Biomerieux BacTAlert 3D 60 Service Manual

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Service Manual

bioMérieux, Inc.

Box 15969, Durham, NC 27704 -0969

http://www.biomerieux.com

© BIOMÉRIEUX 2002 Manual Part Number 48001-6 Rev A

March 2003

BacT/ALERT® 3D 60

All Rights Reserved Worldwide

Printed in the United States of America

No part of this publication may be used or reproduced in any form, electronic or written via database or
retrieval system, without the prior written permission of bioMérieux. Documenting copies of any part of this
publication, for any purpose other than for which has been authorized in advance, is in strict violation of
United States copyright laws.

BioMérieux, Inc.

PO Box 15969

Durham, NC 27704-0969

USA

ASTM is a trademark of American Society for Testing and Materials. Bac T/ALERT, BacT/LINK, BacT/VIEW
and MB are registered trademarks of bioMérieux in the USA and other countries. MS DOS is a registered
trademark of Microsoft Corporation. Zip is a registered trademark of Iomega Corporation. The logo is a
registered and protected trademark of bioMérieux, Inc. or one of its subsidiaries.

Distribution in over 130 countries

Service Manual

BacT/ALERT® 3D 60

This document will be updated for each software modification or any other change.
Information supplied in this document is subject to modificati on before the products described

become available.
This document may contain information or references concerning certain bioMérieux®

products, programs and services not available in certain countries; this, however, shall not
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would therefore be considered fraudulent and sentenced by the applicable law.

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BacT/ALERT® 3D 60 TABLE OF CONTENTS

TABLE OF CONTENTS

0 FRONT MATTER ..................................................................................................................IX

0.1 APPENDICES.................................................................................................................IX

0.2 LIST OF TABLES...........................................................................................................XI

0.3 LIST OF ILLUSTRATIONS..........................................................................................XIII

0.4 TYPOGRAPHY AND GRAPHIC CONVENTIONS.....................................................XIX

0.4.1 Bullets..............................................................................................................xxi

0.4.2 Text Boxes ....................................................................................................... xxi

0.4.3 Bracketed Italics................................................................................................ xxi

0.4.4 Underlined Text................................................................................................. xxi

0.4.5 Bracketed Text .................................................................................................xxii

0.4.6 Text Within Quotation Marks.............................................................................xxii

0.4.7 Italicized (Whether Bold or Not) Text .................................................................xxii

0.5 SAFETY SUMMARY.................................................................................................XXIII

0.5.1 General Information to Follow ........................................................................... xxv

0.5.2 Electrical Warnings...........................................................................................xxv

0.5.3 Electrical Grounding .........................................................................................xxvi

0.5.4 Fuse Replacement Warning..............................................................................xxvi

0.5.5 Hazardous Voltages .........................................................................................xxvi

0.5.6 Cleaning Agents...............................................................................................xxvi

0.5.7 Health Risks ...................................................................................................xxvii

0.5.8 ESD Precautions.............................................................................................xxvii

0.5.9 Moving Parts ...................................................................................................xxvii

0.5.10 Heating Element ............................................................................................. xxvii

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TABLE OF CONTENTS BacT/ALERT® 3D 60

1 GENERAL INFORMATION.............................................................................................. 1-1

1.1 INTRODUCTION...........................................................................................................1-1

1.2 REFERENCE DATA .....................................................................................................1-2

1.3 EQUIPMENT DESCRIPTION .......................................................................................1-3

1.4 ASSEMBLY DESCRIPTIONS......................................................................................1-4

1.4.1 Electrical Components .......................................................................................1-4

1.4.1.1 Power Panel Assembly ....................................................................1-5

1.4.1.2 Transformer Assembly.....................................................................1-5

1.4.1.3 Heater ............................................................................................1-5

1.4.1.4 Blower ............................................................................................1-5

1.4.1.5 Step-5 Motor Assembly ...................................................................1-7

1.4.1.6 Fan ................................................................................................1-7

1.4.1.7 Quick Reference Card .....................................................................1-7

1.4.2 Communications Ports (Input / Output) ...............................................................1-8

1.4.2.1 COMM Port .....................................................................................1-9

1.4.2.2 Printer Port .....................................................................................1-9

1.4.2.3 Internal Speaker w/external Speaker Jack ........................................1-9

1.4.2.4 Power Entry Module (PEM) / ON-OFF Switch ...................................1-9

1.4.2.5 Modem Port ....................................................................................1-9

1.4.2.6 LIS Port ..........................................................................................1-9

1.4.2.7 Monitor Port ....................................................................................1-9

1.4.2.8 UPS Port ........................................................................................1-9

1.4.2.9 UPS Serial Port...............................................................................1-9

1.4.2.10 Mouse Port .....................................................................................1-9

1.4.2.11 Keyboard Port.................................................................................1-9

1.4.2.12 Barcode Scanner Port .....................................................................1-9

1.4.3 Electronic Components....................................................................................1-10

1.4.3.1 CPU PCBA ...................................................................................1-11

1.4.3.2 ModSig PCBA...............................................................................1-11

1.4.3.3 Quad Serial PCBA.........................................................................1-11

1.4.3.4 Thermistor PCBA (Input/Output).....................................................1-11

1.4.3.5 CompactFlash Memory Disk ..........................................................1-13

1.4.3.6 CompactFlash Adapter PCBA........................................................1-13

1.4.3.7 Step-5 PCBA ................................................................................1-13

1.4.3.8 Incubator Chamber Components ....................................................1-15

1.4.3.8.1 Rack...........................................................................1-15

1.4.3.8.2 Cell ............................................................................1-15

1.4.3.8.3 Cell Flag .....................................................................1-15

1.4.3.8.4 Cell Indicator Lamp .....................................................1-15

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1.4.4 Input / Output Devices .....................................................................................1-16

1.4.4.1 Operator Display Monitor ...............................................................1-17

1.4.4.2 Barcode Scanner ..........................................................................1-17

1.4.4.3 Keyboard......................................................................................1-17

1.4.4.4 Zip Drive.......................................................................................1-17

1.4.4.5 56K FAX Modem (Domestic)..........................................................1-19

1.4.4.6 56K Fax Modem (International)......................................................1-19

1.4.5 Uninterruptible Power Supply “UPS” .................................................................1-20

1.4.5.1 On/Off Switch................................................................................1-21

1.4.5.2 UPS Comm Port (Computer Interface Port).....................................1-21

1.4.5.3 Overload Reset Switch..................................................................1-21

1.4.5.4 Test (Check Battery/Alarm Disable) Switch.....................................1-21

1.4.5.5 120V Backup Receptacles .............................................................1-21

1.4.5.6 Accessory Surge Rec eptacles........................................................1-21

1.4.5.7 AC Power Cord .............................................................................1-21

1.5 OPERATOR DISPLAY CONFIGURATION SCREENS............................................1-24

1.5.1 Instrument Configuration Screen ......................................................................1-25

1.5.1.1 Accessing the Configuration Screen ...............................................1-25

1.5.1.2 Instrument Con figuration Screen - Initial Entry.................................1-26

1.5.1.3 Configuration Screen [X Box] Buttons .............................................1-27

1.6 QUICK REFERENCE CARD ......................................................................................1-29

2 BACKGROUND INFORMATI ON .................................................................................... 2-1

2.1 INTRODUCTION...........................................................................................................2-1

2.2 SYSTEM CONTROL - MODSIG PCBA .......................................................................2-2

2.3 THERMISTOR PCBA (INPUT/OUTPUT)....................................................................2-6

2.4 3D 60 POWER SUPPLY ASSEMBLY.........................................................................2-8

2.5 DC POWER SUPPLY.................................................................................................2-10

2.6 CPU PCBA.................................................................................................................2-12

2.7 COMPACTFLASH ADAPTER PCBA ........................................................................2-14

2.8 QUAD SERIAL INTERFACE PCBA..........................................................................2-16

2.9 RACK CONTROLLER PCBA....................................................................................2-18

2.10 STEP-5 PCBA............................................................................................................2-24

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3 INSTALLATION PROCEDU RES.................................................................................... 3-1

3.1 INTRODUCTION...........................................................................................................3-1

3.2 BACT/ALERT 3D 60 INS TALLATION PROCEDURES..............................................3-3

3.2.1 Verification of Site Requirements........................................................................3-3

3.2.2 Record Line Noise.............................................................................................3-3

3.2.3 Unpacking ........................................................................................................3-3

3.2.4 Repacking ........................................................................................................3-3

3.2.4.1 Verification of Contents....................................................................3-6

3.2.4.1.1 3D 60 Instrument Parts ..................................................3-6

3.2.5 Set AC Power...................................................................................................3-7

3.2.6 Instrument Placement........................................................................................3-9

3.2.7 Instrument UPS .................................................................................................3-9

3.2.8 Power Up .......................................................................................................3-11

3.2.9 Instrument Configuration ..................................................................................3-11

3.2.10 Temperature ...................................................................................................3-11

3.2.11 Error Check ....................................................................................................3-11

3.2.12 Modem Functional Test ...................................................................................3-12

3.2.13 Barcode Reader Functional Test......................................................................3-13

3.2.14 UPS Functional Test (3D 60 Only, APC UPS 650).............................................3-13

3.2.15 Complete the Installation Checklist ...................................................................3-13

3.3 RESTRAINT INSTALLATI ON....................................................................................3-14

3.3.1 Overview........................................................................................................3-14

3.3.2 Procedure.......................................................................................................3-14

3.4 SOFTWARE INSTALLATION....................................................................................3-17

3.5 SWITCHING ON.........................................................................................................3-17

3.5.1 Initialization.....................................................................................................3-17

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4 SERVICING.........................................................................................................................4-1

4.1 INTRODUCTION...........................................................................................................4-1

4.2 SPECIFIC TOOLS AND REQUIRED...........................................................................4-3

4.3 POWER UP/DOWN PROCEDURES...........................................................................4-3

4.3.1 Introduction .......................................................................................................4-3

4.3.2 3D 60 Power Down ...........................................................................................4-3

4.3.3 3D 60 Power Up................................................................................................4-4

4.4 MB CONVERSION PROCEDURE...............................................................................4-5

4.4.1 Overview..........................................................................................................4-5

4.4.2 Procedure.........................................................................................................4-5

4.5 DATA BACKUP/RESTORE PROCEDURES..............................................................4-9

4.5.1 BacT/ALERT 3D 60 - Data Backup Procedure ....................................................4-9

4.5.2 BacT/ALERT 3D 60 - Data Restore Procedure ....................................................4-9

4.6 PREVENTIVE MAINTENANCE.................................................................................4-11

4.6.1 Overview........................................................................................................4-11

4.6.2 Perform Data Backup......................................................................................4-11

4.6.3 Barcode Reader Functional Test......................................................................4-11

4.6.4 Printer Maintenance ........................................................................................4-11

4.6.5 Temperature Verification ..................................................................................4-11

4.6.6 Disabled Cell Check........................................................................................4-11

4.6.7 +5 DC Voltage Verification ...............................................................................4-11

4.6.8 UPS Test ........................................................................................................4-11

4.6.9 “Door Open” Test ............................................................................................4-12

4.6.10 Completing the Preventive Maintenance Card...................................................4-12

4.7 DIAGNOSTICS AND TROUBLESHOOTING............................................................4-13

4.7.1 Introduction.....................................................................................................4-13

4.7.2 Symptomatic Errors .........................................................................................4-13

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4.8 SOFTWARE DIAGNOSTICS.....................................................................................4-15

4.8.1 Button Legend ................................................................................................4-15

4.8.2 Purpose of the Section ....................................................................................4-16

4.8.3 Special Equipment ..........................................................................................4-16

4.8.4 Accessing the Diagnostics Screens ..................................................................4-17

4.8.5 Diagnostic Screens Overview ...........................................................................4-18

4.9 ALIGNMENTS AND CALIBRATIONS.......................................................................4-69

4.9.1 Overview........................................................................................................4-69

4.9.2 System Power Supply......................................................................................4-69

4.9.3 Temperature ...................................................................................................4-69

4.9.4 Optics.............................................................................................................4-69

4.9.5 Rack – Single Cell Calibration ..........................................................................4-69

4.9.6 System Power Supply Check and Adjustments .................................................4-74

4.9.7 Door Micro Switch 1 & 2 Checks ......................................................................4-77

4.10 REMOVE AND REPLACE PROCEDURES..............................................................4-79

4.10.1 Introduction.....................................................................................................4-79

4.10.2 CPU PCBA Assembly (P/N 750 -0070-01).........................................................4-81

4.10.3 Quad Serial Interface PCBA (P/N 750 -0066-01) ................................................4-89

4.10.4 CompactFlash Adapter PCBA (P/N 957-0004-356)............................................4-91

4.10.5 Software Installation and CompactFlash Memory Ca rd Replacement .................4-94

4.10.6 ModSig PCBA (P/N 48300 -1) (Order Spare P/N 48300-901) ..............................4-95

4.10.7 ModSig PCBA Fuses (P/N 870-0008-14, -17, -22) ...........................................4-105

4.10.8 Step-5 PCBA (P/N 48301-1) (Order Spare P/N 48301 -901)..............................4-108

4.10.9 Step-5 Motor (P/N 48104 -1) ...........................................................................4-111

4.10.10 Outlet Thermistor PCBA (P/N 32300 -1) ..........................................................4-117

4.10.11 Inlet Thermistor PCBA (P/N 32300-1) .............................................................4-119

4.10.12 Zip™ Drive (P/N 895-0004-38) .......................................................................4-120

4.10.13 System Power Panel .....................................................................................4-124

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4.10.14 Power Supply Transformer (P/N 851-0015-01) ................................................4-126

