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Operating Manual
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tecan cavro xlp 6000 Operating Manual

Operating Manual Cavro
Pump
®
XLP 6000 Modular Syringe
Copyright by Tecan Systems
October 2005
734237-C
Operating Manual Cavro
®
XLP 6000 Modular Syringe Pump
Tecan Systems, Inc. 2450 Zanker Road San Jose, CA 95131 USA T 1 408 953 3100, Toll Free 1 800 231 0711 F 1 408 953 3101 E-mail: tecansystemsinfo@tecan.com Web Site: www.tecansystems.com
Cavro® XLP 6000 Modular Syringe Pump Operating Manual, 734237-C, en
October 2005
734237-C
Copyright © 2005 Tecan Systems, Inc.
Part Number 734237-C
Copyright and Trademark Information
®
Teflon Kel-F CONTRAD Microsoft Windows 2000 Cavro
is a registered trademark of E.I. DuPont de Nemours & Co., Inc.
®
is a registered trademark of the 3M Company
®
is a registered trademark of Decon Laboratories, Inc.
®
®
are registered trademarks of Microsoft Corporation.
®
is a registered trademark of Tecan Systems, Inc.
, Windows 3.1®, Windows 95®, Windows NT®, and Windows
Product Warranty Information
Tecan Systems warrants that instruments manufactured and sold by Tecan Systems will be free from defects in materials and workmanship for a period of twelve (12) months from the date of shipment to customer. Tecan Systems’ liability for the breach of the foregoing warranty is limited to the repair or replacement of the products found to be other than warranted. Such products will be accepted for return only if the customer returns them to Tecan Systems’ factory or repair depot within thirty (30) days from the time of discovery of the alleged defect, and prior to return, fills out a Certificate of Decontamination (document P/N 730171), obtains a return authorization number from Tecan Systems, provides Tecan Systems with the serial number of each instrument to be returned, and prepays freight charges to the factory or a designated Tecan Systems repair depot. No warranty is expressed or implied for:
Breakage Syringes Maltreatment Syringe seals Unauthorized service Tubing and tubing
connections
Units not returned in original or
Cavro valves
adequate packaging
Units which are “life-cycled” Cavro probes
The foregoing warranties and limitations are customer’s exclusive remedies and are in lieu of all other warranties, express or implied, including without limitation any warranty of merchantability or fitness for a particular purpose.
Product Documentation Warranty Information
The information contained in this document is subject to change without notice. Tecan Systems makes no warranty of any kind with regard to this material, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose.
Tecan Systems shall not be liable for errors contained in this document or for incidental or consequential damages in connection with the furnishing, performance, or use of this material.
Document Status Sheet Title: Cavro® XLP 6000 Modular Syringe Pump Operating Manual ID: 734237-C, en Version Revision Issue Major changes
1 C New edition
Cavro® XLP 6000 Modular Syringe Pump Operating Manual, 734237-C, en
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Table of Contents
1 Getting Started
1.1 Regulatory Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 XLP 6000 Features at-a-Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Unpacking the XLP 6000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.1 XLP 6000 Features at-a-Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Unpacking the XLP 6000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 Functional Description of the XLP 6000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.5 Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.6 Tips for Setting Up the XLP 6000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
2 Hardware Setup
2.1 Power and Electrical Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Cabling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3 Communication Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.4 Settings and Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.5 Installing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.6 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
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3 Software Communication
3.1 XLP 6000 Addressing Scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Communication Protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3 Using the XLP 6000 Command Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.4 Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3.5 Operating Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
3.6 Error Codes and Pump Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
4 Setting Up the XLP 6000 for Your Application
4.1 Glossary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Optimizing XLP 6000 Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.3 Helpful Hints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
5 Maintenance
5.1 Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Weekly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.3 Periodic Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.4 On-Site Replacements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Cavro® XLP 6000 Modular Syringe Pump Operating Manual, 734237-C, en
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6 Technical Service
A Ordering Information
A.1 Available Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
A.2 XLP 6000 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
A.3 Other Tecan Systems Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
A.4 Mating Connector Suppliers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
B Plunger Information
B.1 Typical Plunger Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
B.2 Plunger Time Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
C ASCII Chart of Codes for U.S. Characters
D Chemical Resistance Chart
E XLP 6000 Physical Specifications
F CAN Communication Commands
G Command Quick Reference
G.1 Pump Configuration Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1
G.2 Initialization Commands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2
G.3 Valve Commands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-4
G.4 Plunger Movement Commands/Status Bit Reports . . . . . . . . . . . . . . . . . . . G-4
G.5 Set Commands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5
G.6 Control Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5
G.7 Non-Volatile Memory (EEPROM) Commands . . . . . . . . . . . . . . . . . . . . . . . G-6
G.8 Report Commands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6
G.9 Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-7
G.10 Error Codes and Status Byte . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-8
G.11 DA-15 Connector Pin Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-8
List of Figures
Figure 1-1 XLP 6000 Modular Syringe Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Figure 1-2 Syringe Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Figure 1-3 3-Port Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Figure 1-4 XLP 6000 Printed Circuit Assembly External Connectors . . . . . . . . . . 1-6
Figure 2-1 DA-15 Connector Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Figure 2-2 RS-232 Multi-Pump Cabling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Figure 2-3 RS-485 Multi-Pump Cabling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Figure 2-4 CAN Multi-Pump Cabling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Figure 2-5 Address Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Figure 2-6 XLP 6000 Valve Installation (3-Port Valve Shown) . . . . . . . . . . . . . . . 2-12
Figure 2-7 Syringe Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Figure 2-8 XLP 6000 Outline Drawing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Figure 3-1 CAN Message Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Figure 3-2 Valve Position Examples for 3-Port Non-Distribution Valves . . . . . . . 3-28
Figure 3-3 Valve Position Examples for 3-Port Distribution Valves. . . . . . . . . . . . 3-29
Figure 3-4 Valve Position Examples for 4-Port Non-Distribution Valves. . . . . . . . 3-30
Figure 3-5 Valve Position Examples for T Valves (Non-Distribution) . . . . . . . . . . 3-31
Figure 3-6 Valve Position Examples for 6-Port Distribution Valves. . . . . . . . . . . . 3-31
Figure 3-7 Valve Position Examples for 9-Port Distribution Valves. . . . . . . . . . . . 3-32
Figure 4-1 Syringe Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Figure 5-1 Syringe Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Figure 5-2 Syringe Seal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Figure 5-3 XLP 6000 Valve Replacement (3-Port Valve Shown) . . . . . . . . . . . . . 5-7
Figure 6-1 XLP 6000 Label Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
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Cavro® XLP 6000 Modular Syringe Pump Operating Manual, 734237-C, en
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1 Getting Started

