aluminium Fixing Band
136 75230094 Gasket - Reaction Vessel
137 75220180 Reaction Vessel & Seal Carrier

9.4
1PES9GB Iss 03
ITEM PART No. DESCRIPTION (Continuation)

138 75230681 Reaction Chamber Lid Seal - Viton

* P12576 Reaction Chamber Lid Seal - PTFE
139 75220170 Overfill Sensor Complete
140 66130441 Securing Nut - Overfill Sensor
141 66130439 Washer - Overfill Sensor
142 P05984 ‘O' Ring PTFE
143 75230259 Overfill Sensor Body
144 73910136 Overfill Sensor Cap
145 66130442 Securing Nut - Pneumatic Adaptor - NOT SHOWN
146 66130440 Washer - Pneumatic Adaptor - NOT SHOWN
147 75230263 Pneumatic Vent - Reaction Vessel - NOT SHOWN
148 P09516 'O' ring PTFE
149 66130520 Splash Protector - Pneumatic Vent - NOT SHOWN

ELECTRONICS BOX

111 75210044 PCB Enclosure Complete (inc. items 112 - 121) (230V)
Not Shown Mounting Bracket - Time Delay Relay
* Relay Base
* Time Delay Relay - 230V
* Time Delay Relay - 110V
112 Mother Board
113 Fan
114 E.B 186 PCB
115 Reaction I/F PCB
116 SSR
117 Switched Mode Power Supply
118 Loudspeaker Complete
119 Battery - Type AA
120 Battery Enclosure
121 Mains Inlet
158 Remote Alarm Socket

PUMP PLATE ASSEMBLY

57 75230490 Locking Ring - Bottle Cap

58 75230494 Bottle Cap Inner
59 P12568 Glass Bottle
P12567 Bottle seal
106 P13515 Pump - 110V
* P13659 Pump - 230V
75230471 Pump Plate spacer
107 75230469 Solenoid Valve & Manifold - before Serial No xxxxx
107 A75210174 Burkert Valve / Manifold (including fittings) - after Serial No xxxxx
108 75230470 Solenoid Valve
109 73920117 Pressure Relief Valve - are these required?
* P09324 O Ring - Kalrez - Pressure Relief Valve - are these required?

9.5
1PES9GB Iss 03
ITEM PART No. DESCRIPTION (Continuation)

* P09450 O Ring - PTFE - Pressure Relief Valve - are these required?

* P11097 Spring - Pressure Relief Valve - are these required?
110 P08159 Clip
G 75230517 Pump Plate

BOTTLE TRAY ASSEMBLY

122 66130354 1/8" BSP Blanking Plug

123 75210145 Reagent Bottle (pack 3)
124 73910265 Cap - Reagent Bottle (pack 3) - are these required?
125 M03728 Bottle Tube (0.5M) - are these required?
* P12575 O Ring - Bottle Tube
* P12069 Ferrule - Bottle Tube - are these required?
126 P12600 Seal - Spring Energised PTFE
127 75230592 Bottle Connector Male - are these required?
128 P07831 Seal - Bottle Connector
129 75220055 Reagent Bottle Shelf
130 75220046 Clamping Plate (2 off)
* P12707 Thumb Screw - Clamping Plate (4 off)
* P12708 Thumb Nut - Clamping Plate (4 off)

DRAWER ASSEMBLY

57 75230490 Locking Ring - Bottle Cap

58 75230494 Bottle Cap Inner
59 P12568 Glass Bottle
P12567 Bottle seal
63 P12565 Lock - Accessories Drawer
64 75220303 Filter Frame
65 75230499 Filter Clamp
66 75230492 Filter Connector
67 75220302 Handle - Accessories Drawer
68 75220301 Accessories Drawer
69 75230496 Connector Block
75 75220275 Slide Mounting Bracket - Left
76 P12709 Telescopic Slide - Left
77 P12710 Telescopic Slide - Right
78 75220274 Slide Mounting Bracket - Right
82 75230491 Airbag Connector
83 P07923 Airbag
84 P09310 Charcoal Filter
H 75230594 Overflow Bottle
* 73910236 Bottle cap (pack of 3) (or 75230263 single)