4.10.15 Power Supply MOV - Metal Oxide Varistor (P/N 43116 -2) ................................4-128

4.10.16 Power Panel Solid State Relays (P/N 845-0018-01) ........................................4-130

4.10.17 DC Power Supply (P/N 852-0010-01) ............................................................. 4-132

4.10.18 Power Entry Module (PEM) Fuses (P/N 870-0008-14, -17, -24, -25).................4-135

4.10.19 Fan (P/N 941 -0009-07).................................................................................. 4-138

4.10.20 Heater (P/N 847 -0009-01).............................................................................. 4-140

4.10.21 Blower Assembly (P/N 48411 -1).....................................................................4-142

4.10.22 Blower Motor Capacitor (P/N 601-0001-02)..................................................... 4-143

4.10.23 Digital Reference Thermometer (P /N 848 -0003-01) .........................................4-148

4.10.24 Rack Assembly (P/N 43147 -921, -922, -923)...................................................4-149

4.10.25 Step-5 Drive Agitation Linkage Assembly (P/N 48418-1)..................................4-153

4.10.26 Gas Spring Assembly (P/N 926-0037-01)........................................................ 4-156

4.10.27 Magnetic Door Switches (P/N 841 -0012-01)....................................................4-158

4.10.28 Keyboard (P/N 957 -0004-373).......................................................................4-160

4.10.29 Barcode Scanner (P/N 957 -0004-291)............................................................4-161

4.10.30 Domestic 56K Fax Modem (P/N 957-0004-342) ..............................................4-162

4.10.31 International Fax Modem (P/N 957-0004-364).................................................4-163

4.10.32 APC Back-UPS Model 650 (Domestic Model) (P/N 957 -0060-02)..................... 4-164

4.10.33 APC UPS (International Model) (P/N 957-0060-03) .........................................4-169

4.11 POST SERVICE VALIDATION ................................................................................4-175

4.11.1 Overview......................................................................................................4-175

4.11.2 Required Materials ........................................................................................4-175

4.11.3 Procedures ...................................................................................................4-175

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00 FFRROONNTT MMAATTTTEERR

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INDEX .................................................................................................. Index-1

AAPPPPEENNDDIICCEESS

Appendix A GLOSSARY.......................................................................................A.1

Appendix B PARTS LIST ......................................................................................B.1

Appendix C DISINFECTION ..................................................................................C.1

Appendix D ERROR CODES .................................................................................D.1

Appendix E DIAGRAMS ........................................................................................ E.1

Alphabetical Listing.................................................................................

Introduction .......................................................................................C.1

Procedures........................................................................................C.1

Spills .............................................................................................C.1

Instrument Shipping ...........................................................................C.1

Assembly Shipping ............................................................................C.1

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Section 1

Table 1.2.1 Reference Data ........................................................................................1-2

Section 2

Table 2.2.1 Audio Frequency Selection (JP 23 through JP26) .......................................2-4

Table 2.5.1 Power Supply Data.................................................................................2-10

Section 3

Table 3.2.1 3D 60 instrument Parts List .......................................................................3-6

Table 3.2.2 Facility Power Rating and Conversion Chart ...............................................3-8

Table 3.2.3 Setup and Connections Table....................................................................3-9

Table 3.3.3 Restraint Hardware .................................................................................3-14

Table 3.3.4 Table of Equivalent Dimensions...............................................................3-15

Section 4

Table 4.2.1 Required Tools and Equipment..................................................................4-3

Table 4.7.1 Symptomatic Problems ...........................................................................4-13

Table 4.10.18 Facility Power Rating and Fuse Conversion Chart...................................4-135

Appendices

Table C 1.2 Disinfection Equipment .............................................................................C.1

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CHAPTER 0 – FRONT MATTER

Fig. 1 - Text Box ......................................................................................................................................................................... xxi

Fig. 2 - USA 115 VAC Standard............................................................................................................................................xxvi

Fig. 3 - European 230 VAC Standard..................................................................................................................................xxvi

CHAPTER 1 – GENERAL INFORMATION

Fig. 4 - BacT/ALERT 3D 60 Instrument................................................................................................................................1-3

Fig. 5 - 3D 60 Power Panel Assembly ..................................................................................................................................1-4

Fig. 6 - Transformer ..................................................................................................................................................................1-4

Fig. 7 - Blower & Heater...........................................................................................................................................................1-4

Fig. 8 - Step-5 Motor Assembly..............................................................................................................................................1-6

Fig. 9 - Fan Assembly...............................................................................................................................................................1-6

Fig. 10 - BacT/ALERT 3D 60 System Control (Rear View) w/Comm Ports.................................................................1-8

Fig. 11 - CPU PCBA................................................................................................................................................................1-10

Fig. 12 - ModSig PCBA..........................................................................................................................................................1-10

Fig. 13 - Quad Serial PCBA...................................................................................................................................................1-10

Fig. 14 - Thermistor PCBA....................................................................................................................................................1-10

Fig. 15 - CompactFlash Memory Disk ................................................................................................................................1-12

Fig. 16 - CompactFlash Adapter PCBA .............................................................................................................................1-12

Fig. 17 - Step-5 PCBA.............................................................................................................................................................1-12

Fig. 18 - BacT 3D 60 Incubator Chamber..........................................................................................................................1-14

Fig. 19 - Rack Assembly........................................................................................................................................................1-14

Fig. 20 - Operator Display Monitor .....................................................................................................................................1-16

Fig. 21 - Barcode Scanner....................................................................................................................................................1-16

Fig. 22 - Keyboard...................................................................................................................................................................1-16

Fig. 23 - Zip Drive ....................................................................................................................................................................1-16

Fig. 24 - Uninterruptible Power Supply (UPS) Domestic Model – Front and Rear Views....................................1-20

Fig. 25 - Uninterruptible Power Supply (UPS) European Model – Front and Rear Views...................................1-22

Fig. 26 - Instrument Configuration Screen.......................................................................................................................1-24

Fig. 27 - Main Screen ..............................................................................................................................................................1-25

Fig. 28 - Setup Screen w/Field Engineer Password Activation ..................................................................................1-26

Fig. 29 - Instrument Configuration Screen.......................................................................................................................1-26

Fig. 30 - [X Box ] Selection Checkbox................................................................................................................................1-27

Fig. 31 - Quick Reference Card – Front Side ...................................................................................................................1-30

Fig. 32 - Quick Reference Card – Rear Side.....................................................................................................................1-31

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CHAPTER 2 – BACKGROUND INFORMATION

Fig. 33 - ModSig PCBA Diagram...........................................................................................................................................2-2

Fig. 34 - ModSig Block Diagram............................................................................................................................................2-5

Fig. 35 - Thermistor PCBA......................................................................................................................................................2-6

Fig. 36 - Power Distribution Block Diagram.......................................................................................................................2-8

Fig. 37 - CPU PCBA Diagram...............................................................................................................................................2-12

Fig. 38 - CompactFlash Adapter PCBA .............................................................................................................................2-14

Fig. 39 - Quad Serial Interface PCBA Diagram................................................................................................................2-16

Fig. 40 - Rack Controller PCBA Diagram ..........................................................................................................................2-18

Fig. 41 - Rack Controller PCBA Block Diagram ..............................................................................................................2-20

Fig. 42 - Rack Address Concept..........................................................................................................................................2-22

Fig. 43 - Step-5 PCBA Diagram............................................................................................................................................2-24

Fig. 44 - Step-5 PCBA Block Diagram................................................................................................................................2-28

CHAPTER 3 – INSTALLATION PROCEDURES

Fig. 45 - 3D 60 Instrument Repacking Sequence .............................................................................................................3-4

Fig. 46 - 3D 60 Instrument Repack – Web Strapping Diagrams...................................................................................3-5

Fig. 47 - Power Entry Module w. Fuse Holder Removed................................................................................................3-7

Fig. 48 - Fuse Holder w/Fuse..................................................................................................................................................3-7

Fig. 49 - PEM w/115 VAC Version .........................................................................................................................................3-8

Fig. 50 - PEM w/230 VAC Version .........................................................................................................................................3-8

Fig. 51 - Installation and Setup Diagram...........................................................................................................................3-10

Fig. 52 - Communications Panel Connection Diagram .................................................................................................3-12

Fig. 53 - Modem Configuration & Dip Switch Settings Diagram................................................................................3-12

Fig. 54 - Countertop/Surface Mounting Diagram............................................................................................................3-12

Fig. 55 - Mounting Surface Diagram..................................................................................................................................3-15

Fig. 56 - Mounting Surface (Drilling) Template...............................................................................................................3-16

Fig. 57 - Installation Checklist.............................................................................................................................................3-18

CHAPTER 4 - SERVICING

Fig. 58 - 3D 60 Instrument – Power Switch........................................................................................................................4-3

Fig. 59 - Step-5 Motor PCBA Power Disconnect...............................................................................................................4-5

Fig. 60 - MB Conversion – Lock Screw Removal.............................................................................................................4-6

Fig. 61 - MB Conversion – Lock Screw Installation.........................................................................................................4-7

Fig. 62 - Backup Management Button .................................................................................................................................4-9

Fig. 63 - Cancel Button ............................................................................................................................................................4-9

Fig. 64 - ModSig PCBA LED 55 and 56 location..............................................................................................................4-12

Fig. 65 - Scanner Default Settings Barcode.....................................................................................................................4-13

Fig. 66 - Diagnostics Setup Screen Buttons....................................................................................................................4-15

Fig. 67 - Diagnostic Test Selection (Setup) Screen.......................................................................................................4-17

Fig. 68 - 1.7 Inc Module/Flag Check...................................................................................................................................4-18

Fig. 69 - 1.5 Inc Module 1/Temperature Log (Find Text String) ..................................................................................4-19

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Fig. 70 - 1.5 Inc Module 1/Temperature Log (Text String Output)..............................................................................4-20

Fig. 71 - 1.5 Inc Module 1/Temperature Log (Save Output to Zip) .............................................................................4-20

Fig. 72 - 1.5 Inc Module 1/Temperature Log (Scroll/Anchor Buttons) ......................................................................4-21

Fig. 73 - 1.5 Inc Module 1/Temperature Log (Slide Bar) ...............................................................................................4-22

Fig. 74 - 1.1 Inc Module 1/Loopback Test Screen...........................................................................................................4-24

Fig. 75 - 1.2 Inc Module 1/Port Stats Test Screen ...........................................................................................................4-25

Fig. 76 - 1.3 Inc Module 1/Message Stats Test Screen..................................................................................................4-26

Fig. 77 - 1.4 Inc Module 1/ Message Log Test Screen....................................................................................................4-27

Fig. 78 - 1.5 Inc Module 1/Temperature Log Test Screen .............................................................................................4-28

Fig. 79 - 1.6 Inc Module 1/Reading Log Test Screen.....................................................................................................4-29

Fig. 80 - 1.7 Inc Module 1/Flag Check Screen.................................................................................................................4-30

Fig. 81 - 1.7 Inc Module 1/Flag Check Test Screen........................................................................................................4-31

Fig. 82 - 1.7 Inc Module 1/Flag Check (Calibration Screen..........................................................................................4-31

Fig. 83 - 1.8 Inc Module 1/Heater Screen..........................................................................................................................4-32

Fig. 84 - 1.9 Inc Module 1/LED Check................................................................................................................................4-33

Fig. 85 - 1.9 Inc Module 1/LED Check (Walking).............................................................................................................4-33

Fig. 86 - 7.1 Instrument Cntrl/ZIP Drive Test Screen.....................................................................................................4-35

Fig. 87 - 7.2 Instrument Cntrl/Barcode Loopback Test Screen...................................................................................4-36

Fig. 88 - 7.4 Instrument Cntrl/Power Event Log Screen...............................................................................................4-39

Fig. 89 - 7.6 Instrument Cntrl/Software Test Screen – Scan........................................................................................4-62

Fig. 90 - 7.6 Instrument Cntrl/Software Test Screen – Misc........................................................................................4-66

Fig. 91 - Diagnostic Test Selection Screen – Flag Check............................................................................................4-70

Fig. 92 - Incubator Flag Check – Cell Differences Screen...........................................................................................4-71

Fig. 93 - Flag Check – Cell Calibration Screen................................................................................................................4-72

Fig. 94 - System Power Panel and DC Supply.................................................................................................................4-74

Fig. 95 - Step-5 PCBA at Connector J4.............................................................................................................................4-75

Fig. 96 - ModSig PCBA with +5 VDC Test Points ...........................................................................................................4-75

Fig. 97 - DC Power Supply....................................................................................................................................................4-75

Fig. 98 - Door Micro Switches and Magnets....................................................................................................................4-77

Fig. 99 - Top Panel Screw Locations (Removal).............................................................................................................4-81

Fig. 100 - CPU PCBA w/Quad Serial PCBA plugged in.................................................................................................4-82

Fig. 101 - CPU PCBA - Screw Removal.............................................................................................................................4-83

Fig. 102 - CPU PCBA – J27 and J7 Cable Routing.........................................................................................................4-84

Fig. 103 - Quad Serial PCBA Removed from CPU PCBA.............................................................................................4-85

Fig. 104 - CPU PCBA Cable Connections.........................................................................................................................4-86

Fig. 105 - WinSystems

®

CPU Connector Locations.......................................................................................................4-87

Fig. 106 - Quad Serial PCBA................................................................................................................................................4-89

Fig. 107 - Quad Serial PCBA Cable Connections ...........................................................................................................4-90

Fig. 108 - EMC – CompactFlash PCBA..............................................................................................................................4-91

Fig. 109 - CompactFlash Adapter & ZIP Drive Installed...............................................................................................4-92

Fig. 110 - CompactFlash Adapter w/WinSystems Computer......................................................................................4-92

Fig. 111 - CompactFlash Card (Memory Removal) ........................................................................................................4-93

Fig. 112 - CompactFlash Adapter (Removal) ...................................................................................................................4-93

Fig. 113 - ModSig PCBA – Connector Location..............................................................................................................4-95

Fig. 114 - ModSig PCBA........................................................................................................................................................4-96

Fig. 115 - ModSig PCBA – Tie Wrap Removal.................................................................................................................4-97

