Tecan Genesis Service manual

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Page 1

Service Manual

Genesis RSP Instrument

Genesis RWS Logistics Workstation

Genesis RWS Assay Workstation

Doc ID 391895 Version 1.0, August 2002

Genesis RMP Instrument

Page 2

Customer Support Tecan Schweiz AG and its representatives maintain a fully trained staff of technical

specialists around the world. For any technical question, contact your nearest Tecan representative or:

TECAN Schweiz AG Seestrasse 103 CH-8708 Männedorf

Expertline Telephone

Document History Doc ID Version Major changes Issue

391895 V1.0 first issue August 2002

The information contained in this document is subject to change without notice.

Telephone Te le f ax E-mail Internet

Te le f ax E-mail

+41 1 922 81 11 +41 1 922 81 12 info@tecan.com www.tecan.com

+41 1 922 81 81 +41 1 922 84 84 expertline-eu@tecan.com

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Table of Contents

1 About This Manual

2 Safety

2.1 User Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 1

2.2 Notices and Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 1

2.2.1 Warning Notices Used in This Manual . . . . . . . . . . . . . . . . 2 – 1

2.2.2 Warning Notices Attached to the Product or Its

Surroundings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 2

2.3 Use of the Product. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 3

2.4 Product Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 4

2.4.1 Instrument-Related Hazards and Safety Measures. . . . . . . 2 – 4

2.4.2 Other Hazards and Safety Measures . . . . . . . . . . . . . . . . . 2 – 4

2.4.3 Safety Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 5

2.5 Decontamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 5

2.6 General Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 6

3 Product Description

3.1 Technical Data and Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 2

3.1.1 Dimensions and Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 2

3.1.2 Supply Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 6

3.1.3 Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 7

3.1.4 Computer and Software Requirements . . . . . . . . . . . . . . . . 3 – 8

3.1.5 Additional Data for System Modules . . . . . . . . . . . . . . . . . . 3 – 8

3.2 Compatibility Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 9

4 Transport and Installation

4.1 Site Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 1

4.2 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 2

4.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 3

4.3.1 Unpacking and Positioning . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 3

4.3.2 RMP Specific Installation Tasks . . . . . . . . . . . . . . . . . . . . . 4 – 3

4.3.3 RWS Specific Installation Tasks . . . . . . . . . . . . . . . . . . . . 4 – 13

4.3.4 Further Options and Modules for RSP/RWS . . . . . . . . . . . 4 – 14

4.3.5 Computer, Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 15

4.4 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 16

4.5 Conformity Assessment and CE Marking for RWS . . . . . . . . . . . . . 4 – 18

4.6 Site Acceptance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 18

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Table of Contents

5 Maintenance

5.1 Concerning Your Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 1

5.2 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 1

5.3 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 2

5.3.1 Daily/Weekly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 2

5.3.2 Half-Yearly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 2

5.3.3 Yearly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 4

6 Replacement of Spare Parts, Repair

6.1 General Notes on Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 4

6.1.1 Concerning Your Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 4

6.1.2 General Repair Tasks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 5

6.1.3 Operating Tests after Repair . . . . . . . . . . . . . . . . . . . . . . . 6 – 6

6.2 Abstract of Important Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 7

6.2.1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 7

6.2.2 Jumper and Address Settings Overview. . . . . . . . . . . . . . . 6 – 8

6.2.3 CAN-Bus Resistance Test . . . . . . . . . . . . . . . . . . . . . . . . 6 – 10

6.2.4 Software Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 11

6.3 Instrument – Disassembly and Assembly Procedures . . . . . . . . . . 6 – 22

6.3.1 Worktable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 22

6.3.2 Door Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 24

6.3.3 X-Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 25

6.3.4 Power Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 34

6.3.5 Electronic Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 37

6.4 Liquid System – Disassembly and Assembly Procedures . . . . . . . 6 – 46

6.4.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 46

6.4.2 Tubing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 47

6.4.3 Diluter and Dilback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 50

6.4.4 MPO/FWO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 54