9.6
1PES9GB Iss 03
ITEM PART No. DESCRIPTION (Continuation)

WAX VESSEL / SELECTOR VALVE ASSEMBLY

33 75210003 Rotary Valve Complete (inc. pipes, sensors & heaters)

* 75220009 Rotary Valve Electrical (inc. pipes & heaters) - service number?
* 00LIF003 Motor Brushes (Pair) - service number?
* 00LIFPC004 Encoder Assembly - service number?
34 75220153 Convoluted Tube (12 off) - required separately?
35 75220082 Heated Pipe - required separately?
Not shown 75230018 Extension -Valve Outlet Port
36 75220175 Temperature Sensor - required separately?
37 P12711 Thermal Cut-out - Manual Reset
38 P09460 Pipe Connectors (12 off) - seal
39 00LIFW009 Cartridge Heaters - Rotary Valve - service number?
40 P09460 Pipe Connectors (4 off) - seal
41 00LIFSE005 Seals - Wax Inlet - Rotary Valve (4 off) - service number?
42 75230144 Wax Tank Hole Strip - Side
43 75230145 Wax Tank Front/Rear Hole
44 75230141 Wax Tank
45 75230151 Valve Spindle - Wax Manifold
46 P12640 Seal - Viton - 'O' ring
53 75230146 Wax Tank Manifold
* 75220089 Wax Tank Manifold Assembly - needed? - inc 40, 45, 46, 53
54 75230148 Wax Tank Gasket
55 P13507 Thermal Switch - Manual Reset - Wax Tank
56 75220107 Wax Temp Switch
P12155 Spacers
162 75220110 Cartridge Heaters - Linked - C & D
163 75220104 Cartridge Heater - B
164 75220105 Cartridge Heater - A
165 75230173 Insulation - Wax Tank Manifold
166 75230193 Insulation - Wax Tank - Ends (2 off) - check 167
167 P12650 Insulation - Wax Tank Side - Inside - check 167
168 75230174 Insulation - Wax Tank Side - Outside - check 167
169 75220108 Temperature Sensor - Digital
170 75230143 Wax Tank Side Tapping Strip
171 P09123 Seal - Gasket Clamp Screw (4 off)
172 75220113 Clamp Screw - Wax Tank (4 off) - 75230202 = wax manifold clamp screws
173 P09292 Seal - ‘O' Ring - Wax Tank (4 off)
D 75230206 Wax Drain Spout and Deflector
E 75230192 Backing washer (4)

DOOR ASSEMBLIES

18 75220250 Stay
47 75230004 Catch Body - J.Lawton?
48 75230006 Catch Roller - J.Lawton?
P04203 Retainer

9.7
1PES9GB Iss 03
ITEM PART No. DESCRIPTION (Continuation)

49 75230007 Roller Pin - J.Lawton?

50 75220587 Hinge Body Assembly (inc bearings)
51 75230016 Reaction Door Outer
52 75220012 Reaction Door Inner
75230571 Hinge cover (not on drawing)
75230015 Tapping strip - reaction door (x3)
A 75220085 LH Pivot Block Assembly
B 75220086 RH Pivot Block Assembly
* P04203 Retainer
89 P13155 Hinge - Lay On
174 75220116 Door - Wax Drain
175 75220103 Fascia Assembly
75230002 Locating pin hinge cover (x3)
75230674 Lid lock tag