Fig. 116 - ModSig PCBA – Bundled Cable Disconnection...........................................................................................4-98

Fig. 117 - ModSig PCBA – JP19 Cable Removal.............................................................................................................4-99

Fig. 118 - ModSig PCBA – JP21, MS-JP11, JP12, &JP31 Cable Removal................................................................4-99

Fig. 119 - ModSig PCBA – MS-JP1 Cable Removal....................................................................................................4-100

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TABLE OF CONTENTS BacT/ALERT® 3D 60

Fig. 120 - ModSig – Rear Panel Screw Removal..........................................................................................................4-100

Fig. 121 - ModSig PCBA – Mounting Screw Locations..............................................................................................4-101

Fig. 122 - ModSig – Step -5 MCJ4 Connection..............................................................................................................4-102

Fig. 123 - ModSig – Rear Panel Hex Nut & Knurled Nut Removal..........................................................................4-103

Fig. 124 - ModSig PCBA – JP10, JP1 and Ground Cable .......................................................................................... 4-103

Fig. 125 - ModSig PCBA Fuse Locations.......................................................................................................................4-105

Fig. 126 - ModSig PCBA – Fuse Locations 1 ................................................................................................................ 4-106

Fig. 127 - ModSig PCBA (Installed) - Fuse Locations 2.............................................................................................4-107

Fig. 128 - Step-5 PCBA Location ...................................................................................................................................... 4-108

Fig. 129 - Step-5 PCBA Connector and Wiring Locations ........................................................................................4-109

Fig. 130 - Step-5 Motor Windings ....................................................................................................................................4-111

Fig. 131 - Step-5 Motor Removal – MCJ3 Disconnection..........................................................................................4-112

Fig. 132 - Step-5 Motor Removal – Set-Screw Removal............................................................................................4-113

Fig. 133 - Step-5 Motor Removal – Mounting Screw Removal.................................................................................4-114

Fig. 134 - Step-5 Motor Removal......................................................................................................................................4-114

Fig. 135 - Step-5 Motor Removal – Reinstalling Mounting Screws........................................................................4-115

Fig. 136 - Outlet Thermistor PCBA Removal................................................................................................................4-117

Fig. 137 - Inlet Thermistor PCBA Removal....................................................................................................................4-119

Fig. 138 - Zip™ Drive Removal ......................................................................................................................................... 4-120

Fig. 139 - Zip Drive – Flash Adapter PCBA Removal ................................................................................................. 4-120

Fig. 140 - Zip Drive Screw Removal................................................................................................................................4-121

Fig. 141 - Zip Drive Removal – Cutout Hole .................................................................................................................. 4-121

Fig. 142 - Zip Drive Sled Removal (Side Screws)........................................................................................................4-122

Fig. 143 - Zip Drive Sled Removal (Bottom Screws)...................................................................................................4-122

Fig. 144 - Zip Drive – Reconnecting IDE Cable and Power Connector..................................................................4-122

Fig. 145 - Power Panel Assembly – Screw Removal..................................................................................................4-124

Fig. 146 - Power Panel Assembly....................................................................................................................................4-125

Fig. 147 - Power Panel Assembly – Installed...............................................................................................................4-125

Fig. 148 - Power Supply Transformer – Power Supply Panel Removed...............................................................4-126

Fig. 149 - Power Panel with Transformer Installed.....................................................................................................4-127

Fig. 150 - Transformer – PEM Connections .................................................................................................................. 4-127

Fig. 151 - Power Supply – Simplified Schematic.........................................................................................................4-128

Fig. 152 - Term Board 1 (TB1)...........................................................................................................................................4-128

Fig. 153 - Power Panel Solid State Relay Layout ........................................................................................................ 4-130

Fig. 154 - Power Supply Assembly w/DC Power Supply...........................................................................................4-132

Fig. 155 - DC Power Supply – J1 and J2 Disconnection ........................................................................................... 4-133

Fig. 156 - Power Panel Assembly – DC Supply Screw Removal.............................................................................4-134

Fig. 157 - Power Entry Module w/Fuse Holder Removed..........................................................................................4-135

Fig. 158 - Fuse Holder Fuse Installation ........................................................................................................................ 4-135

Fig. 159 - PEM Fuse Removal w/ Screwdriver..............................................................................................................4-136

Fig. 160 - PEM Fuse Holder Removal.............................................................................................................................4-136

Fig. 161 - PEM Fuse Holder Pulled Out..........................................................................................................................4-136

Fig. 162 - PEM w/115 VAC Version..................................................................................................................................4-137

Fig. 163 - PEM w/230 VAC Version..................................................................................................................................4-137

Fig. 164 - Fan – Inside View...............................................................................................................................................4-138

Fig. 165 - Fan Wiring Connections .................................................................................................................................. 4-138

Fig. 166 - Heater Terminal Connectors..........................................................................................................................4-140

Fig. 167 - Heater Removal..................................................................................................................................................4-141

Fig. 168 - Blower Motor ......................................................................................................................................................4-142

Fig. 169 - Blower Motor Capacitor...................................................................................................................................4-143

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BacT/ALERT® 3D 60 TABLE OF CONTENTS

Fig. 170 - Power Supply Panel – BHP1 Connector ......................................................................................................4-144

Fig. 171 - Power Supply Panel – HBJ1/HBP1 Connector .......................................................................................... 4-144

Fig. 172 - Power Supply Panel – Mounting Screw Remo val.....................................................................................4-145

Fig. 173 - Blower Motor Capacitor – Boot and Clamp Removal .............................................................................. 4-146

Fig. 174 - Reference Thermometer..................................................................................................................................4-148

Fig. 175 - Rack Blocks Installed.......................................................................................................................................4-149

Fig. 176 - Rack Assembly w/Cable Cover Removed...................................................................................................4-150

Fig. 177 - Rack Cable Clamp Removed .......................................................................................................................... 4-150

Fig. 178 - Rack Cable Disconnection..............................................................................................................................4-150

Fig. 179 - Rack Assembly – Captive Screw Removal.................................................................................................4-151

Fig. 180 - Step-5 Drive Agitation Linkage Assembly..................................................................................................4-153

Fig. 181 - Drive Linkage and Bushings Specs.............................................................................................................4-154

Fig. 182 - Gas Spring Assembly ....................................................................................................................................... 4-156

Fig. 183 - Gas Spring Assembly Removal ..................................................................................................................... 4-157

Fig. 184 - Magnetic Door Switches..................................................................................................................................4-158

Fig. 185 - Door Switch LEDs – ModSig PCBA..............................................................................................................4-159

Fig. 186 - 3D 60 Rear Panel – Keyboard Port Connection ........................................................................................ 4-160

Fig. 187 - 3D 60 Rear Panel – Barcode Scanner Port Connection..........................................................................4-161

Fig. 188 - Fax Modem Port Connections (Domestic Model).....................................................................................4-162

Fig. 189 - Domestic 56K Fax Modem – Rear Port Connection.................................................................................4-162

Fig. 190 - Modem Port Connections (International Model).......................................................................................4-163

Fig. 191 - International 56K Fax Modem – Rear Port Connection...........................................................................4-163

Fig. 192 - APC UPS Domestic Model – BackUPS 650 (120V) (Front and Rear View).........................................4-164

Fig. 193 - 3D 60 System Rear Communications Ports (UPS Cable Connection)................................................4-164

Fig. 194 - UPS Battery Connection Preparation .......................................................................................................... 4-165

Fig. 195 - UPS Battery Cover Removal...........................................................................................................................4-165

Fig. 196 - Connecting UPS Battery Cable to Terminal............................................................................................... 4-166

Fig. 197 - Domestic UPS with Battery Cables Connected.........................................................................................4-166

Fig. 198 - Domestic UPS with Battery Cover Secured...............................................................................................4-167

Fig. 199 - Domestic UPS Peripheral Connections.......................................................................................................4-167

Fig. 200 - APC UPS International Model _BackUPS 650 (240V) (Front and Rear View) ....................................4-169

Fig. 201 - 3D 60 System Rear Communications Ports (UPS Cable Connection)................................................4-169

Fig. 202 - International UPS Battery Connection Preparation ................................................................................. 4-170

Fig. 203 - International UPS Battery Cover Removal.................................................................................................4-170

Fig. 204 - Connecting UPS Battery Cable to Terminal ............................................................................................... 4-171

Fig. 205 - International UPS with Battery Cables Connected...................................................................................4-171

Fig. 206 - International UPS with Battery Cover Secured.........................................................................................4-172

Fig. 207 - International UPS Peripheral Connections.................................................................................................4-172

Fig. 208 - Instrument Status Code 710................................................................................................................................D-9

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xviii Service Manual

BacT/ALERT® 3D 60 TYPOGRAPHY AND GRAPHIC CONVENTIONS

00..44

TTYYPPOOGGRRAAPPHHYY AANNDD GGRRAAPPHHIICC CCOONNVVEENNTTIIOONNSS

The following is a comprehensive list of the typographical and graphic elements of this manual.

0.4 TYPOGRAPHY AND GRAPHIC CONVENTIONS.....................................................XIX

0.4.1 Bullets..............................................................................................................xxi

0.4.2 Text Boxes ....................................................................................................... xxi

0.4.3 Bracketed Italics................................................................................................ xxi

0.4.4 Underlined Text................................................................................................. xxi

0.4.5 Bracketed Text .................................................................................................xxii

0.4.6 Text Within Quotation Marks.............................................................................xxii

0.4.7 Italicized (Whether Bold or Not) Text .................................................................xxii

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Important Steps

BacT/ALERT® 3D 60 TYPOGRAPHY AND GRAPHIC CONVENTIONS

00..44..11

00..44..22

BBuulllleettss

Bullets are used to designate items in a list (•, -) or steps in a procedure (1, 2, et c)

TTeexxtt BBooxxeess

Whenever text is contained within a box (Reference Figure 1) it identifies things that require
special attention. There are three different text boxes used within this manual:

• NOTES: Used to clarify or explain a particular step. These text boxes are identified by

• CAUTIONS: Used to identify actions that could cause DAMAGE to the instrument or

• WARNINGS: Used to identify actions that could result in INJURY or DEATH to

• IMAGE NOTES: Used to explain steps of a process, identify component parts,

A text box can be a NOTE, CAUTION, WARNING or Image Note.

Fig. 1 - Text Box

the word 'NOTE' (bold and all caps) centered at the top of the box and normal text
following.

test equipment. These text boxes are identified by the word 'CAUTION' (bold and all
caps) centered at the top of the box and bold text following.

personnel performing the procedure (or close by). These text boxes are identified by the
word 'WARNING ' centered at the top of the box and bold capitalized text following.

suggestions and other steps related to the functionality of the instrument. The text
boxes are not identified with any special markings. Generally they will surround photos
and drawings and will explain processes, parts or other related information.

00..44..33

00..44..44

Service Manual xxi

BBrraacckkeetteedd IIttaalliiccss

Brackets around Italics text, [Italics Text], identifies items to be clicked on the display screen.
(I.E.: Press [On Line] to continue).

UUnnddeerrlliinneedd TTeexxtt

Underlined text identifies words, groups, or characters that are to be typed on the keyboard.
(I.E.: Type <Y><E><S> to continue, or Press <ALT> + <CTRL> + <DEL> to reboot.)

TYPOGRAPHY AND GRAPHIC CONVENTIONS BacT/ALERT® 3D 60

00..44

00..44..55

00..44..66

00..44..77

TTYYPPOOGGRRAAPPHHYY AANNDD GGRRAAPPHHIICC CCOONNVVEENNTTIIOONNSS ((CCOONNTTIINNUUEEDD))

BBrraacckkeetteedd TTeexxtt

Single text within brackets identifies single keys to be pressed on the keyboard. (I.E.: Press
<Esc> to exit the system.)

TTeexxtt WWiitthhiinn QQuuoottaattiioonn MMaarrkkss

Whenever text is displayed within quotation marks, it usually means that this a displayed
message on the screen. (I.E.: After previous step is complete, the system will display 'Press
Any Key to Continue'.)

IIttaalliicciizzeedd ((WWhheetthheerr BBoolldd oorr NNoott)) TTeexxtt

Whenever text is in Italics (or Bold Italics), it provides for emphasis, or identifies key words
or concepts. Whenever this format is seen, it is an important operative part of the meaning of
the text or added notation. Bold Italics designate STRONG emphasis and is not to be
ignored or taken lightly.

xxii Service Manual

BacT/ALERT® 3D 60 SAFETY SUMMARY

00..55

SSAAFFEETTYY SSUUMMMMAARRYY

The following is a comprehensive list of the safety issues outlined in this chapter.

0.5 SAFETY SUMMARY.................................................................................................XXIII

0.5.1 General Information to Follow ........................................................................... xxv

0.5.2 Electrical Warnings...........................................................................................xxv

0.5.3 Electrical Grounding .........................................................................................xxvi

0.5.4 Fuse Replacement Warning..............................................................................xxvi

0.5.5 Hazardous Voltages .........................................................................................xxvi

0.5.6 Cleaning Agents...............................................................................................xxvi

0.5.7 Health Risks ...................................................................................................xxvii

0.5.8 ESD Precautions.............................................................................................xxvii

0.5.9 Moving Parts ...................................................................................................xxvii

0.5.10 Heating Element ............................................................................................. xxvii

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BacT/ALERT® 3D 60 SAFETY SUMMARY

00..55..11

00..55..22

GGeenneerraall IInnffoorrmmaattiioonn ttoo FFoollllooww

This manual contains WARNINGS, CAUTIONS and NOTES, specific instructions and other
information that must be followed and observed at all times. This will help ensure the safe
handling and operation of the instrument.

• NOTE: Clarifies or explains a particular step or procedure. A note box is identified with
the word NOTE in bold text and the explanatory body text is not bolded.

• CAUTION: Warns of a risk of DAMAGING equipment or components. A caution may be
identified with the word CAUTION and its explanatory body text is bolded.