Congratulations on your purchase of the Cavro® XLP 6000 Modular Syringe Pump from Tecan Systems.
The XLP 6000 is a fully programmable, open frame, precision liquid handling pump module, designed for applications in the 5 µL to 25 mL range. It is controlled by an external computer or microprocessor and automates pipetting, diluting, and dispensing functions.
This chapter includes these topics:
Regulatory Considerations XLP 6000 Features at-a-Glance Unpacking the XLP 6000 Functional Description of the XLP 6000 Safety Tips for Setting Up the XLP 6000
Regulatory Considerations
1 - Getting Started

1.1 Regulatory Considerations

The XLP 6000 is a general laboratory module. Since it not a medical device, it is not subject to FDA regulatory approval. The XLP 6000 uses only recognized components and bears the UL Recognized Component Mark:
The use of UL Recognized components in a product or system allows UL to focus the evaluation of the complete system on its intended end-use, and thus speeds up the evaluation of that product or system. For more information regarding UL certification of Tecan Systems’ syringe pumps, please visit the Underwriters Laboratories Inc. website at http://www.ul.com/info/st andard.htm. Tecan Systems’ customer file number for the recognized component is E164638.

1.1.1 CE

As a module designed for incorporation into larger systems that require independent testing and certification, the XLP 6000 does not carry its own CE mark.
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1 - Getting Started
XLP 6000 Features at-a-Glance

1.1.2 Radio Interference

1.0.1 Radio Interference

The XLP 6000 can radiate radio frequency energy , which may cause interference
The XLP 6000 can radiate radio frequency energy , which may cause interference to radio and television communications. Follow standard good engineering
to radio and television communications. Follow standard good engineering practices relating to radio frequency interference when integrating the XLP 6000
practices relating to radio frequency interference when integrating the XLP 6000 into electronic laboratory systems.
into electronic laboratory systems.