MAIN INSTRUMENT

32 75230008 Radial Manifold

60 73910212 Vacuum Relief Valve
61 73910211 Pressure Relief Valve
* P05919 O Ring - Viton - Vacuum/Pressure Relief Valves
* P09082 Diaphragm - PTFE - Vacuum/Pressure Relief Valves
* P09594 Spring - Vacuum/Pressure Relief Valves
* P09634 Washer - PTFE - Vacuum/Pressure Relief Valves
* P09633 Gasket - Vacuum/Pressure Relief Valves
62 P07677 Clip
70 75230592 Male Bottle Connector
71 P07831 Seal - Bottle Connector - (3 off)
72 P09466 Solvent Connector Socket (3 off)
66130241 Restraining washer
75230495 Connector plate + grommet and clips
* 66130241 Clip - Solvent Connector Socket (3 off)
* P09026 Washer - Polyprop - Solvent Connector Socket (3off)
* P07942 Spring - Solvent Connector Socket (3 off)
* P03293 Grommet - Solvent Connector Socket (3 off)
73 P02900 Microswitch - Accessories Drawer
74 75230502 Valve Cover Assembly
79 75230472 Anti Rotation Castor Clamp (2 off) on brake - wrong picture
79A 75230462 Lock nuts (4 on back, 2 on front)
80 P12573 Castor - With Brake (2 off)
81 P12572 Castor (2 off)
* 75230462 Castor Lock Nut
85 75220037 Back Panel - Outer
86 75220043 Side Panel - Outer
87 75230062 Gasket - Reaction Keyboard
88 P12586 Touch Panel - Reaction Vessel
150 75230084 Shelf Liner

9.8
1PES9GB Iss 03
ITEM PART No. DESCRIPTION (Continuation)

151 75230042 Door - Reagent Storage (2 off)

152 75220585 Handle - Door - Reagent Storage
153 75230048 Pivot Pin - Door Guide (4 off)
154 75230049 Guide - Door - Reagent Storage
155 P12081 Clip
156 75220001 Pressure Transducer
157 75220015 Condensing Pipe - Right Angle
160 P12546 Solenoid - Reaction Vessel Lid
* 75210160 Cap -Wax Drain Spout
C 75230172 Wax Drain Fascia
* 75230206 Wax Drain Spout Outer
75230207 Wax Drain Deflector Plate
M 66130511 Bleed Valve Block
M 66130510 Bleed Valve Screw
75220583 Release Cable Interlock

GENERAL

P12680 Aluminium Tape

P12676 Ty-Wrap
P11263 Mounting Kit
M02900 Klinger Sealant
M03662 Gasket -
P05146 Insulation Sheet - Microswitch
P13509 Special Screwdriver - Reaction Chamber lid
P13532 Festo connector - straight, metal
30 P07840 Festo Connector - Straight
31 P07919 Festo Connector - Elbow

RELAYS
P07970 SSR 2& 3 Reaction Inlet & Valve
P12201 SSR 4 Agitation Motor
P12552 SSR 1,5,6,7 Wax Bath Heaters
P12589 SSR Reaction Vessel Heaters
P12617 Relay Lid Open
P13519 SSR Air Pump

CABLES

* 75220003 Cable - 7 Segment Display to Electronics Box

* 75220004 Cable - Digital Sensors to Electronics Box
* 75220005 Cable - Sensors to Electronics Box
* 75220006 Cable - Valve Encoder to Electronics Box
* 75220007 Cable - Electronics Box to Reaction
* 75220008 Cable - Electronics Box to Heaters
* 75220016 Cable - 15 Way to D.C Drive
* 75220017 Cable - Command I/F to LCD

9.9
1PES9GB Iss 03
ITEM PART No. DESCRIPTION (Continuation)

* 75220018 Cable - Command I/F to Inverter

* 75220026 Cable - I/F PCB to LCD Driver
* 75220027 Cable - D.C Driver to Command I/F PCB
* 75220030 Cable - LCD Driver to Command I/F
* 75220059 Cable - 5v I/F to EB186 PCB
* 75220060 Cable - Reaction I/F to PSU
* 75220069 Cable - LCD 186 PCB to Electronics Box
* 75220075 Cable - Heater to Reaction
* 75220076 Cable - DC Supply - Electronics Box
* 75220077 Cable - Loudspeaker Feed
* 75220079 Cable - SSR - Power
* 75220080 Cable - SSR - Control
* 75220106 Thermal Cutout Cableform
* 75220279 Drawer Switch Cableform
* 75220323 Fluid Transfer to Solenoid Cableform
* 75220324 Purge Solenoid Cableform
* 75220570 Cable - Command to Electronics Box
* 75220571 Cable - Command I/F to Plinth
* 75220606 Electronics Box to Heaters
* 75220608 Rotary Valve / Burkit Valve to solenoids
* P12741 Screened Data Link