• WARNING: Identifies a process step that may cause injury or DEATH to personnel. A
warning may be identified with the word WARNING and its explanatory body text is
bolded in all caps.

EElleeccttrriiccaall WWaarrnniinnggss

The BacT/ALERT 3D 60 has been designed and tested IAW IEC Publication 61010-1: Safety
Requirements for Electrical Equipment for Measurement, Control, and Laboratory Use, UL
3101-1, CAN/CSA C22.2 No. 1010.1-92 and has been supplied in safe condition. A CB
Certificate and Construction File have been established for the instrument.

1. Before applying power, ensure that the Power Entry Module (PEM) is properly

configured for the specific facility power voltage. Also ensure that the fuse(s) is (are)
installed and of proper rating value. (See Subsection 3.2.5 – Set AC Power)

2. Any interruption of the protective conductor inside or outside of the instrument or

disconnection of the protective earth terminal is likely to make the instrument dangerous
to lab personnel and other users.

3. Any adjustment, maintenance or repair of the opened instrument while under voltage

should be avoided. If power to the instrument is necessary, repair or maintenance shall
be carried out only by a trained and qualified individual who is aware of the hazard(s)
involved with the task. In addition, a second individual will be nearby to render aid, if
necessary.

4. Make sure that only fuses with the required current rating and of the specified type are

used for a replacement. The use of makeshift fuses or the short-circuiting of any fuse
holder is extremely dangerous and prohibited. (See Subsection 3.2.5 – Set AC Power)

5. Whenever it is likely that a BacT/ALERT 3D 60 has been impaired, it will be made

inoperative by powering it down and disconnecting the power cord. If there is evidence
of moisture within the instrument, turn the facility power off at the circuit breaker junction
box before removing the power cable. The instrument is likely to be impaired if it:

• Shows visible damage

• Fails to perform an intended operation

• Has been subjected to storage or operation under unfavorable conditions. (i.e.,

above 80% humidity, dusty environment, prolonged storage. (Refer to Section 1-

2, Table 1.2.1, for tolerances.

• Has been subjected to severe transport stresses.

6. If any of the above conditions occur, a qualified service technician must check the

instrument out prior to use.

Service Manual xxv

WARNING

SAFETY SUMMARY BacT/ALERT® 3D 60

00..55

00..55..33

SSAAFFEETTYY SSUUMMMMAARRYY ((CCOONNTTIINNUUEEDD))

EElleeccttrriiccaall GGrroouunnddiinngg

An electrical ground is required and must be in place for this instrument.
Before installing the instrument, ensure that a grounded wall receptacle is available for each

unit. It must be plugged into a mating grounding type wall receptacle in accordance with
National Electrical Codes (US Domestic) and/or applicable local codes and ordinances
(domestic or international) for this type of installation. (Reference Figure 2, below)

UNDER NO CIRCUMSTANCES IS THE GROUND PRONG TO BE REMOVED. IF THE
GROUND PRONG, THE PL UG, OR THE CORD HAVE ANY PHYSICAL DAMAGE, THE CORD
IS TO BE REPLACED. IT IS EXTREMELY HAZARDOUS TO OPERATE THIS (OR ANY)

INSTRUMENT WITH A MISSING GROUND PRONG OR A FAULTY CABLE IN PLACE.

00..55..44

00..55..55

00..55..66

Fig. 2 - USA 115 VAC Standard Fig. 3 - European 230 VAC Standard

FFuussee RReeppllaacceemmeenntt WWaarrnniinngg

There are no user-serviceable fuses in the BacT/ALERT® 3D 60. Only trained and qualified
service technicians are to replace any fuse within the instrument. The only exception to fuse
installation will be during the initial installation of the unit. At the time of installation, the
customer does install PEM fuses according to steps outlined in the Installation section of the
BacT/ALERT 3D 60 Operator’s Manual.

HHaazzaarrddoouuss VVoollttaaggeess

DC voltages used within the instrument are low voltage and low current. They do not pose
any immediate hazard to technicians. There is, however, facility power of either 115 VAC or
230 VAC within or near the power supply assembly, which could pose an electrical hazard if
proper precautions are not observed. Note: All voltages are potentially hazardous under the
proper circumstances.

CClleeaanniinngg AAggeennttss

Follow manufactures’ instructions and MSDS (Material Safety Data Sheets) information to
prevent any possible hazards that may be present when using cleaning agents (or other
chemicals).

xxvi Service Manual

BacT/ALERT® 3D 60 SAFETY SUMMARY

00..55

00..55..77

00..55..88

00..55..99

00..55..1100

SSAAFFEETTYY SSUUMMMMAARRYY ((CCOONNTTIINNUUEEDD))

HHeeaalltthh RRiisskkss

Specimens and inoculated culture bottles are to be assumed as though they are capable of
transmitting infectious agents. Handling of any bottles or spec imens must be done with the
utmost care. Spills must be cleaned as soon as possible, using the disinfection procedures
outlined in the BacT/ALERT® 3D 60 Operator’s Manual and Appendix C of this manual.

EESSDD PPrreeccaauuttiioonnss

The BacT/ALERT® 3D 60 contains several electrostatic sensitive devices within the modules.
Proper ESD precautions, in addition to the use of a grounding strap, are imperative whenever
working on or near any ESD components.

MMoovviinngg PPaarrttss

There are moving parts within the left side of the instrument’s chassis. At times, personnel
may be exposed to the Agitation Drive Arm, Motor Offset Round and other internal moving
parts. Care must be taken to avoid exposure of clothing, hands, fingers, arms, etc. Prior to
performing maintenance procedures around moving parts, it is advised that loose clothing
(i.e. ties, long sleeves, etc.) be secured.

HHeeaattiinngg EElleemmeenntt

The instrument contains a heater to perform the incubation process. The heater may remain
hot for a period of time after the unit is first shut down for maintenance. To prevent burns,
avoid contact with the heater until it is known that it is cool enough to touch.

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SAFETY SUMMARY BacT/ALERT® 3D 60

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xxviii Service Manual

BacT/ALERT® 3D 60 CHAPTER 1 – GENERAL INFORMATION

CHAPTER 1

GENERAL INFORMATION

CHAPTER 1 – GENERAL INFORMATION BacT/ALERT® 3D 60

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Service Manual

BacT/ALERT® 3D 60 1 – GENERAL INFORMATION

11 GGEENNEERRAALL IINNFFOORRMMAATTIIOONN

This chapter describes the theory of operation and the general characteristics of the equipment.

11..11

IINNTTRROODDUUCCTTIIOONN

The following is a comprehensive list of the general descriptions of instrument components,
operational reference data, subassemblies and operator display configurations.

1 GENERAL INFORMATION ..............................................................................................1-1

1.1 INTRODUCTION...........................................................................................................1-1

1.2 REFERENCE DA TA.....................................................................................................1-2

1.3 EQUIPMENT DESCRIPTION.......................................................................................1-3

1.4 ASSEMBLY DESCRIPTIONS......................................................................................1-4

1.5 OPERATOR DISPLAY CONFIGURATION SCREENS............................................1-24

1.6 QUICK REFERENCE CARD ......................................................................................1-29

1-1

1 – GENERAL INFORMATION BacT/ALERT® 3D 60

11..22

RREEFFEERREENNCCEE DDAATTAA

This chart represents the environmental conditions for use, including the physical, functional and
technical characteristics of the BacT/ALERT 3D 60 instrument.

Electrical Power
Service Required 100/120/220/240VAC @ 50/60Hz

Power Consumed
In Watts 120VAC: 480W Max
240VAC: 480W Max

Heat Dissipated
In BTU/hr 1639 BTU/Hr. Max

Equipment Characteristics
Width 23.1 in. / 58.7cm
Height 23.9 in./ 60.7cm
Depth 19.9 in. / 60.5 cm
Weight 94 lbs. / 42.5Kg

Environmental Characteristics
Operating Temperature Range 10°C - 30°C (50°F - 86°F)

Storage Temperature

Range 17°C - 57°C (0°F - 135°F)

Operating and Storage

Humidity Range 10% - 90% RH (non-condensing)
Operating and Storage

Altitude No restrictions

1-2 Service Manual

Table 1.2.1 – Combination Module Reference Data

1 – GENERAL INFORMATION BacT/ALERT® 3D 60

11..33

EEQQUUIIPPMMEENNTT DDEESSCCRRIIPPTTIIOONN

The BacT/ALERT® 3D 60 instrument is a compact and automated microbial detection system
capable of incubating, agitating, and continuously monitoring specimens suspected of
contamination from bacteremia / fungemia.

The instrument consists of a WinSystems CPU and one 60 -bottle chamber consisting of three
racks of 20 culture bottles each. An externally attached display monitor permits the operator to
control and monitor the racks. (Refer to Figure 4, below)

Service Manual 1-3

Fig. 4 - BacT/ALERT 3D 60 Instrument

DC Power

1 – GENERAL INFORMATION BacT/ALERT® 3D 60

11..44

11..44..11

AASSSSEEMMBBLLYY DDEESSCCRRIIPPTTIIOONNSS

The following paragraphs indicate the composition of the system, (i.e., the equipment, hardware,
software and consumables required for it to operate.

EElleeccttrriiccaall CCoommppoonneennttss

Fan

Supply

Fig. 5 - 3D 60 Power Panel Assembly Fig. 6 - Transformer

Relays

TB1

Transformer

Blower

Heater

Fig. 7 - Blower & Heater

1-4 Service Manual

1 – GENERAL INFORMATION BacT/ALERT® 3D 60

11..44..11

EElleeccttrriiccaall CCoommppoonneennttss ((CCoonnttiinnuueedd))

1.4.1.1 Power Panel Assembly

The BacT/ALERT® 3D 60 instrument uses a standard BTA cabinet power supply. The
Power Panel Assembly provides the AC and DC power supply voltages that are used
within the 3D 60. With the use of relays, this will also shut down incubation processes
when instructed to do so by the ModSig PCBA. The power supply provides the four
separate DC voltages (+ 5V and ±12V) used throughout the instrument. (Refer to Figure

5)

1.4.1.2 Transformer Assembly

This is a transformer to isolate the instrument from facility power and is installed on the
System Power Panel. (Refer to Figure 6)

1.4.1.3 Heater

The heater provides the necessary heat for the incubation process of bottle cultures.
(Refer to Figure 7)

1.4.1.4 Blower

For the incubation process, the blower circulates heat (produced by the heater)
throughout the 3D 60 instrument. (Refer to Figure 7)

Service Manual 1-5

1 – GENERAL INFORMATION BacT/ALERT® 3D 60

11..44..11

Step-5 Motor

EElleeccttrriiccaall CCoommppoonneennttss ((CCoonnttiinnuueedd))

Fig. 8 - Step-5 Motor Assembly Fig. 9 - Fan Assembly

Fan

1-6 Service Manual

1 – GENERAL INFORMATION BacT/ALERT® 3D 60

11..44..11

EElleeccttrriiccaall CCoommppoonneennttss ((CCoonnttiinnuueedd))

1.4.1.5 Step-5 Motor Assembly

This Step-5 Motor (Figure 8) provides agitation to the racks, unless the incubation
chamber has been converted to MB and the motor has been disconnected to bypass
this process. (Refer to Subsection 4.4.2, Figures 59, 60 and 61 for MB Conversion)

1.4.1.6 Fan

A fan circulates air over the electronic components within the Electronics Compartment
to help prevent overheating. This fan may also be called the E-Fan. (Refer to Figure 9)

1.4.1.7 Quick Reference Card

This card identifies specific error codes and outlines instructions regarding system
operation. Refer to Section 1.6, Figure 31 - Front Side and Figure 32 - Rear Side)

Service Manual 1-7

1 – GENERAL INFORMATION BacT/ALERT® 3D 60

11..44..22

CCoommmmuunniiccaattiioonnss PPoorrttss ((IInnppuutt // OOuuttppuutt))

Fig. 10 - BacT/ALERT 3D 60 System Control (Rear View) w/Comm Ports

1-8 Service Manual

1 – GENERAL INFORMATION BacT/ALERT® 3D 60

11..44..22

CCoommmmuunniiccaattiioonnss PPoorrttss ((IInnppuutt // OOuuttppuutt)) ((CCoonnttiinnuueedd))

The communications ports are input/output ports that peripheral devices connect to on the
rear of the BacT/ALERT 3D 60 instrument. (Refer to Figure 10)

1.4.2.1 COMM Port

This port is reserved for future use.

1.4.2.2 Printer Port

A printer connects to this port via a parallel cable and produces hard copy reports.

1.4.2.3 Internal Speaker w/external Speaker Jack

The system has a remote speaker feature with a 5mm external mini-jack to drive two
remote stereo speakers from a distance of up to 450 feet (see Remote Speakers P/N
880-0002-01 and 02, along with 100-ft. of speaker wiring, P/N 957 -0004-350.

1.4.2.4 Power Entry Module (PEM) / ON-OFF Switch

The PEM contains the fuse protection for the unit when connected to main facility AC
power. The PEM also houses the main power switch for the instrument.

1.4.2.5 Modem Port

Used to connect the BacT 3D 60 to an external modem.

1.4.2.6 LIS Port

This port is used for connection to the facility’s LIS system.

1.4.2.7 Monitor Port

This port is used for connection to an external VGA or SVGA monitor.

1.4.2.8 UPS Port

Used to connect an external UPS to the instrument.

1.4.2.9 UPS Serial Port

Reserved for future use.

1.4.2.10 Mouse Port

Used for connecting the mouse to the instrument.

1.4.2.11 Keyboard Port

A port for connecting the keyboard to the instrument.

1.4.2.12 Barcode Scanner Port

Port for connecting the barcode -scanning wand to the instrument.