1.2 XLP 6000 Features at-a-Glance

1.1 XLP 6000 Features at-a-Glance

The XLP 6000 is a syringe pump that is designed for OEM precision liquid
The XLP 6000 is a syringe pump that is designed for OEM precision liquid handling applications. It has the following standard features and functions:
handling applications. It has the following standard features and functions:
Syringe sizes ranging from 50 L to 25 mL
Syringe sizes ranging from 50 L to 25 mL Accuracy 1.0% at full stroke
Accuracy 1.0% at full stroke Precision 0.05% at full stroke
Precision 0.05% at full stroke Standard dispense/aspirate resolution of 6,000 increments
Standard dispense/aspirate resolution of 6,000 increments Microstep dispense/aspirate resolution of 48,000 increments
Microstep dispense/aspirate resolution of 48,000 increments 3-Port, 4-Port, Y-Block, T-Valve, 3-Port Distribution, 6-Port Distribution, and 9-
3-Port, 4-Port, Y-Block, T-Valve, 3-Port Distribution, 6-Port Distribution, and 9- Borosilicate glass, Kel-F and Teflon fluid contact
Borosilicate glass, Kel-F and Teflon fluid contact RS-232, RS-485 and CAN interface
RS-232, RS-485 and CAN interface Programmable plunger speeds from 1.2 sec/stroke to 160 min/stroke, with
Programmable plunger speeds from 1.2 sec/stroke to 160 min/stroke, with Teflon coated lead screw drive with a quadrature encoder for lost-step
Teflon coated lead screw drive with a quadrature encoder for lost-step Pump diagnostics, self-test, and error reporting
Pump diagnostics, self-test, and error reporting Auxiliary inputs and outputs
Auxiliary inputs and outputs Operates using a single 24V DC power supply
Operates using a single 24V DC power supply
Port Distribution valves
Port Distribution valves
ramps and on-the-fly speed changes
ramps and on-the-fly speed changes detection
detection

1.3 Unpacking the XLP 6000

1.2 Unpacking the XLP 6000

To unpack the module, follow these steps:
To unpack the module, follow these steps:
1 Remove the pump module(s) and accessories from the shipping cartons.
1 Remove the pump module(s) and accessories from the shipping cartons. 2 Check the contents against the packing slip to make sure that all the
2 Check the contents against the packing slip to make sure that all the
components are present.
components are present.

1.3.1 ESD Considerations

1.2.1 ESD Considerations

The XLP 6000 is an electronic device that is sensitive to electrostatic discharge
The XLP 6000 is an electronic device that is sensitive to electrostatic discharge (ESD). Static discharge from clothing or other fixtures can damage these
(ESD). Static discharge from clothing or other fixtures can damage these
1 - 2 Cavro® XLP 6000 Modular Syringe Pump Operating Manual, 734237-C, en
Functional Description of the XLP 6000
components. To prevent premature failure of pump components, use good ESD practices when handling the XLP 6000. These include, but are not limited to:
Using wrist or ankle straps ESD mats or worktables ESD wax on the floor
Prepare an ESD-free work area before the chassis is grounded.

1.4 Functional Description of the XLP 6000

The XLP 6000 uses a stepper-motor driven syringe and valve design to aspirate and dispense measured quantities of liquid. Both the syringe and the valve are replaceable. Functional descriptions and illustrations of each major XLP 6000 component are provided in the following sections.
1 - Getting Started
Figure 1-1 XLP 6000 Modular Syringe Pump
Cavro® XLP 6000 Modular Syringe Pump Operating Manual, 734237-C, en 1 - 3
1 - Getting Started
Functional Description of the XLP 6000

1.4.1 Syringe and Syringe Drive

The syringe plunger is moved within the syringe barrel by a lead screw drive that incorporates a 1.8 stepper motor and quadrature encoder to detect lost steps.
The syringe drive has a 60 mm travel length and resolution of 6,000 increments (48,000 increments in fine-positioning and microstep mode). When power is not applied to the pump, the syringe drive can be removed by releasing the pin assembly.
The base of the syringe plunger is held to the drive by a knurled screw. The top of the syringe barrel attaches to the pump valve by a 1/4-28" fitting.
Figure 1-2, ’Syringe Components” shows the components of a typical syringe.
Figure 1-2 Syringe Components
Syringes are available in these sizes: 50 L, 100 L, 250 L, 500 L, 1.0 mL,
2.5 mL, 5.0 mL, 10 mL, and 25 mL.. For ordering information, see Appendix A, "Ordering Information".
Note: To obtain optimal performance and maximum life from any syringe, please follow the syringe cleaning and maintenance procedure included with each Cavro Syringe. Technical Note #1 (PN 730317) contains practical tips for the use and maintenance of Cavro Syringes.