9.10
1PES9GB Iss 03
10.1 DRAWING NO. TITLE

C752 - 1001 PNEUMATIC SCHEMATIC

E752 - 0103 CIRCUIT DIAGRAM - OVERALL ELECTRICAL SCHEMATIC
E752 - 0102 CIRCUIT DIAGRAM - REACTION I/F BOARD
F75220062 REACTION I/F BOARD
F75220071 MOTHER BOARD
C75220061 E.B.186 PCB
E752-0109 CIRCUIT DIAGRAM - I/F BOARD - COMMAND CONSOLE

PATHCENTRE EXPLODED VIEW (SECTION 8.1)

10.1
1PES10GB Iss 03
10.2
1PES10GB Iss 03
C
CONTENTS ....................................................... . . . . . . iii
D
DRAWINGS ....................................................... . . . . . . 10.1
E

F
FAULT FINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
Chart 1: Solenoid Valve Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
Chart 2: Air Pump Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
Chart 3: Wax Baseplate Over-Temperature Cut-Out . . . . . . . . . . . . . . . . . . . . . . . 6.6
Chart 4: Overfill Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
Chart 5: Battery Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
Chart 6: Heated Tube Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
Chart 7: Heaters ............................................ . . . . . . 6.10
Gross Wax Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
Single Channel Fault: temperature too high . . . . . . . . . . . . . . . . . . . . . . 6.12
Single Channel Fault: temperature too low ................ . . . . . . 6.13
Twin Channel Wax Fault .............................. . . . . . . 6.11
Chart 8: Accessories Drawer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14
Chart 9: Temperature Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
Chart 10a: RC Lid (electrical) .................................. . . . . . . 6.16
Lid open detect switch ................................ . . . . . . 6.16
Chart 10b: RC Lid (electrical) .................................. . . . . . . 6.17
Chart 10c: RC Lid (mechanical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18
Chart 11: Pressure Transducer ................................ . . . . . . 6.23
Chart 12: Agitate Motor; to Locate Faults and To Check Serviceability . . . . . . . . 6.24
Chart 13a: Pneumatic Circuit Diagnostics ........................ . . . . . . 6.26
Chart 13b: Restriction in Air Return Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.27
Chart 13c: Restriction in Direct Air Circuit ........................ . . . . . . 6.28
Solenoid Valves to Reaction Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . 6.28
Chart 13d: Leak Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.29
Chart 14: Rotary Valve ....................................... . . . . . . 6.31
Error 1: Failure to Pressurise the Reaction Chamber . . . . . . . . . . . . . . . . . . . . . . 6.32
Error 2: Failed to Release Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.33

11.1
1PES11GB Iss 03
 Error 3: Failed to Draw Fluid (Bottle Empty) ....................... . . . . . . 6.34
Error 4: Failed to Draw Fluid (Bottle Blocked) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.35
Error 6: Failed to Release Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.36
Error 7: Failed to Release Pressure ............................. . . . . . . 6.37
Error 8: Failure to Raise Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.38
Error 9: Failure to Draw Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.39
Error 10: Lid No Longer Appears Locked ......................... . . . . . . 6.40
Error 16: Timeout on Reagent Blowout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.41
Software to Issue 10 (BIOS201a) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.41
Software Issue 11 (BIOS313) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.43
Error 17: Failure to Empty Reaction Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.42
Software to Issue 10 (BIOS201a) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.42
Software Issue 11 (BIOS313) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.43
Error 18: Wax Bath 'n' Failed to Reach Temperature . . . . . . . . . . . . . . . . . . . . . . . 6.44
Error 19: Rotary Valve Failed to Reach Temperature . . . . . . . . . . . . . . . . . . . . . . 6.46
Error 20: Temperature too High in the Reaction Chamber . . . . . . . . . . . . . . . . . . 6.47
Error 21: Temperature too High on 'n' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.48
Error 22: Accessories Drawer Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.49
Error 23: Non-continuable Memory Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.50
Error 25: Non-continuable Error Combination. ..................... . . . . . . 6.51
Error 28: Overfill on Wax . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.52
Error 29: Overfill Sensor Triggered When Not Running .............. . . . . . . 6.53
Error 30: Opto Detector Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.54
Error 31: D.C. Motor Failure ................................... . . . . . . 6.55
Error 32: Overfill from Reagent 'n' (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.56
Error 33: Overfill from Reagent 'n' (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.57
Error 34: Overfill from Reagent 'n' (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.58
Error 35: Program Held For More Than 5 Mins . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.59
Error 37: Communications Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.60
Error 39: Opto Detector Failure (1) .............................. . . . . . . 6.61
Error 40: Opto Detector Failure (2) .............................. . . . . . . 6.62
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
NEW BIOS (Changes to the Rotary Valve Controller for BIOS 201 Onwards) . . . . . 6.1
Obsolete Errors, and Errors Not Supported . . . . . . . . . . . . . . . . . . . . . . 6.2
Pressure and Vacuum Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
Pressure test: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
Vacuum test: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2