Service Manual 1-9

1 – GENERAL INFORMATION BacT/ALERT® 3D 60

11..44..33

EElleeccttrroonniicc CCoommppoonneennttss

CPU Board ModSig Board

Fig. 11 - CPU PCBA Fig. 12 - ModSig PCBA

Quad Serial Board Thermistor Board

Fig. 13 - Quad Serial PCBA Fig. 14 - Thermistor PCBA

1-10 Service Manual

1 – GENERAL INFORMATION BacT/ALERT® 3D 60

11..44..33

EElleeccttrroonniicc CCoommppoonneennttss ((CCoonnttiinnuueedd))

The Electronics Compartment is situated in the top part of the 3D 60 instrument. It contains
the internal WinSystems® computer (CPU PCBA and Quad Serial PCBA), CompactFlash
Adapter PCBA, Zip™ Drive, Step-5 PCBA and the ModSig PCBA.

1.4.3.1 CPU PCBA

The CPU is a 586 processor with an operating clock speed of 133MHz. This is the heart
of the system and controls all system operations. (Reference Figure 11)

1.4.3.2 ModSig PCBA

This board provides an interface between the CPU PCBA and the rest of the system. It
serves as a module controller for the system PCBAs, monitors incubation temperature
and the external port devices (i.e., modem, scanner, LIS, etc.) that are attached to the
3D 60 instrument. It also monitors several independent system tasks such as DC
voltages, switches, the frequency output of the speaker, power reset and other
functions. (Reference Figure 12)

1.4.3.3 Quad Serial PCBA

This board provides the communications interface from the WinSystems computer to
the rest of the system (incubator). (Reference Figure 13)

1.4.3.4 Thermistor PCBA (Input/Output)

There are two Thermistor PCBAs. One is the Input Thermistor and the other is the
Output Thermistor. The Input Sensor measures the air temperature from the warmer air
circulated by the heater fan and the Output Sensor the temperature of the cooler air
measured after Incubator Chamber circulation. A reading is taken from each sensor and
the average temperature reading of the two comprise the Incubator Chamber’s
temperature used by the temperature control logic. (Refer to Figure 14)

Note: The Input and Output Thermistors are not components of the Electronics
Compartment, yet they are described as integrated PCBAs of the electronic system.
The thermistors boards are installed in the lower compartment of the left and right inside
chassis, respectively.

Service Manual 1-11

1 – GENERAL INFORMATION BacT/ALERT® 3D 60

11..44..33

NOTE: Flash memory disk above may not necessarily reflect the actual
memory disk or size being used in the 3D 60 instrument.

EElleeccttrroonniicc CCoommppoonneennttss ((CCoonnttiinnuueedd))

Fig. 15 - CompactFlash Memory Disk Fig. 16 - CompactFlash Adapter PCBA

1-12 Service Manual

Fig. 17 - Step-5 PCBA

1 – GENERAL INFORMATION BacT/ALERT® 3D 60

11..44..33

EElleeccttrroonniicc CCoommppoonneennttss ((CCoonnttiinnuueedd))

1.4.3.5 CompactFlash Memo ry Disk

This CompactFlash disk is a removable mass storage device installed on the
CompactFlash Adapter PCBA. It is a device about the size of a matchbook and weighs
about one -half ounce. Since it is a solid-state device utilizing flash memory, it contains
no moving parts and requires no battery for data retention. The CompactFlash Disk is
compatible with IDE/ATAPI standards and serves as the C: drive in the BacT/ALERT 3D
60 application, where it holds the operating program, bottle records, system
configurations, event log files and miscellaneous other information needed for
BacT/ALERT operation. (Refer to Figure 15)

1.4.3.6 CompactFlash Adapter PCBA

The PCM-CFLASH PCBA (Reference Figure 16) is a PC/104 compatible adapter
module, designed specifically to adapt CompactFlash memory disks for use in
embedded systems such as the BacT/ALERT 3D 60. The adapter provides for
master/slave selection and a visual drive status indicator. The CompactFlash Adapter
PCBA is installed on the top cover of BacT/ALERT 3D 60 system.

1.4.3.7 Step-5 PCBA

The Step-5 controller board (Reference Figure 17) is designed to drive a five-phase
stepper motor at the speed of 60 revolutions per minute. The board operates with input
voltages of +5V and +12V, drives the stepper motor directly, and provi des starting and
stopping functions based on inputs received from the ModSig PCBA.

Service Manual 1-13

1 – GENERAL INFORMATION BacT/ALERT® 3D 60

11..44..33

Fig. 18 - BacT 3D 60 Incubator Chamber Fig. 19 - Rack Assemb ly

EElleeccttrroonniicc CCoommppoonneennttss ((CCoonnttiinnuueedd))

1-14 Service Manual

1 – GENERAL INFORMATION BacT/ALERT® 3D 60

11..44..33

EElleeccttrroonniicc CCoommppoonneennttss ((CCoonnttiinnuueedd))

1.4.3.8 Incubator Chamber Components

The Incubation Chamber (Reference Figure 18) contains three specimen racks, relays,
power supply, ModSig PCBA, rack controller PCB As, heater and blower. As viewed by
the operator, the bottles are loaded into the front of the 3D 60 instrument.

1.4.3.8.1 Rack

Each rack contains 20 bottle cells. Unless the instrument is designated as an MB
unit, the racks are continuously rocked (to provide agitation for the specimen
bottles). Also, three fascia plates identify the bottle locations and are not
interchangeable between replacement racks. (Refer to Figure 19)

1.4.3.8.2 Cell

There are 60 cells per instrument, with cells identified as 1 through 20 in the first
(top) rack, 21 through 40 in the middle rack and 41 through 60 in the bottom rack.

1.4.3.8.3 Cell Flag

The cell flag serves as a clip securing the bottles into their cells. The cell flag is
also a key component in bottle detection and cell diagnostics.

1.4.3.8.4 Cell Indicator Lamp

A lamp is located next to each cell and provides feedback to the operator.
Depending on the function selected by the operator, illuminated lamps identify the
positions of positive or negative bottles, cells that can be loaded, and so on. A
flashing indicator lamp indicates an operator error.

Service Manual 1-15

NOTE

1 – GENERAL INFORMATION BacT/ALERT® 3D 60

11..44..44

Note: The figure above shows a flat panel monitor and

IInnppuutt // OOuuttppuutt DDeevviicceess

Fig. 20 - Operator Display Monitor Fig. 21 - Barcode Scanner

may not represent the model or type of monitor
actually shipped with the 3D 60 instrument.

Fig. 22 - Keyboard Fig. 23 - Zip Drive

The photos of output devices shown above may not necessarily reflect the models being installed.

1-16 Service Manual

1 – GENERAL INFORMATION BacT/ALERT® 3D 60

11..44..44

IInnppuutt // OOuuttppuutt DDeevviicceess ((CCoonnttiinnuueedd))

1.4.4.1 Operator Display Monitor

The display monitor is a standard VGA monitor used for displaying diagnostic and
module setup information. (Reference Figure 20)

1.4.4.2 Barcode Scanner

The QuickScan™ 6000 Barcode Scanner scans bottle labels, identifying the bottles
whenever loading or unloading. (Reference Figure 21)

1.4.4.3 Keyboard

This is a standard-sized 101-key keyboard. It is used as an alternative input device to
the barcode scanner or mouse. (Reference Figure 22)

1.4.4.4 Zip Drive

This drive provides an internal resource for loading new operating system software and
performing system data backup. (Reference Figure 23)

Service Manual 1-17

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IInnppuutt // OOuuttppuutt DDeevviicceess ((CCoonnttiinnuueedd))

1.4.4.5 56K FAX Modem (Domestic)

The fax modem serves as an interface to the BacT 3D 60 instrument for remote access.
The remote user is able to download and upload information, including seeing what is on
the display -screen that the local operator views. The Technical Support Center is able
to perform remote diagnostics and other troubleshooting of the instrument.

The modem interfaces the 3D 60 instrument through a connection to the Modem port on
the rear of the unit. Digital signals are converted to tones by the modem for sending to
the telephone system through the telephone jack connection and to a remote modem at
on the receiving end. Conversely, tones from the remote modem are converted to digital
signals and sent to the instrument through the Modem port. Power for the modem is
supplied by a wall-mounted power supply that supplies low voltage required by the
modem. The wall -mounted power supply plugs directly into a standard electrical outlet.

1.4.4.6 56K Fax Modem (International)

The international fax modem differs slightly from the domestic version, by having CE
markings and is shipped with a 220V AC adapter. It also has two additional DIPswitch
settings (9 & 10). (See Subsection 3.2.12, Figure 53, for instructions on International
Fax Modem DIP switch settings.

The fax modem serves as an interface to the BacT 3D 60 instrument for remote access.
The remote user is able to download and upload information, including seeing what is on
the display -screen that the local operator views. The Technical Support Center is able
to perform remote diagnostics and other troubleshooting of the instrument.

The modem interfaces the instrument through a connection to the Modem port on the
rear of the unit. Digital signals are converted to tones by the modem for sending to the
telephone system through the telephone jack connection and to a remote modem at on
the receiving end. Conversely, tones from the remote modem are converted to digital
signals and sent to the instrument through the Modem port. Power for the modem is
supplied by a wall-mounted power supply that supplies low voltage required by the
modem. The wall -mounted power supply plugs directly into a standard electrical outlet.

Service Manual 1-19

Telephone Surge

Protection

120V Backup

Accessory Surge

Overload

1 – GENERAL INFORMATION BacT/ALERT® 3D 60

11..44..55

On/Off Switch

Test Switch

UUnniinntteerrrruuppttiibbllee PPoowweerr SSuuppppllyy ““UUPPSS””

Computer Interface Port

Protector

Receptacles

Receptacles

Fig. 24 - Uninterruptible Power Supply (UPS) Domestic Model – Front and Rear Views

1-20 Service Manual

1 – GENERAL INFORMATION BacT/ALERT® 3D 60

11..44..55

UUnniinntteerrrruuppttiibbllee PPoowweerr SSuuppppllyy ““UUPPSS”” ((CCoonnttiinnuueedd))

Refer to Figure 24 for the following component descriptions of the domestic UPS.

1.4.5.1 On/Off Switch

Turns the UPS and BacT/ALERT 3D 60 unit ON and OFF from the UPS.

1.4.5.2 UPS Comm Port (Computer Interface Port)

The UPS Computer Interface Port is a standard 9-pin port used to connect a cable that
monitors communications between the UPS and the 3D 60 Instrument. (The port
connection is shown as Computer Interface Port in Figure 24)

1.4.5.3 Overload Reset Switch

The Overload Switch is a reset switch (breaker) allowing for UPS reset following a power
surge or uncommon UPS shutdown. The overload is rated 120VAC, 12 Amp (Max) at
50/60Hz.

1.4.5.4 Test (Check Battery/Alarm Disable) Switch

By pressing the top of Test (toggle) switch, the UPS battery may be checked. The UPS
powers the loads from the battery. If the UPS emits the battery exhaustion alarm, the
battery is weak and requires extended charge or replacement.

1.4.5.5 120V Backup Receptacles

These 120V AC receptacles are used when devices connected to the UPS require full
battery backup to allow proper shutdown of the equipment. A device that may require
such battery backup might be the Display Monitor, since it is required to shut down the
3D 60 instrument in a “facility power-fail” situation.

1.4.5.6 Accessory Surge Receptacles

These 120V receptacles are used when devices connected to the UPS do not require
battery backup but may require voltage surge protection. A device that may require
surge protection but not battery backup might be a Parallel Printer.

1.4.5.7 AC Power Cord

The AC Power Cord is a standard three-pronged AC (grounded) cord.

Service Manual 1-21

Accessory Surge

240V Backup

Overload

Computer Interface

1 – GENERAL INFORMATION BacT/ALERT® 3D 60

11..44..55

UUnniinntteerrrruuppttiibbllee PPoowweerr SSuuppppllyy ““UUPPSS”” ((CCoonnttiinnuueedd))

On/Off Switch

Test Switch

Fig. 25 - Uninterruptible Power Supply (UPS) European Model – Front and Rear Views

P ort

Protector

Receptacle

Receptacles

1-22 Service Manual

1 – GENERAL INFORMATION BacT/ALERT® 3D 60

11..44..55

UUnniinntteerrrruuppttiibbllee PPoowweerr SSuuppppllyy ““UUPPSS”” ((CCoonnttiinnuueedd))

The European UPS model is very similar to the US domestic model. The voltage rating,
power cord and fuse ratings, however, are for the European power conversions. (Refer to
Figure 25 for International/European UPS components)

Service Manual 1-23

1 – GENERAL INFORMATION BacT/ALERT® 3D 60

11..55

OOPPEERRAATTOORR DDIISSPPLLAAYY CCOONNFFIIGGUURRAATTIIOONN SSCCRREEEENNSS

Fig. 26 - Instrument Configuration Screen

1-24 Service Manual

Next Screen

1 – GENERAL INFORMATION BacT/ALERT® 3D 60

11..55

11..55..11

OOPPEERRAATTOORR DDIISSPPLLAAYY CCOONNFFIIGGUURRAATTIIOONN SSCCRREEEENNSS ((CCOONNTTIINNUUEEDD))

The BacT/ALERT 3D 60’s Operator’s Manual describes most of the screens displayed on the
display monitor. Specifically, it describes the screens used to: load/unload bottles, set the date
and time, enable/disable cells, calibrate incubation temperature, perform single cell calibration,
set maximum test times, set audible alarm options and change passwords. For detailed
information on these screens, refer to the BacT/ALERT 3D 60 Operator’s Manual.

IInnssttrruummeenntt CCoonnffiigguurraattiioonn SSccrreeeenn

This screen is primarily used when an instrument is being installed. It allows the field service
engineer to enter information regarding rack installation. (Refer to Figure 26)

1.5.1.1 Accessing the Configuration Screen

Perform the following steps to gain access to the Configuration Screen:

1. At the “Main Screen”, click on the [Next Screen] button (Refer to Figure 27, below)

button

2. Once at the “Setup Screen” (Refer to Figure 28), enter the Field Engineer password

<4><3><4><3><2><1><2><1>, by clicking on the number buttons at the top of the
screen. After entering the password, click on the [Key] button. (See “Setup Screen”
on the next page for Screen Diagnostics).