6.4.5 Low Volume Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 62

6.4.6 6-Way Valve Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 69

6.5 LiHa 1 – Disassembly and Assembly Procedures . . . . . . . . . . . . . 6 – 73

6.5.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 73

6.5.2 Complete LiHa 1 Assembly . . . . . . . . . . . . . . . . . . . . . . . 6 – 75

6.5.3 X-Flex Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 76

6.5.4 ILID Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 76

6.5.5 ILID Flat Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 76

6.5.6 Electronic Boards for LiHa 1 . . . . . . . . . . . . . . . . . . . . . . . 6 – 78

6.5.7 Y-Belt and Y-Spreading Belt. . . . . . . . . . . . . . . . . . . . . . . 6 – 79

6.5.8 Y-Motor and Y-Spreading Motor. . . . . . . . . . . . . . . . . . . . 6 – 80

6.5.9 Tip Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 81

6.5.10 Ensure Operating Readiness . . . . . . . . . . . . . . . . . . . . . . 6 – 81

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Table of Contents

6.6 LiHa 2 – Disassembly and Assembly Procedures. . . . . . . . . . . . . . 6 – 83

6.6.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 83

6.6.2 Complete LiHa 2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . 6 – 85

6.6.3 X-Flex Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 88

6.6.4 ILID Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 89

6.6.5 ILID Flat Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 90

6.6.6 Electronic Boards for LiHa 2 . . . . . . . . . . . . . . . . . . . . . . . 6 – 91

6.6.7 Y-Belt and Y-Spreading Belt . . . . . . . . . . . . . . . . . . . . . . . 6 – 95

6.6.8 Y-Motor and Y-Spreading Motor . . . . . . . . . . . . . . . . . . . . 6 – 97

6.6.9 Tip Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 98

6.6.10 Lower DiTi Eject Option. . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 99

6.6.11 Ensure Operating Readiness . . . . . . . . . . . . . . . . . . . . . 6 – 104

6.7 RoMa 1 – Disassembly and Assembly Procedures . . . . . . . . . . . 6 – 106

6.7.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 106

6.7.2 Complete RoMa 1 Assembly . . . . . . . . . . . . . . . . . . . . . . 6 – 109

6.7.3 Gripper Fingers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 109

6.7.4 Gripper Module Head, Gripper Board . . . . . . . . . . . . . . . 6 – 109

6.7.5 Rotator Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 110

6.7.6 X-Flex Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 110

6.7.7 Gripper/Rotator Flex Cables . . . . . . . . . . . . . . . . . . . . . . 6 – 110

6.7.8 Y/R- and Z/G-DC-Servo Board . . . . . . . . . . . . . . . . . . . . 6 – 110

6.7.9 RoMa 1 Backplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 111

6.7.10 Y-Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 111

6.7.11 Y- and Z-Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 111

6.7.12 Z-Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 112

6.7.13 Ensuring Operating Readiness . . . . . . . . . . . . . . . . . . . . 6 – 113

6.8 RoMa 2 – Disassembly and Assembly Procedures . . . . . . . . . . . 6 – 114

6.8.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 114

6.8.2 Complete RoMa 2 Assembly . . . . . . . . . . . . . . . . . . . . . . 6 – 117

6.8.3 Mechanical Adjustment After Reinstallation . . . . . . . . . . 6 – 118

6.8.4 Gripper Fingers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 121

6.8.5 Gripper Module Head, Gripper Board . . . . . . . . . . . . . . . 6 – 122

6.8.6 Rotator Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 125

6.8.7 X-Flex Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 126

6.8.8 Gripper/Rotator Flex Cables . . . . . . . . . . . . . . . . . . . . . . 6 – 129

6.8.9 Y/R- and Z/G-DC-Servo Board . . . . . . . . . . . . . . . . . . . . 6 – 131

6.8.10 RoMa 2 Backplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 132

6.8.11 Y-Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 133

6.8.12 Y-Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 135

6.8.13 Z-Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 136

6.8.14 Z-Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 137

6.8.15 Ensuring Operating Readiness . . . . . . . . . . . . . . . . . . . . 6 – 138

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Table of Contents

6.9 PosID 1 – Disassembly and Assembly Procedures . . . . . . . . . . . 6 – 139

6.9.1 Complete PosID 1 Assembly . . . . . . . . . . . . . . . . . . . . . 6 – 139

6.9.2 X-Drive Assembly (X-Belt, X-Motor, X-Flex Cable) . . . . 6 – 140

6.9.3 Electronic Boards for PosID 1. . . . . . . . . . . . . . . . . . . . . 6 – 141

6.9.4 Scanner Assembly (Scanner Head, B-Motor). . . . . . . . . 6 – 144

6.9.5 Y-Belt Assembly (Y-Belt, Y-Motor) . . . . . . . . . . . . . . . . . 6 – 146

6.9.6 No Tube Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 147

6.9.7 Ensure Operating Readiness . . . . . . . . . . . . . . . . . . . . . 6 – 148

6.10 PosID 2 – Disassembly and Assembly Procedures . . . . . . . . . . . 6 – 149

6.10.1 Complete PosID 2 Assembly . . . . . . . . . . . . . . . . . . . . . 6 – 150

6.10.2 X-Drive Assembly (X-Belt, X-Motor, X-Flex Cable) . . . . 6 – 153

6.10.3 Electronic Boards for PosID 2. . . . . . . . . . . . . . . . . . . . . 6 – 155