11.2
1PES11GB Iss 03
 FUNCTIONAL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
ADDITIONAL GUIDANCE TO USE PRODUCTION SERVICES ....... . . . . . . 5.9
Temperature Monitoring Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
To Delete the Temperature Monitoring Display ............. . . . . . . 5.9
FAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
PRINTOUTS ............................................... . . . . . . 5.8
PROCEDURE 1 - Air Pump and Reaction Chamber Seals Test . . . . . . . . . . . . . . 5.10
PROCEDURE 2 - Fluid Connector and Pipe Leak Test . . . . . . . . . . . . . . . . . . . . 5.13
PROCEDURE 3 - Agitate Motor and Linkage Test . . . . . . . . . . . . . . . . . . . . . . . . 5.14
PROCEDURE 4 - Temperature Control Tests ..................... . . . . . . 5.16
PROCEDURE 5 - Electronics Module System Checks . . . . . . . . . . . . . . . . . . . . . 5.17
PRODUCTION SERVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
For Display Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
Production Services Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
Sequenced Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
Single Port Outputs .................................. . . . . . . 5.3
Temperature Control ................................. . . . . . . 5.2
RESETS .................................................. . . . . . . 5.7
RESET 5 - General Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
RESET 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
RESET 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
G
GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
COMMAND CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
ELECTRONICS MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
Extension Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
Processing Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
PRINCIPLES OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
I
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1
INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
The Accessories Kit Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3

11.3
1PES11GB Iss 03
 THE I/O CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
TO ASSEMBLE THE PROCESSING MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
TO CONNECT A PRINTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
TO CONNECT AN EXTENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
TO LEVEL THE INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
TO UNPACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
TO LOAD THE SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
NEW INSTRUCTIONS ....................................... . . . . . . 1.1
TISSUE PROCESSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
TOOLKIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
TORQUE SETTINGS ........................................ . . . . . . 1.4
WARNING NOTICES ........................................ . . . . . . 1.1
P
PARTS REMOVAL AND REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
AGITATION MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13
To Fit the Agitiation Motor ............................. . . . . . . 7.13
To Remove the Agitation Motor ......................... . . . . . . 7.13
To Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15
AIR PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19
To Fit the Air Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19
To Remove the Air Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19
To Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19
BOTTOM HEATER - REACTION CHAMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
To Fit the Bottom Heater .............................. . . . . . . 7.9
To Remove the Bottom Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
To Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
CARTRIDGE HEATERS - ROTARY SELECTORVALVE . . . . . . . . . . . . . . . . . . . 7.17
To Fit the Cartridge Heaters into the Rotary Selector Valve ... . . . . . . 7.17
To Remove the Cartridge Heaters from the Rotary Selector Valve . . . . . . 7.17
To Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19
CARTRIDGE HEATERS - WAXBATHS .......................... . . . . . . 7.27
To Fit the Wax Bath Cartridge Heaters ................... . . . . . . 7.27
To Remove the Wax Bath Cartridge Heaters . . . . . . . . . . . . . . . . . . . . . 7.27
To Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.29
COMMAND CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5