Fig. 27 - Main Screen

Service Manual 1-25

Determines whether

Designates which

When checked, this

NOTE

required. “Hash marks” exist with

NOTE

Password Key

Configure Screen

1 – GENERAL INFORMATION BacT/ALERT® 3D 60

1.5.1.1 Accessing the Configuration Screen (Continued)

Key button

buttons

System Setup

Screen

button

Previous Screen button

Fig. 28 - Setup Screen w/Field Engineer Password Activation

Clicking on the [Configure Screen] button will access the “Configuration Screen”.

To get back to the Main Screen,

press the [Previous Screen] button.

1.5.1.2 Instrument Configuration Screen - Initial Entry

Use this screen to configure the instrument. (Refer to Figure 29, below.)

a period or comma,

this is used as a

decimal point.

Checks for enable/disabled racks
as well as rack configuration is

or without enable/disabled racks
or rack configuration.

Fig. 29 - Instrument Configuration Screen

racks are installed in

the 3D 60 instrument.

box designates the

unit as an MB unit.

1-26 Service Manual

1 – GENERAL INFORMATION BacT/ALERT® 3D 60

1.5.1.3 Configuration Screen [X Box] Buttons

Several configuration options are represented by a graphical element called an [X Box]
button. As shown in Figure 30 below, an [X Box] button can appear with or without an
“X” in the box. The “X” determines the active selection. Clicking inside the box with the
mouse switches the box to the opposite state.

Fig. 30 - [X Box ] Selection Checkbox

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1-28 Service Manual

1 – GENERAL INFORMATION BacT/ALERT® 3D 60

11..66

QQUUIICCKK RREEFFEERREENNCCEE CCAARRDD

The Quick Reference Card (Figure 31 and Figure 32 on the following pages, Front and Rear
Sides, respectively) is simply that…a quick reference. The card contains references to errors and
fault codes that may appear on the BacT/ALERT® 3D 60 during operation. The card’s purpose is
to aid the operator in determining what may have caused a particular problem. It does not
contain corrective action measures . For more information, refer to Appendix D – Error Codes of
this manual and the BacT/ALERT® 3D 60 Operator’s Manual for possible solutions.

Service Manual 1-29

1 – GENERAL INFORMATION BacT/ALERT® 3D 60

11..66

QQUUIICCKK RREEFFEERREENNCCEE CCAARRDD ((CCOONNTTIINNUUEEDD))

Card P/N 955-0500-03 Rev A

OPERATION ERROR CODES

Refer to Operator Manual for detailed error description and troubleshooting instructions.

Code Description Code Description

901
902
910
911
912
942

913

921

923

CORRUPTED BOTTLE RECORD HAS BEEN SELECTED
REQUIRED DATA MISSING
INVALID CELL LOAD
INVALID CELL UNLOAD
INVALID CELL RELOAD
BOTTLE ID JUST SCANNED MATCHES THAT OF A

CURRENTLY LOADED BOTTLE
BARCODE SCAN NOT ALLOWED IN THIS MODE

INVALID BARCODE ENTRY

932

940
941

943
944
945

960

930

931

INCORRECT OR UNEXPECTED BARCODE SCANNED
AFTER UNLOADING A BOTTLE

DETECTION ALGORITHM HAS BEEN CHANGED

SEE REVERSE FOR INSTRUMENT FAULT CODES

961

BOTTLE ID SCANNED MATCHES THAT OF A PREVIOUSLY UNLOADED
BOTTLE

BOTTLE DETAIL NOT FOUND
BOTTLE ID ENTERED MATCHES THAT OF A BOTTLE THAT IS

CURRENTLY LOADED IN A DIFFERENT CELL
BOTTLE TYPE CHANGE REQUIRES DIFFERENT ALGORITHM

IDENTIFIED BOTTLE CHANGED TO ANONYMOUS
MANUAL UNLOAD OF ANONYMOUS BOTTLE
BOTTLE ID ENTERED MATCHES THAT OF A PREVIOUSLY UNLOADED

BOTTLE
DUPLICATE ENTRIES

INVALID BLANK FIELD

Fig. 31 - Quick Reference Card - Front Side

Detailed error descriptions and troubleshooting instructions may also be found in Appendix D of this manual.

1-30 Service Manual

1 – GENERAL INFORMATION BacT/ALERT® 3D 60

11..66

QQUUIICCKK RREEFFEERREENNCCEE CCAARRDD ((CCOONNTTIINNUUEEDD))

INSTRUMENT FAULT AND STATUS CODES

Refer to Operator Manual for detailed error description and troubleshooting instructions.

Code Description Code Description

1
2
3
4
5
10
11
12
19
20
21
22
39
41-47
51-57

POWER FAULT IN INCUBATION MODULE
COMMUNICATION LOST WITH INCUBATION MODULE
INCUBATION MODULE TEMPERATURE IS TOO HIGH
INCUBATION MODULE TEMPERATURE IS TOO LOW
INCORRECT INCUBATION MODULE CONNECTION
CONTROLLER MODULE POWER FAULT
INSUFFICIENT CHARGE IN UPS
LIS COMMUNICATION FAULT
SOFTWARE EXCEPTION
DRAWER OPEN FOR TOO LONG
DRAWER AGITATION FAILURE
UNEXPECTED DRAWER AGITATION
RACK TEMPERATURE FAULT
RACK(S) NOT RESPONDING
RACK HARDWARE FAILURE

SEE REVERSE FOR OPERATOR ERROR CODES

60
62
71
72
73
74
75
77
78
79
99

710

800
810

CELL FAILED QC
ERRONEOUS CELL LOAD STATUS REPORTED
INVALID TIME STAMP
INVALID CALCULATION DATA
INVALID METHOD DATA
ALGORITHM CHANGE
BOTTLE DATA CORRUPTED
READING POLYNOMIAL CHANGE
INCOMPLETE TEST DATA
BOTTLE RELOADED VIA WRONG CONTROLLER
BOTTLE LOADED IN A NON-OPERATIONAL CELL
INCUBATION MODULE TEMPORARILY UNAVAILABLE WHILE POWER UP

INITIALIZATION TAKES PLACE
PRINTER FAULT
BACKUP FAILED

Fig. 32 - Quick Reference Card - Rear Side

Detailed error descriptions and troubleshooting instructions may also be found in Appendix D of this manual.

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1-32 Service Manual

BacT/ALERT® 3D 60 CHAPTER 2 – BACKGROUND INFORMATION

CHAPTER 2

BACKGROUND INFORMATION

Service Manual

CHAPTER 2 – BACKGROUND INFORMATION BacT/ALERT® 3D 60

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Service Manual

BacT/ALERT® 3D 60 2 – BACKGROUND INFORMATION

22 BBAACCKKGGRROOUUNNDD IINNFFOORRMMAATTIIOONN

22..11

IINNTTRROODDUUCCTTIIOONN

The following is a comprehensive list of items outlined in this chapter. Included are the system
PCBAs and the function of each, as well as the Incubation Chamber and Power Supply.

2 BACKGROUND INFORMATI ON .................................................................................... 2-1

2.1 INTRODUCTION...........................................................................................................2-1

2.2 SYSTEM CONTROL - MODSIG PCBA .......................................................................2-2

2.3 THERMISTOR PCBA (INPUT/OUTPUT)....................................................................2-6

2.4 3D 60 POWER SUPPLY ASSEMBLY.........................................................................2-8

2.5 DC POWER SUPPLY.................................................................................................2-10

2.6 CPU PCBA.................................................................................................................2-12

2.7 COMPACTFLASH ADAPTER PCBA ........................................................................2-14

2.8 QUAD SERIAL INTERFACE PCBA..........................................................................2-16

2.9 RACK CONTROLLER PCBA....................................................................................2-18

2.10 STEP-5 PCBA............................................................................................................2-24

Service Manual 2-1

2 – BACKGROUND INFORMATION BacT/ALERT® 3D 60

22..22

SSYYSSTTEEMM CCOONNTTRROOLL -- MMOODDSSIIGG PPCCBBAA

2-2 Service Manual

Fig. 33 - ModSig PCBA Diagram

BacT/ALERT® 3D 60 2 – BACKGROUND INFORMATION

22..22

SSYYSSTTEEMM CCOONNTTRROOLL -- MMOODDSSIIGG PPCCBBAA ((CCOONNTTIINNUUEEDD))

The MODSIG PCBA provides interfaces to the 3D 60 Instrument Controller section, the Step-5
board, external peripherals and the Rack PCBA’s. It uses a 68HC11 microprocessor with
firmware stored in the EPROM. The microprocessor uses an external 16 MHz crystal for its
clock. 32Kbytes of EPROM and 32Kbytes of static RAM are external, with no internal ROM.
There are 512 bytes of EEPROM and 1024 bytes of RAM, both of which are internal.

A 4.5-volt reference is on the PCBA for A/D reference and a 2.5-volt reference for temperature
control. Power-fail circuitry detects if the +5VDC is out of tolerance. LED’s on the board show E
Fan ON, Power -Enable ON, Blower ON, Heater ON, Agitation ON, +5V ON for ModSig, +5V ON
for Step-5 PCBA, +5V ON for Racks, Door Switches Closed, six status indicators and RS -485
transmit and receive indicators.

Temperature sensors on the board are used for E-Fan control and to report electronics over­temperature conditions. External input and output temperature sensors are used by PID control
firmware on the microprocessor for incubation temperature control and are connected to JP1.
Heater, blower and fan ON/OFF time control signals connect through a connector at JP2. A 12­bit, 8-channel A to D converter integrated circuit does conversion from analog values to digital
values for microprocessor use.

The front door has two separate interlock switches. These connect to the MODSIG PCBA
through JP11 and JP12. One switch, which the firmware cannot override, functions as a safety
interlock that disables the heater and blower if the door should open. The second switch is for
logic functions and redundancy. Both switches are monitored by the firmware and by the Step -5
agitation motor control firmware.

An instrument ID thumbwheel switch, normally set to 1, is available if there should be a need to
separately identify a 3D 60 at a customer’s site.

A Piezo buzzer is provided as an audible alarm. A remote speaker system may be used, by
connecting to J1. The keyboard connects to JP16. A barcode reader connects to P1 and a
mouse connects to P2. A parallel port printer connects to P4. A LIS system is interfaces via P8
and a modem via P9.

JP13, JP15, JP17, JP18 and JP19 connect to the Instrument Controller CPU in the 3D 60. JP29
and JP30 are used for transferring serial data signals from the Quad Serial PCBA. The Serial
UPS connec tor at P7 is for future use. The UPS is controlled through the connector at P5 and
must be connected for proper system operation. The VGA display monitor is connected at P6.
Five-volt power is connected to the board at JP31 and is supplied to the Zip Drive and the
CompactFlash PCBA through JP21. Control and data signals for the racks are supplied through
JP10.

Jumpers on the ModSig PCBA control the audio frequencies supplied to the remote speakers.
The remote speakers control volume. Volume jumpers on the board are for future use only. See

Table 2.2.1 for remote speaker audio frequency selections.

Service Manual 2-3

2 – BACKGROUND INFORMATION BacT/ALERT® 3D 60

22..22

SSYYSSTTEEMM CCOONNTTRROOLL -- MMOODDSSIIGG PPCCBBAA ((CCOONNTTIINNUUEEDD))

FREQUENCY JP23 JP24 JP25 JP26

600 Hz In In In In
800 Hz In In In Out

1 KHz In In Out Out

1.5 KHz In Out Out Out
3 KHz Out Out Out Out

Table 2.2.1 - Audio Frequency Selection (JP23 through JP26)

2-4 Service Manual

TO: Step-5 PCBA

JP1

Heater Inlet/Outlet

JP11

A/D

2 Temp

Instrument

Undervoltage/

• Blower ON

JP12

Door Interlock

Switches

JP13

JP15

JP17

JP18

JP29

JP30

JP31

JP19

Keyboard,

From CPU

Parallel I/O

RS-232,

RS-232 from

Quad Serial PCBA

Video from CPU

To & From

• Drawer ID

PS2 Keyboard

Barcode Port

Mouse Port

Parallel Printer

Port

UPS Control

VGA Monitor

+5V

Remote Speaker

Parallel I/O

To/From CPU

RS-232 from

BacT/ALERT® 3D 60 2 – BACKGROUND INFORMATION

22..22

Temperature

Sensors

SSYYSSTTEEMM CCOONNTTRROOLL -- MMOODDSSIIGG PPCCBBAA ((CCOONNTTIINNUUEEDD))

32KB RAM

68HC11

32KB RAM

Drivers

Converter

Overvoltage

Detector

Piezo Buzzer

Sensors

Oscillator

ID Switch

J2

JP2

JP10

JP16

P1

• Door Interlock
Switches

• +5 Power

• Agitate ON

FROM: Step- 5 PCBA

• Error Signal

• Heater ON

• Agitate ON

• E Fan ON

• Power En ON

Drawer A (#1)
Rack PCBA

• DC Power

• Rack ID

• Event Request

• RS-485

CPU

RS-232, Printer

To/From CPU

Rs-485 from

Quad Serial

+5VDC Power In

Driver

Fig. 34 - ModSig Block Diagram

Driver

P2

P4

P5

P6

JP21

J1

P7

P8

P9

CompactFlash

Zip Drive

Serial UPS

LIS

Modem

Service Manual 2-5

J3

J2

J1

2 – BACKGROUND INFORMATION BacT/ALERT® 3D 60

22..33

TTHHEERRMMIISSTTOORR PPCCBBAA ((IINNPPUUTT//OOUUTTPPUUTT))

2-6 Service Manual

Fig. 35 - Thermistor PCBA

BacT/ALERT® 3D 60 2 – BACKGROUND INFORMATION

22..33

TTHHEERRMMIISSTTOORR PPCCBBAA ((IINNPPUUTT//OOUUTTPPUUTT)) ((CCOONNTTIINNUUEEDD))

The Thermistor board uses an Analog device AD592BN temperature transducer to produce a
current flow proportional to temperature. The voltage source is +9VDC. The temperature
transducer has a nominal flow of 298.2µa+ 25ºC.