1.4.2 Valve and Valve Drive

The valve is made of a Kel-F body and Teflon plug. The plug rotates inside the valve body to connect the syringe port to the various input and output ports. In addition to input and output ports, non-distribution valves also have a bypass position. This position “bypasses” the syringe and connects the input and output ports. The bypass position is often used for flushing fluid lines. The valve is turned by a 1.8 stepper motor that has an encoder coupled to it for positioning feedback.
1 - 4 Cavro® XLP 6000 Modular Syringe Pump Operating Manual, 734237-C, en
Figure 1-3 shows the components of a 3-port valve.
Figure 1-3 3-Port Valve Components
Functional Description of the XLP 6000
1 - Getting Started

1.4.3 Printed Circuit Assembly

The printed circuit assembly (PCA) holds the microprocessor and circuitry to control the syringe and valve drive. The PCA provides connectors for electrical inputs and outputs as well as a communication address switch. For information on modes of operation, see Chapter 3, "Software Communication".
Figure 1-4 shows the accessible components on the printed circuit board assembly.
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1 - Getting Started
Functional Description of the XLP 6000
Figure 1-4 XLP 6000 Printed Circuit Assembly External Connectors
The XLP 6000 PCA has a DA-15 connector to handle power and communications. For more information on the printed circuit assembly inputs/outputs and the address switch, see Chapter 2, "Hardware Setup".

1.4.4 Communication Interfaces

Depending on the pump configuration, the XLP 6000 can communicate singly or in a multi-pump configuration through an RS-232, RS-485, or CAN (Controller Area Network) interface. For RS-232 and RS-485, baud rates of 9600 and 38400 are supported. For CAN, baud rates of 100K,125K, 250K, 500K, and 1M are supported.
For details on the communications interfaces, see Chapter 2, "Hardware Setup".
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1.4.5 Multi-Pump Configurations

Up to fifteen (15) XLP 6000 pumps can be connected together in a multi-pump configuration (also called “daisy-chaining”). In this configuration each pump is
addressed separately from a single terminal via its unique address, which is set using the address switch on the back panel of the pump.
Within a multi-pump configuration, the RS-485 communications bus is required, although the first pump in the chain may receive either RS-232 or RS-485 communications. For CAN communications, neither RS-232 nor RS-485 is required. For more information on setting addresses, see Chapter 2.

1.5 Safety

1 - Getting Started
Safety
The Cavro® XLP 6000 Modular Syringe Pump is designed for pipetting and dispensing operations in the 5 µL to 25 mL range. Any other use is considered improper and may result in damage to the pump and/or unreliable test results.
The XLP 6000 is designed to meet recognized technical regulations and is built with state-of-the-art components. Nevertheless, risks to users, property and the environment can arise when the module is used carelessly or improperly. Appropriate warnings in this Operating Manual serve to make the user aware of possible hazards.

1.5.1 Notices and Symbols

Warning Notices Used in this Manual
The triangle warning symbol indicates the possibility of personal injury if the instructions are not followed.
Specific symbols indicate the hazard to which a user is exposed. A few examples follow.
Toxic Substance
Chemical or biological hazards can be associated with the substances used or the samples processed with the XLP 6000. Always be aware of possible hazards associated with these substances.
Explosion and Fire Hazard
Never process explosive or highly flammable liquids with the XLP 6000.
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1 - Getting Started
Tips for Setting Up the XLP 6000
Pinch Point, Mechanical Hazards
Automatically moving parts may cause injuries (crushing, piercing)
Attention
The general “Read This” symbol indicates the possibility of equipment damage, malfunction or incorrect process results, if instructions are not followed.