11.4
1PES11GB Iss 03
 To Fit the Command Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
To Remove the Command Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
To Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
ELECTRONICS MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
To Fit the Electronics Module - Complete ................. . . . . . . 7.3
To fit the replacement Electronics Module ......... . . . . . . 7.3
To remove the SSR from the air pump . . . . . . . . . . . . . . . . . . 7.3
To Remove the Electronics Module - Complete . . . . . . . . . . . . . . . . . . . 7.3
ToTest ............................................ . . . . . . 7.3
GENERAL INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
To Fit a Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
To Remove a Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
INLET HEATERS - INLET COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.29
To Fit the Inlet Column Cartridge Heaters . . . . . . . . . . . . . . . . . . . . . . . 7.29
To Remove the Inlet Column Cartridge Heaters ............ . . . . . . 7.29
To Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.29
INTERCONNECTING HEATED PIPE - REACTION CHAMBER FEED . . . . . . . . 7.31
To Fit the Interconnecting Heated Pipe ................... . . . . . . 7.31
To Remove the Interconnecting Heated Pipe .............. . . . . . . 7.31
To Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.31
INTERCONNECTING PIPES - BOTTLES TO VALVE . . . . . . . . . . . . . . . . . . . . . 7.31
To Fit the Interconnecting Pipes Between the Bottles and the Valve . . . . 7.33
To Remove the Interconnecting Pipes Between the Bottles and the Valve 7.31
To Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.33
MANUAL RESET SAFETY CUT-OUT SWITCH - ROTARY VALVE . . . . . . . . . . . 7.49
To Fit the Manual Safety Cut-Out Switches to the
Rotary Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.49
To Remove the Manual Safety Cut-Out Switches from the
Rotary Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.49
To Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.51
MANUAL RESET SAFETY CUT-OUT SWITCHES - WAX BATHS MANIFOLD . . . . 7.45
To Fit the Manual Safety Cut-Out Switches to the Wax Baths
Heater Manifold ..................................... . . . . . . 7.47
To Remove the Manual Safety Cut-Out Switches from the Wax Baths
Heater Manifold ..................................... . . . . . . 7.45
To Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.47
MANUAL RESET SAFETY SWITCH - INLET MANIFOLD . . . . . . . . . . . . . . . . . . 7.53

11.5
1PES11GB Iss 03
 To Fit the Manual Reset Safety Switch to the Reaction Chamber . . . . . . 7.53
To Remove the Manual Reset Safety Switch from the Inlet Manifold . . . . 7.53
MANUAL RESET SAFETY SWITCH - REACTION CHAMBER . . . . . . . . . . . . . . 7.51
To Fit the Manual Reset Safety Switch to the Reaction Chamber . . . . . . 7.51
To Remove the Manual Reset Safety Switch from the
Reaction Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.51
To Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.53
OVERFILL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
To Fit the Overfill Sensor .............................. . . . . . . 7.13
To Remove the Overfill Sensor ......................... . . . . . . 7.11
To Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13
PRESSURE TRANSDUCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.53
To Fit the Pressure Transducer ......................... . . . . . . 7.53
To Remove the Pressure Transducer .................... . . . . . . 7.53
To Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.55
REACTION CHAMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
To Fit the Reaction Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
To Remove the Reaction Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
To Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
ROTARY SELECTOR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15
To Fit the Rotary Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17
To Remove the Rotary Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15
To Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17
SEE-THROUGH LID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.55
To Fit the See-through Lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.55
To Remove the See-through Lid ........................ . . . . . . 7.55
To Set and Adjust the See-through Lid after installation . . . . . . . . . . . . 7.57
ToTest ............................................ . . . . . . 7.61
SIDE-WALL HEATER - REACTION CHAMBER . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
To Fit the Side-wall Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
To Remove the Side-wall Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
To Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
SOLENOID ASSEMBLY - COMPLETE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.21
To Fit the Solenoid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.21
To Remove the Solenoid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.21
To Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.21
SOLENOIDS - INDIVIDUAL ................................... . . . . . . 7.21