There are two Thermistors PCBAs in the 3D 60 instrument. The Input and Output Thermistors
measure input and output air temperature, respectively. The Input and Output temperature
readings are averaged together to comprise the Incubation Chamber’s temperature used by the
temperature control logic.

Service Manual 2-7

Facility

Heater

Blower

Power

Enable

+12 VDC

E Fan

Elec.

2 – BACKGROUND INFORMATION BacT/ALERT® 3D 60

22..44

33DD 6600 PPOOWWEERR SSUUPPPPLLYY AASSSSEEMMBBLLYY

Power Distribution Block Diagram

Power

UPS

Power

Entry

Module

CPU PCBA

Isolation

Transformer

Common Logic Ground Return 3

+5 VDC

-12 VDC

MOV

TB 1

Blower

Heater

DC Power

Supply

Comp.

Fan

Relay

Relays

Relays

ModSig PCBA

Power Panel

+5VDC

Step Five PCBA

Agitation Motor

GND

Fig. 36 - Power Distribution Block Diagram

2-8 Service Manual

BacT/ALERT® 3D 60 2 – BACKGROUND INFORMATION

22..44

33DD 6600 PPOOWWEERR SSUUPPPPLLYY AASSSSEEMMBBLLYY ((CCOONNTTIINNUUEEDD))

Input power for the 3D 60 (Refer to Figure 36) is either 115 VAC or 220 VAC. The installation
technician sets the proper voltage selection at the Power Entry Module (PEM). The circuitry is
protected by one 6.3A “time -delay” 250 VAC fuse (120 VAC version) or two 5A “time-delay” 250
VAC fuses (240 VAC version). AC voltage is coupled across the isolation transformer thus
insulating the instrument from facility power for circuit protection including a 120:120VAC or a
240:120VAC (step-down) voltage ratio.

Input power is routed to a metal oxide varistor (MOV) that’s mounted between terminals 2B & 3B
of TB1. The varistor provides inline surge protection for the internal circuitry of the system. From
TB1, power is routed to the fan, DC power supply and all “power-enable” relays.

The DC power supply provides the necessary DC voltages on J2 for various sub-units throughout
the 3D 60 Instrument. There are three separate voltages; ± 12VDC and + 5VDC, with a common
DC return providing a logic ground. In addition, the DC power supply provides a “Power Fail”
signal that is routed to the ModSig PCBA.

Service Manual 2-9

2 – BACKGROUND INFORMATION BacT/ALERT® 3D 60

22..55

Input Voltage 85 - 264 VAC
Input Frequency Range 47 - 440 Hz
Input Surge Current Cold Start, 110 VAC/220 VAC 17 A maximum/ 34A maximum
Output Voltage Adjustability +5.1 VDC output (Supply Only)

DDCC PPOOWWEERR SSUUPPPPLLYY

Parameter Condition Limits

PIN CHART

P1 AC Ground

J1

J2

Table 2.5.1 - Power Supply Data

P2 AC Neutral
P3 AC Hot

P1 + 5.1 VDC
P2 + 5.1 VDC
P3 + 5.1 VDC
P4 Return
P5 Return
P6 Return
P7 Return
P8 + 12 VDC

P9 + 12 VDC
P10 PFD
P11 - 12 VDC
P12
P13 - 5 VDC

± 3%

2-10 Service Manual

BacT/ALERT® 3D 60 2 – BACKGROUND INFORMATION

22..55

DDCC PPOOWWEERR SSUUPPPPLLYY ((CCOONNTTIINNUUEEDD))

The BacT/ALERT 3D 60’s power supply is a quad output switcher intended for small to medium­sized digital systems. These power supplies also contain built-in over-voltage protection and a
“power fail detect” signal.

Universal input voltage allows these supplies to be powered in any country of the world without
changing any jumpers or individual switch settings. The unit is capable of supplying the high
peak currents necessary to start disk drives and peripheral devices. An integral filter reduces
line-conducted noise below FCC and VDE limit B.

The over-voltage protection circuits are designed to activate at 6.25 VDC (± 0.75 VDC) for 5 VDC
output. The power supply has a “Power Fail Detection” circuit that produces a “power fail
detection” (PFD) output. The PFD signal occurs within milliseconds following an abnormal AC
line condition. The delay between the abnormal AC line condition and the PFD output varies
depending on AC line variation and power supply load.

If this condition is met, the PFD signal will go to a low state within approximately 3ms. Once the
output returns to the +4.75 VDC the PFD signal will return to a high state in 50ms to 200ms.

Refer to Table 2.5.1, on the previous page, for Power Supply data and output pin locations.

Service Manual 2-11

+

R2

R3

U8

J8

U19

U20

+

U25

J37

J23

26

J30

U18

J14

J15

J16

J9
D1

J17

C8C7C6

J12

J13

J38

2 – BACKGROUND INFORMATION BacT/ALERT® 3D 60

22..66

CCPPUU PPCCBBAA

J4

J1

J2

C5

Y2 U7

J5 U11

T1

J

J28 J22

J3
C2

C1

U1

J21

U2

LITHIUM

KEEPER

II

LTC-3PN

U16

R1

R16 R5

R4

U3

C3 C4

U4

U14

J6

J10

U5

J21 J20

J24

J11

U9 U6

Y1

U15

J25

J41 U17

J31

U10

D2

J18

J27 J33

LS1

T2

J32

U21

J34

J40

C11

J35

U23

U27

U24

U29

U28

Y3

J36

D6 D5D4 D3

J39

+ + C9C10

U22

U26

SIM1

Fig. 37 - CPU PCBA Diagram

2-12 Service Manual

BacT/ALERT® 3D 60 2 – BACKGROUND INFORMATION

22..66

CCPPUU PPCCBBAA ((CCOONNTTIINNUUEEDD))

The CPU PCBA (Reference Figure 37) is an “off-the-shelf” internally mounted WinSystems®
computer that combines a 586 (or higher) CPU with Video, Floppy, IDE, Serial and Digital I/O.

The chipset provides the core logic that makes the board PC/AT software compatible. It includes
the DRAM controller, bus interface, integrated peripheral controllers (8237 DMA, 82C54 timer,
82C59 PIC, RTC, KYBD controller and CMOS memory) and an internal PCI bus for high -speed
operation.

Up to 32 MB of memory can be populated on board with a 72 -pin SIMM. The BIOS can detect
and automatically support either Fast Page or EDO memory modules. Seven DMA channels are
supported, with Channel 2 dedicated to the floppy disk controller. The LPT is jumper selectable
for ECP operation. The other DMA channels are wired to the PC/104 connector. An onboard
256KB x 16 DRAM provides 512KB of video memory.

Service Manual 2-13

2 – BACKGROUND INFORMATION BacT/ALERT® 3D 60

22..77

CCOOMMPPAACCTTFFLLAASSHH AADDAAPPTTEERR PPCCBBAA

Fig. 38 - CompactFlash Adapter PCBA

2-14 Service Manual

BacT/ALERT® 3D 60 2 – BACKGROUND INFORMATION

22..77

CCOOMMPPAACCTTFFLLAASSHH AADDAAPPTTEERR PPCCBBAA ((CCOONNTTIINNUUEEDD))

A CompactFlash Adapter PCBA (with CompactFlash Memory Disk™ installed) is mounted near
the WinSystems® motherboard. It is connected by a flat ribbon cable to the motherboard’s IDE
port. (Refer to Figure 38 or Subsection 4.10.4, Figures 108-112)

The Flash-Memory Disk contains the operating system, BacT/ALERT® 3D 60’s software,
instrument configurations, operator settings, layout of the instrument pictorial, along with the
bottle record data.

Service Manual 2-15

C7

R7

C5

J9

J10

C27 +

J12

2 – BACKGROUND INFORMATION BacT/ALERT® 3D 60

22..88

QQUUAADD SSEERRIIAALL IINNTTEERRFFAACCEE PPCCBBAA

R9

R1 R2

R10 R12

J3

U5

R11

1

U1

R36 R37

C1

RP1

U11

R5

R13

U9

C12

C13

J4

1

U12

R35

U2

J1

R6

R14

U7

Com 3 and Com 4, J3

1

R27

R28 R30

U18

1 1

R23 R24

J11

R29

U16

C26

C17 C18

C20 C21

U15

J7 J8

1

1

U3

C2

U6

C11

R22 R21 C8

C14

C3

RP2

U17

RP4

Copyright 1995 Made in USA

1

J2

R8

R15

R16

C9

C15

C23

C25

U13 R18 R20

U8

C19
C22
C24

RP3

R17

C10

U4

1

R31

R32

U10

J5

U14

C6

R3 R4

1

R38

R25 R26

1

C4

R19

J6

Com 1 and Com 2, J6

R34 R33

32

D C

WinSystems® PCM-COM4A Rev. B

Fig. 39 - Quad Serial Interface PCBA Diagram

2-16 Service Manual

BacT/ALERT® 3D 60 2 – BACKGROUND INFORMATION

22..88

QQUUAADD SSEERRIIAALL IINNTTEERRFFAACCEE PPCCBBAA ((CCOONNTTIINNUUEEDD))

The Quad Serial Interface (Com4) board (Reference Figure 39) is a daughter board that plugs
into the PC/104 bus on the WinSystems® motherboard.

There are four ports on the board. Com 1 is configured as a RS -485 port. Com 2 3 and 4 are
configured as RS -232 ports. Com 1 and Com 2 are located on connector J6, while Com 3 and
Com 4 are located on connector J3. All communications ports are software supported and
operate at a 9.6K Baud data rate.

The Quad Serial is a four-channel serial (INS8250 compatible) P/C 104 module that is based on
the 16C554 UART. It is ideally suited for applications running DOS programs or languages that
require exact register compatible hardware for program execution. Each of the channels
supports RS-232, with optional RS-485 and RS-422 electrical levels to interface with a wide
variety of serial communications devices.

The Quad Serial PCBA is I/O mapped. Each channel requires eight port addresses and each is
independently decoded within the I/O map. The interrupt status register also requires one I/O
port. The addresses are decoded in the PAL and are jumper -selectable, with eight different I/O
maps. The Com4 card is a 16-bit stack-through card that supports 8-bit data transfers only.

Service Manual 2-17

2 – BACKGROUND INFORMATION BacT/ALERT® 3D 60

22..99

RRAACCKK CCOONNTTRROOLLLLEERR PPCCBBAA

2-18 Service Manual

Fig. 40 - Rack Controller PCBA Diagram

BacT/ALERT® 3D 60 2 – BACKGROUND INFORMATION

22..99

RRAACCKK CCOONNTTRROOLLLLEERR PPCCBBAA ((CCOONNTTIINNUUEEDD))

The Rack Controller PCBA (Refer to Figure 40), using EPROM-stored software, controls the
excitation LEDs. The LED light illuminates and reflects on the bottle sensors, creating emitted
measurable values at the photo detectors. The Rack Controller digitizes each cell’s photo­detector output for reading by the ModSig’s Control Module and for bottle presence detection.

Cell indicator LEDs are controlled for operator information. Status and data are communicated
through an RS-485 cable from the Rack Controller to the ModSig board. The microprocessor
software also monitors the bottle rack rocking motion with a “Hall-Effect” sensor. In addition, the
software normalizes illumination readings with cell and temperature calibration factors. Address
lines from the ModSig are used to confirm that the 3D 60’s WinSystems® CPU board is
addressing the correct Rack Controller thus eliminating the need for switches on each Rack
Controller. Calibration values are stored onboard the Rack Controller PCBA in a non-volatile
RAM (NVRAM). The Rack Controller PCBA is located in the rear portion of the rack channel of
the Incubation Chamber. A fully implemented Incubation Chamber will have three Rack
Controller PCBAs.

The microprocessor is the Motorola 68HC11 and the same used on the ModSig PCBA. This
microprocessor has separate 16-bit address and 8-bit data lines defined. This eliminates the
need of having external address and data multiplexing for the external 32KB of RAM and 32KB of
EPROM included on the PCBA.

The clock speed of the 68HC11 is set at 16 MHz by an external crystal. Internally, the
microprocessor contains 512 bytes of EPROM, 1024 bytes of RAM, and no ROM. External
memory for the microprocessor is on the Rack Controller PCBA. A 16 -bit free running counter,
driven by a programmable prescaler and other divider chains, provides for a wide range of
internal timing periods for software use. Included is a watchdog timer.

The Rack Controller PCBA uses 32KB of static RAM in a surface mount package. The software
for most dynamic storage uses this memory. The Rack Controller uses 32KB of EPROM for
program storage. Jumpers are included to allow the installation of larger memory, in the event
that the 27C256 microprocessor becomes obsolete. Memory parts with less than 90ns access
are required.

There are two 20-pin connector positions on the board. Power (+5 volts for each board) is
supplied through a cable from the ModSig to the JP2 connector. The other connector, JP1, is
cabled to JP2 of the next rack. No other power is required. A fuse on the ModSig protects the
set of three Rack Controllers in the Incubator Chamber.

The +5 volt input voltage produces two reference voltages. A +4.5V reference is provided to the
A-D converter. A +2.5V reference is provided for the Rack temperature operational amplifiers as
well as an accurate current control of the exciter LED’s current by an operational amplifier.

Each cell has one exciter LED. Each of these LEDs is driven by an output from a 74ACT374
driver.

One indicator LED is provided for each bottle holder or cell. Each of the LEDs is driven by an
output from a 74ACT374 driver. In addition, there are four “status ” LEDs for general purpose and
are explained in the firmware.