1.6 Tips for Setting Up the XLP 6000

For complete information on setting up the XLP 6000, see Chapter 2, "Hardware Setup" and “Chapter 3, "Software Communication".
Note: Before performing any work with the XLP 6000, first read this Operating Manual carefully.
To ensure proper operation, follow these tips: Always set up and mount the pump in an upright position. Failure to do so can
cause problems priming the system.
Always run liquid through the syringe and valve when they are moving. Failure
to do so can damage the sealing surfaces.
Before running any organic solvents through the pump, see Appendix D,
"Chemical Resistance Chart" for more information on chemical compatibility.
Always power down the instrument when connecting or disconnecting pumps.
Caution! Keep fingers out of the syringe slot while the pump is running. Failure to do so can cause injury.
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2 Hardware Setup

This chapter includes these sections describing the various parts of hardware setup:
Power and Electrical Considerations Cabling Communication Interfaces Settings and Options Installing Components Mounting

2.1 Power and Electrical Considerations

Power and Electrical Considerations
2 - Hardware Setup
The XLP 6000 requires a 24V DC power supply with a current rating of at least
1.5A, provided through a DA-15 connector. Tecan Systems recommends using one power cable for every two pumps to provide noise immunity, i.e., power should not be daisy-chained to more than two pumps.

2.1.1 Choosing a Power Supply

The 24V DC supply for a single XLP 6000 should meet the following basic requirements:
Output voltage: 24V nominal Output voltage tolerance: ±10% maximum, ±5% preferred. Well-regulated power supplies are recommended, as operating pumps below
24V will affect performance.
Output voltage regulation: ±1% with varying line (input voltage) and load Output current (not including loads other than a single pump):
– 1.5A for power supplies with minimal capacitance. – 850mA for power supplies with internal filter capacitance of at least 1000
F per amp of output current
– 850mA for power supplies with external capacitance of at least 1000 F
per amp of output current (aluminum electrolytic capacitor preferred)
Output voltage ripple: 50mV rms maximum at full load Conformance to required safety and EMI/RFI specifications Voltage turn-on and turn-off overshoot: < 2 volts Minimum current load (for switchers): see “Switching Power Supplies” in this
chapter.
To meet the above basic requirements, the supply must incorporate either linear or switching regulation and must have adequate output filter capacitance.
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2 - Hardware Setup
Power and Electrical Considerations
A current-limiting power supply is recommended. Current limiting above 1.0A is acceptable, assuming that no additional equipment is operated from the supply.
If the power supply uses current feedback, the time-current foldback point must be sufficient to allow charging of a 470 F capacitor without folding back. If an external capacitor is used, exercise care to ensure that the supply always starts after foldback, particularly at low AC line voltage.

2.1.2 Integrating a Power Supply

When a power supply is used to operate more than one XLP 6000 or other device, it must provide the total average current for all devices. The power supply and filter capacitance together must satisfy the total peak input current for all devices.
For example, if a system incorporates six XLP 6000 pumps with other equipment that together require 4 amps, a 10A power supply is satisfactory, provided the output filter capacitance in the supply is at least 10,000 F:
6 x 0.85 = 5.1A; +4A = 9.1A (choose a 10A power supply)
If the power supply filter capacitance is less than 10,000 F, use either additional external capacitance or a 15A power supply:
6 x 1.5 = 9.0A; +4A = 13A (choose a 15A power supply)
In this example, it is assumed that all the pumps and other equipment will sometimes operate simultaneously.
External equipment with inadequate bypass capacitance or that is inadequately sourced for current can cause overvoltage transients and sags, and can create unnecessary ripple current in the XLP 6000. This can result in decreased component life. Additionally , it is possible for a regulated power supply to become unstable with certain loads and oscillate if adequate filter capacitance is not present. Some forms of oscillation can cause failures in the XLP 6000. These issues can be avoided by using a properly designed commercial power supply.
Consideration should also be given to the wiring of the XLP 6000 and any additional devices. Wiring should be of sufficient gauge for the current, and as short as possible. Unless otherwise required by safety requirements, the power supply lines to the XLP 6000 should be 20AWG or heavier. Multiple XLP 6000s can be daisy-chained, provided that the wire size and the power supply are adequate for the total current. In the example of the six XLP 6000 pumps above, use 18AWG wire if the units are daisy-chained. It is best if each pair is twisted or dressed together from the device to the supply. For more information on multi­pump cabling, see Section 2.2, Cabling.
To control power to the XLP 6000, switch power to the power supply. Do not use a relay or switch contacts between the 24V supply and the XLP 6000 (i.e., do not switch DC input to the pump).
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2.1.3 Switching Power Supplies