11.6
1PES11GB Iss 03
 To Fit an Individual Solenoid Valve ...................... . . . . . . 7.23
To Remove an Individual Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . 7.21
To Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
TEMPERATURE SENSING TRANSISTOR - INDIVIDUAL WAX BATHS . . . . . . . 7.33
To Fit the Temperature Sensing Transistor from a Wax Bath .. . . . . . . 7.35
To Remove the Temperature Sensing Transistor from a Wax Bath . . . . . . 7.33
To Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.35
TEMPERATURE SENSING TRANSISTOR - INLET MANIFOLD . . . . . . . . . . . . . 7.45
To Fit the Temperature Sensing Transistor to the Reaction Chamber . . . 7.45
To Remove the Temperature Sensing Transistor from the
Inlet Manifold ....................................... . . . . . . 7.45
To Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.45
TEMPERATURE SENSING TRANSISTOR - REACTION CHAMBER . . . . . . . . . 7.43
To Fit the Temperature Sensing Transistor to the Reaction Chamber . . . 7.43
To Remove the Temperature Sensing Transistor from the
Reaction Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.43
To Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.43
TEMPERATURE SENSING TRANSISTOR - ROTARY SELECTOR VALVE . . . . . 7.41
To Fit the Temperature Sensing Transistor in the Rotary Selector Valve . 7.41
To Remove the Temperature Sensing Transistor From the
Rotary Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.41
To Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.43
TEMPERATURE SENSING TRANSISTOR CABLEFORM - WAX BATHS . . . . . . 7.35
To Remove the Temperature Sensing Transistor Cableform . . . . . . . . . 7.35
To Replace the Temperature Sensing Transistor Cableform . . . . . . . . . 7.37
To Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.37
THERMALCUT-OUT SWITCHES - WAX BATHS MANIFOLD . . . . . . . . . . . . . . . 7.39
To Fit the Wax Bath Thermal Cut-Out Switches . . . . . . . . . . . . . . . . . . . 7.39
To Remove the Wax Bath Thermal Cut-Out Switches . . . . . . . . . . . . . . 7.39
To Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.41
WAX BATH DRAIN TAPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.61
To Fit the Wax Bath Drain Taps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.63
To Remove the Wax Bath Drain Taps . . . . . . . . . . . . . . . . . . . . . . . . . . 7.61
To Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.63
WAX BATHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
To Fit the Wax Baths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25
To Remove the Wax Baths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23

11.7
1PES11GB Iss 03
 To Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25
S
SERVICE ADJUSTMENTS and AMENDMENTS .......................... . . . . . . 8.1
RECOMMENDED ROUTINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
RECOMMENDED SPARES ................................... . . . . . . 8.2
SERVICE HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
SPECIFICATION, ACCESSORIES AND SPARES LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
BOTTLE TRAY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
COMMAND MODULE ................................ . . . . . . 9.3
DECK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
DOOR ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
DRAWER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
ELECTRONICS BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
GENERAL ......................................... . . . . . . 9.9
MAIN INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
PUMP PLATE ASSEMBLY ............................ . . . . . . 9.5
REACTION VESSEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
WAX VESSEL / SELECTOR VALVE ASSEMBLY . . . . . . . . . . . . . . . . . 9.7
SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
Extended Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
Indicator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
Physical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
StandardFlush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
STANDARD ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
T
TECHNICAL DESCRIPTION .......................................... . . . . . . 3.1
AGITATE MECHANISM ...................................... . . . . . . 3.11
AIR PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
COMMAND CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
SOLENOID VALVE LED SIGNIFICANCES . . . . . . . . . . . . . . . . . . . . . . 3.12
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1

11.8
1PES11GB Iss 03
 HEATERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
MINIATURE CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
PNEUMATIC VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
SOFTWARE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
Non-Routine Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
‘Underfill’ recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
Abort . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
BACKUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
RECOVER ................................. . . . . . . 3.16
The Flush cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
The Process Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
Routine Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
Quality Control .............................. . . . . . . 3.15
To Control the Communications System . . . . . . . . . . . . . . . . . 3.15
To Control the Rotary Valve .................... . . . . . . 3.14
To Monitor the Temperatures and To Control the Heaters . . . . . 3.14
Software Issues and Up-Dates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
To Load the Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
THE ELECTRONICS MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
The Controller PCB (EB186) ........................... . . . . . . 3.1
The D.C. Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
Air Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
Air Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
Heated Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
Lid Solenoid ................................ . . . . . . 3.5
Remote Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
The Interface PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
The Motherboard .................................... . . . . . . 3.7
The Opto-electronic devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
The Overfill Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
The Power Supply ................................... . . . . . . 3.7
The Simple Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
The Solid State Relays (SSR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
The Watchdog Circuitry ............................... . . . . . . 3.6
THE MAIN CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7

11.9
1PES11GB Iss 03
 PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
THE ROTARY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9

11.10
1PES11GB Iss 03