Service Manual 2-19

Sensors OP

Reference

previous Rack

2 – BACKGROUND INFORMATION BacT/ALERT® 3D 60

22..99

RRAACCKK CCOONNTTRROOLLLLEERR PPCCBBAA ((CCOONNTTIINNUUEEDD))

Rack Controller Block Diagram

Agitation

Sensor

Cell

Amps 1-20

Analog

Multiplexer

Rack

Temperature

Voltage

68HC11 Microprocessor

w/internal RAM and EPROM

12-Bit

A-D

Converter

Drivers

Constant

Current
Control

32 KB

RAM

32 KB

RAM

Cell

Exciters

1-20

Cell

Indicators

1-20

To/From

ModSig or

Controller

+5V IN

RS-485

Rack ID

Event Request

Rack ID OUT

Drawer ID

Drawer ID

Rack ID Output

Event Request

Fig. 41 - Rack Controller PCBA Block Diagram

RS-485

RCVR/XMTR

To/From Next

Rack Controller:

+5 V OUT

RS-485

Rack ID

Drawer ID

Event Request

Rack ID OUT

2-20 Service Manual

BacT/ALERT® 3D 60 2 – BACKGROUND INFORMATION

22..99

RRAACCKK CCOONNTTRROOLLLLEERR PPCCBBAA ((CCOONNTTIINNUUEEDD))

Each cell has an individual external sensor. The sensor outputs are multiplexed to cascaded
operational amplifiers that drive the analog input of an A-D Converter. The cell sensor readings
are sent, on request, to the instrument. The Rack Controller firmware detects bottle presence
from these photodiode sensors as well.

Circuitry is provided to develop the analog signals to the A-D Converter for the two temperature
sensors on the Rack PCBA. These sensors are part of the calibration factors for the bottle cells.

The agitation sensor is a “Hall-Effect” sensor. The sensor detects bottle rack motion for a change
in magnetic flux from a rare-earth magnet as the rack is agitated. Each board has a sensor;
however, only one position in each drawer is utilized for monitoring.

The Event Request signal is a common open drain signal driven by the ModSig PCBA and all
Rack Controller PCBAs. The ModSig, Rack Controller and WinSystems CPU board can also
read the signal. Its purpose is similar to an interrupt signal; it's to notify the WinSystems CPU
board that an event such as a bottle removal has occurred. For the ModSig, this signal is both an
output to the WinSystems CPU board and an input from the Rack Controller. When the Event
Request is pulled low, the Drawer ID low signal used by the Rack Controllers is disabled. The
Rack Controller drives the Drawer ID lines to indicate which Rack Controller(s) activated the
Event Request line. The Rack Control firmware reads the Event Request line before and after
reconfirming its address, to ensure address lines are not in use.

With only one of four lines low for each drawer, the Rack Controllers can determine which drawer
they are in for each address identification for WinSystems CPU board commands. When the
Event Request is low, this is disabled; allowing the same lines to be used by the Rack Controllers
to identify which ones activated the Event Request. The driving circuitry and input circuitry is
provided on the Rack Controller. Firmware on the ModSig aids the WinSystems CPU board in
selecting which Rack Controllers read status, thus expediting bottle detection state changes.

The ModSig makes only one of the three Rack ID lines low for each rack, and then polling this
line within the Rack PCBAs, the Rack Controllers can determine their address without having
individual address switches. (Refer to Figure 42 on the next page)

Four outputs from one of the 74ACT374 -exciter LED drivers serve as the output drivers for the
Rack ID Out signals, through open-drain inverters.

The communication between the modules is over RS-485 full-duplex circuitry. The necessary
conversion between RS-485 differential signals and single-ended CMOS compatible serial
signals, for use by the software, is contained on the Rack Controller. The actual RS -485 signals
connect to all Rack Controllers through a connector on the ModSig PCBA.

Service Manual 2-21

JP2 JP1

JP2 JP1

Polling line

2 – BACKGROUND INFORMATION BacT/ALERT® 3D 60

22..99

RRAACCKK CCOONNTTRROOLLLLEERR PPCCBBAA ((CCOONNTTIINNUUEEDD))

Rack Address Concept

JP10

ModSig

PCBA

+ 5V

+ 5V

16

17

18

connects via

JP2 on each

Rack PCBA

RACK #1

16 16

17 17

18 18

Rack #1 Address Code Rack #2 Address Code Rack #3 Address Code

Input pins 18-17-16 Input pins 18-17-16 Input pins 18-17-16
Binary 1- 1 - 0 Binary 1- 0- 1 Binary 0- 1- 1

RACK #2

16 16

17 17

18 18

Fig. 42 - Rack Address Concept

RACK #3
JP2 JP1

16 16

17 17

18 18

2-22 Service Manual

BacT/ALERT® 3D 60 2 – BACKGROUND INFORMATION

22..99

RRAACCKK CCOONNTTRROOLLLLEERR PPCCBBAA ((CCOONNTTIINNUUEEDD))

A 12-bit A-D Converter is provided to convert the rack temperature sensor’s analog signals to the
digital signals used by the Rack Controller software. The same A-D Converter is used for
converting cell sensor analog signals into digital signals.

Using the +2.5V reference voltage, the resistor voltage dividers, an operational amplifier and a
MOSFET controls the current for the exciter LEDs. Only one exciter LED is activated at any one
time.

Service Manual 2-23

2 – BACKGROUND INFORMATION BacT/ALERT® 3D 60

22..1100

SSTTEEPP--55 PPCCBBAA

2-24 Service Manual

Fig. 43 - Step-5 PCBA Diagram

BacT/ALERT® 3D 60 2 – BACKGROUND INFORMATION

22..1100

SSTTEEPP--55 PPCCBBAA ((CCOONNTTIINNUUEEDD))

The Step-5 controller board (Reference Figure 43) is designed to drive a five-phase stepper
motor at the speed of 60 revolutions per minute. The board operates with input voltages of +5V
and +12V, drives the stepper motor directly, and provides starting and stopping functions based
on inputs received from the ModSig PCBA.

The STEP-5 controller board drives a Vextra 5-phase stepper motor at 1 revolution per second
(+10%) to provide rack agitation. The controller board’s inputs, outputs and features are listed
below.

1. Input (DC voltages): +5V and +12V

2. Input (Control)

• Interlocks: Two door switches are used. The two door switches are mechanical reed
switches that are closed when the door is closed. The STEP-5 uses optical isolators for
these inputs; when a switch is closed, current flows through the corresponding optical
isolator’s LED. If either switch is open, indicating a door open condition, motor rotation
stops. System design uses open switch position to indicate open door so that a
disconnected switch will also prevent motor operation. LED 55 & 56, are located on the
ModSig PCBA. The LED is on when a switch is closed.

• Start/Stop signal: The start/stop signal will go high to indicate that the STEP-5 should
run the agitation motor. This signal, generated by the ModSig PCBA goes high to enable
agitation. The input signal is optically isolated on the STEP-5.

• Position Sensor: A Hall -Effect sensor is located at the edge of the Step-5 board and
detects the magnet installed in the motor’s drive wheel. Both motor motion and drive
wheel position tracking is performed in the Step -5 board. Also, when the door is opened,
the sensor is used to determine how long to drive the motor so that the racks become
stationary in the correct position. If the position sensor is not functioning a fault output
will be generated. If the position sensor is not working, the STEP -5 will stop the motor
when the door is opened, but the position will be undefined.

3. Outputs:

A Fault Code is sent to the ModSig PCBA if certain conditions occur. The four conditions
that initiat e this code are:

• Motor over current

• Door switch (one door switch indicates open, the other indicates closed)

• Position sensor not changing state

• Safety timer not functioning (doesn’t go high after door opened)

(Also, See internal Output Codes)

Service Manual 2-25

PHASE 1

2 – BACKGROUND INFORMATION BacT/ALERT® 3D 60

22..1100

SSTTEEPP--55 PPCCBBAA ((CCOONNTTIINNUUEEDD))

Motor Output: The PM589 motor is a 5-phase stepper, wired in a pentagon configuration,

500 steps per revolution in full step mode. Step sequence example for the 5 phases is:

If an over current occurs, the motor will be stopped. The fault signal is generated by the
open-collector of Q16, and goes LOW to indicate a fault. By design, a disconnected power
cable will also result in a fault indication.

4. Internal indicators:

• LED 1 Output Codes:

[1 flash]: Motor stopped OK
[2 flashes ]: Motor running OK
[3 flashes]: Motor over current
[4 flashes]: Door switch (one switch open, the other closed)
[5 flashes]: Position sensor not changing state
[6 flashes]: Safety timer not functioning (doesn’t go high after door opened)
[7 flas hes] Motor power bad (12VDC)

Note: LED 1 on the Step-5 PCBA constantly outputs one of the above codes. To interpret
the code, count the number of longer flashes (LED on periods) after the short start flash.

• Redundant door timer: The Step-5 includes a timer, independent of the microcontroller.
It disables the stepper motor after the door is opened and some delay has elapsed.

The redundant door timer consists of an oscillator clocking a pair of 14 -bit counters,
which are wired to result in a 28-bit binary divider. The counters are continuously reset
as long as both doors are closed. If either door interlock opens, the timers are allowed
to run. Either of two outputs from the high -order counter may be selected by installing a
zero-ohm resistor on the board. The selected output is applied to the PLD that drives
the low -side motor transistors. When the output goes high, the drive transistors are
disabled, regardless of the state of the microcontroller outputs.

The redundant timer is included to preclude the possibility that some undefined failure of
the microcontroller would leave the motor running after the door is open. The timer delay
is selected to insure that, under normal conditions, the microcontroller has time to stop
the motor normally before the delay expires. Once the delay expires, the PLD inhibits
the clock to the high-order counter to prevent the delay output from cycling. Delay
values are selected as described below (output selected is denoted as IC outputs are
labeled on schematic): The door timer output is monitored by the microcontroller, which
generates a fault output after some delay if the door is open and the timer output does
not go high.

PHASE 2
PHASE 3

PHASE 4
PHASE 5

2-26 Service Manual

BacT/ALERT® 3D 60 2 – BACKGROUND INFORMATION

22..1100

SSTTEEPP--55 PPCCBBAA ((CCOONNTTIINNUUEEDD))

5. Motor voltage fault: If the motor supply voltage goes off, the microcontroller will turn off
motor drive until the motor supply is restored.

6. Power up protection: The high side predriver transistors require that the 16C74 source
current to turn them on. On power up, the I/O port pins of the 16C74 initialize inputs with no
pull-ups. This prevents cross-conduction between the high and low side MOSFETS. In
addition, as part of firmware initialization, the PLD that controls the low -side drivers does not
enable any outputs until PD7 is driven high.

7. Power down protection: The configuration bits for the 16F74 will enable the brownout
protection that resets the microcontroller if the supply drops below approximately 4V.

8. Crossover Protection: While running, the STEP -5 uses a stepping sequence that never
switches a motor phase from high to low or low to high. All motor phases go through a step
where the phase is off (neither the high or low side driver is on) between high and low
transitions. If this sequence is changed (for instance, if the board is ever used to drive a 4­phase stepper), then crossover protection will need to be added to the firmware.

9. Temperature sensor: The printed circuit board and schematic provide for a temperature
sensor. This part is not installed in the current vers ion of the board.

10. Firmware: Firmware is developed in Microchip PIC assembly language. Firmware performs
the following functions:

• Debounce interlock switches

• Turn motor driver transistors on and off to generate motor drive waveform.

• Ramp motor up and down

• Control motor current during ramp up and ramp down using PWM duty cycle

• Track position of motor using position sensor as ‘home’ position

• Monitor motor current for over current condition

• Program microcontroller hardware to generate PWM clock

• When door open, monitor safety timeout circuit for proper operation

• Stop driving motor if 12V motor supply goes off

• Generate fault outputs

The firmware defines seven states for the stepper motor:

Stopped
Ramping up
Holding (constant speed)
Seeking (waiting for position count to reach ramp down point)
Ramping down
Fault (over current)
Motor power bad

Voltage is applied to the stepper motor using a Microchip PIC16C74 microcontroller and five pairs
of MOSFET transistors (5 ea. IRL520 and 5 each IRF9530).

Service Manual 2-27

HIGH -SIDE

INTERLOCKS

2 – BACKGROUND INFORMATION BacT/ALERT® 3D 60

22..1100

SSTTEEPP--55 PPCCBBAA ((CCOONNTTIINNUUEEDD))

POSITION

SENSOR

STOP/RUN

COMMAND

(FROM

MODULE

CONTROLLER)

DC IN

INDEPENDENT

SAFETY TIMER

Microchip

PIC16C74

PLD

DRIVE

MOSFETS

PREDRIVERS

MOTOR

FAULT
OUTPUT

Fig. 44 - Step-5 PCBA Block Diagram

2-28 Service Manual

BacT/ALERT® 3D 60 CHAPTER 3 – INSTALLATION PROCEDURES

CHAPTER 3

INSTALLATION PROCEDURES

Service Manual

CHAPTER 3 – INSTALLATION PROCEDURES BacT/ALERT® 3D 60

THIS PAGE

INTENTIONALLY

LEFT BLANK

Service Manual

BacT/ALERT® 3D 60 3 – INSTALLATION PROCEDURES

33 IINNSSTTAALLLLAATTIIOONN PPRROOCCEEDDUURREESS

33..11

IINNTTRROODDUUCCTTIIOONN

This paragraph presents the Installation Procedures chapter contents.

3 INSTALLATION PROCEDU RES.................................................................................... 3-1

3.1 INTRODUCTION...........................................................................................................3-1

3.2 BACT/ALERT 3D 60 INS TALLATION PROCEDURES..............................................3-3

3.3 RESTRAINT INSTALLATI ON....................................................................................3-14

3.4 SOFTWARE INSTALLATION....................................................................................3-17

3.5 SWITCHING ON.........................................................................................................3-17

Service Manual 3-1

3 – INSTALLATION PROCEDURES BacT/ALERT® 3D 60

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3-2 Service Manual