Be sure to check carefully the minimum load requirement of the power supply. Typically, switching supplies have a minimum load requirement of up to 10% of the rated output current.
Note: The XLP 6000 idle current is less than 10% of the full running current.
For example, in a system with multiple XLP 6000 pumps, a 24V 5-amp switcher with a minimum load less that 500mA may not provide sufficient current when the XLP 6000 motors are idle and all other devices are in a low current state. If the XLP 6000 is the only load on the 24V supply, a switcher should have a minimum load specification of 50mA or less. An appropriate external power resistor can be used to ensure that the minimum load is met.
2 - Hardware Setup
Cabling

2.2 Cabling

A single cable supplies both power and communications to each XLP 6000. A unique address identifies each pump module. For more information, see “Address Switch Settings” later in this chapter. See also Chapter 3, "Software Communication".”
Power requirements are described in Section 2.1, Power and Electrical Considerations.
Table 2-1 DA-15 Connector Pin Assignments
Pin Function Remarks
124V DC 2 RS-232 TxD line Output data 3 RS-232 RxD line Input data 4Reserved 5 CAN high signal line 6 CAN low signal line 7 Auxiliary input #1 TTL level 8 Auxiliary input #2 TTL level
9 Ground Power and logic 10 Ground Power and logic 11 RS-485 A line Data +
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2 - Hardware Setup
Communication Interfaces
Figure 2-1 DA-15 Connector Pins
Pin Function Remarks
12 RS-485 B line Data ­13 Auxiliary output #1 TTL level 14 Auxiliary output #2 TTL level 15 Auxiliary output #3 TTL level
Figure 2-1 shows the pin positions of the DA-15 connector on the printed circuit assembly. This is a male connector that requires a female connector on the mating cable.

2.3 Communication Interfaces

The computer or controller communicates with the XLP 6000 through an RS-232 interface, RS-485 interface, or CAN (Controller Area Network) interface.The XLP 6000 automatically detects the communication interface.
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Examples of cabling connections are shown in Figure 2-2, Figure 2-3, and Figure 2-4 on the following pages.

2.3.1 RS-232/RS-485 Interface

The RS-232 interface automatically converts the protocol to RS-485 for the benefit of any other devices which may be connected to the XLP 6000’s RS-485 communication bus (this constitutes the so-called “multi-drop” device configuration).
Note: The RS-232 interface does not support hardware handshaking and requires only three lines: RXD, TXD, and Signal Ground.
When using a multi-drop arrangement, up to 15 pumps can be addressed by the controller on the same communications bus. Take special care to ensure that the RS-485 A and B lines are not reversed. Refer to the cabling illustrations on the following pages. These illustrations show the multi-pump cabling for RS-232, RS­485, and CAN connections, respectively. Also shown is the external termination scheme for the RS-485 chain.
2 - Hardware Setup
Communication Interfaces

2.3.2 CAN Interface

The CAN interface is a two-wire serial system. The bus is driven differentially in a manner similar to RS-485. The major difference is in the protocol. The CAN protocol is designed to allow any device on the bus to send a message at any time. This is unlike other two-wire interfaces in which the slave devices can only transmit in response to a query. Using the CAN interface, the pump can send a message to inform the master that it has completed its task. Anti-collision detection (which reconciles problems that occur when two devices talk at once) is carried out by the CAN controller hardware.
Caution! Always power off pumps before connecting to or disconnecting from the bus.
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2 - Hardware Setup
Communication Interfaces
RS-232 Cabling
Figure 2-2 RS-232 Multi-Pump Cabling
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RS-485 Cabling
2 - Hardware Setup
Communication Interfaces
Figure 2-3 RS-485 Multi-Pump Cabling
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2 - Hardware Setup
Communication Interfaces
CAN Cabling
Figure 2-4 CAN Multi-Pump Cabling
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2.4 Settings and Options

2.4.1 Configuration Commands

The XLP 6000 firmware allows the user to configure the pump for different modes of operation. The U commands (see Chapter 3, "Software Communication") are used to write the configuration information to the non-volatile memory and control the following options:
Valve type: The pump can be configured to operate with different valve
options (3-port, 4-port, T-valve, Y Block, 3-port distribution, 6-port distribution, and 9-port distribution).
Baud rate: RS-232/RS-485 communication is possible at 9600 baud (default)
and 38400 baud. CAN communication is possible at 100K baud (default), 125K baud, 250K baud, 500K baud, and 1M baud rates.
Non-Volatile Memory Auto Mode: Allows the pump to run command strings
out of the non-volatile memory.
2 - Hardware Setup
Settings and Options

2.4.2 Address Switch Settings

The address switch (see Figure 2-5, "Address Switch") is located near the top of the XLP 6000 electronic circuit board. It is used to give each XLP 6000 in a multi­pump configuration a unique or specific address, allowing the user to direct commands to specific pumps. The address switch has sixteen positions (numbered 0 through F). Fifteen positions (addresses 0 through E) are valid pump addresses.
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2 - Hardware Setup
Settings and Options
Figure 2-5 Address Switch
To set the address switch:
To set the address switch, use a jeweler’s screwdriver or small flat head screwdriver and turn the switch in either direction to the desired position.
Note: Power cycle (or power up) the pump after setting the address switch.
For information on the addressing schemes for different pump configurations, see Chapter 3, "Software Communication".

2.4.3 Self-Test

The “F” address switch position is used to activate the XLP 6000 self-test. Self­test causes the XLP 6000 to initialize, then cycle repeatedly through a series of plunger movements. The self-test cycles through speed codes 0 to 14. If an error condition occurs, the pump stops moving.
To run the self-test, set the address switch to position “F.” Then supply power to the pump.
Caution! Always run liquid through the syringe and valve. Failure to do so can damage the valve and syringe seal.
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2.4.4 J5 Inputs/Outputs

The XLP 6000 provides two auxiliary inputs and three auxiliary outputs that can be accessed through the DA-15 connector, J5. They provide TTL level signals. The outputs are controlled by the [J] command.
The auxiliary inputs are located on J5, pins 7 and 8. They can be read back using report commands ?13 and ?14. Additionally, the inputs can be used to externally trigger a command sequence using the [H] command. The commands are described in Chapter 3, "Software Communication".
The auxiliary outputs are located on J5, pins 13, 14, and 15.

2.5 Installing Components

2 - Hardware Setup
Installing Components

2.5.1 Installing the XLP 6000 Valve

To install the XLP 6000 valve, follow these steps:
1 Remove as much fluid as possible from the system by cycling the pump and
using air as the system fluid.
2 Initialize the pump using the [ZR] command so that the valve motor shaft is in
the correct position.
3 Issue an [A6000R] command to move the plunger to the bottom of travel. 4 Remove the syringe and tubing. 5 Remove the two socket head screws on the front of the valve, then remove
the valve from the pump. Do not remove the spacer.
6 Install the new valve by placing it on the front panel so that the screw holes
line up. The valve coupler fitting mates to the valve motor shaft. The shaft should be in the correct position. If it is not, re-initialize the pump using the command [ZR].
7 Replace the valve screws but do not tighten completely. 8 Install the syringe and pull the syringe plunger until it is aligned with the
carriage. Align the valve using the plunger as a guide, and tighten from 1/4 to 1/2 turn after the screws contact the valve body.
9 Pull the syringe plunger all the way into the carriage and secure by tightening
the plunger lock screw.
Caution! Be sure to reconfigure the pump firmware when changing valve types. Failure to do so may damage the valve. See Section 3.3.2, Pump Configuration Commands, for instructions on reconfiguring the pump.
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2 - Hardware Setup
Installing Components
Figure 2-6 XLP 6000 Valve Installation (3-Port Valve Shown)

2.5.2 Installing a Syringe

To install a syringe, follow these steps:
1 Remove the plunger lock screw. 2 Install the syringe as shown in Figure 2-7, following these steps:
a. Screw the syringe into the valve. b. Pull the syringe plunger down to the plunger holder assembly. c. Align the plunger button through hole to the carriage mounting hole. d. Slide the plunger lock screw through the plunger button and fasten to the
carriage.
Note: Make sure the plunger lock screw is securely tightened and the plunger button is free to move on the plunger lock screw.
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