6.10.4 Scanner Assembly (B-Motor, Scanner Head and Cable) 6 – 157

6.10.5 Y-Drive Assembly (Y-Belt, Gripper Assembly, Y-Motor). 6 – 159

6.10.6 No Tube Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 161

6.10.7 Ensure Operating Readiness . . . . . . . . . . . . . . . . . . . . . 6 – 162

7 Check Lists Spare Parts

7.1 Spare Parts Instrument. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 2

7.1.1 Spare Parts Worktable . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 2

7.1.2 Spare Parts Door Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 3

7.1.3 Spare Parts X-Drive Assembly . . . . . . . . . . . . . . . . . . . . . . 7 – 4

7.1.4 Spare Parts Power Modules . . . . . . . . . . . . . . . . . . . . . . . . 7 – 5

7.1.5 Spare Parts Electronic Boards . . . . . . . . . . . . . . . . . . . . . . 7 – 7

7.2 Spare Parts Liquid System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 10

7.2.1 Spare Parts Tubing Systems . . . . . . . . . . . . . . . . . . . . . . 7 – 10

7.2.2 Spare Parts Diluter/Dilback. . . . . . . . . . . . . . . . . . . . . . . . 7 – 12

7.2.3 Spare Parts MPO/FWO . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 14

7.2.4 Spare Parts Low Volume Option . . . . . . . . . . . . . . . . . . . 7 – 16

7.2.5 Spare Parts 6-Way Valve Option . . . . . . . . . . . . . . . . . . . 7 – 18

7.3 Spare Parts LiHa 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 20

7.4 Spare Parts LiHa 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 22

7.5 Spare Parts RoMa 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 25

7.6 Spare Parts RoMa 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 27

7.7 Spare Parts PosID 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 29

7.8 Spare Parts PosID 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 31

8 Instruments at a Glance

8.1 Genesis RSP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 2

8.2 Genesis RMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 3

8.3 Genesis RWS Logistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 4

8.4 Genesis RWS Assay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 5

vi Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 August 2002

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9Diagrams

9.1 Genesis RSP, RMP and RWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 1

9.2 Instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 5

9.2.1 Power Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 5

9.2.2 Electronic Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 12

9.3 Liquid System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 40

9.3.1 MPO/FWO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 40

9.3.2 Diluter/Dilback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 44

9.3.3 Low Volume Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 48

9.4 LiHa 1 and LiHa 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 51

9.5 RoMa 1 and RoMa 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 56

9.6 PosID 1 and PosID 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – 64

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viii Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 August 2002

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1 About This Manual

1 – About This Manual

Purpose of This Chapter

Introduction The structure and contents of this manual were compiled based on the results of a

Applicability The instructions given in this document are applicable for Genesis Instruments type …

Purpose of This Document

This chapter points out the purpose of the manual, specifies the instruments the manual deals with and for whom the manual is intended. Furthermore, it contains a list with relevant reference documents, explains the symbols, conventions and abbreviations used and offers general information.

worldwide survey between Tecan field service engineers. We hope the manual fits your requirements and would be happy to get any feedback. Just contact the documentation service group of Tecan Schweiz AG.

• Genesis RSP

• Genesis RWS Logistics

• Genesis RWS Assay

• Genesis RMP

This document serves as a reference guide for Tecan trained and authorized personnel only. It provides all relevant information for installation and servicing of the instrument – with exception of information covered by the respective reference documents (see section ‘Reference Documents’ later in this chapter).

Target Groups This manual addresses the following target groups:

Target group Description Tasks/responsibilities

Field service engineer

System integrator A legal person (e.g. a RO within

August 2002 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 1 – 1

Experienced field service engineer who has visited a Tecan service training and has been authorized for servicing the Genesis RSP, RMP and RWS instruments.

Tecan group or a distributor) who acts in a legal sense between Tecan Schweiz AG (manufacturer of sub-assembly) and end-user.

• Site inspection

• Installation

• Commissioning

• Site acceptance

• Maintenance

• Repair

• Calibration

• Conformity assessment and CE marking (see

Section 4.5).

Page 10

1 – About This Manual

Reference Documents

The following documents are helpful for installation and servicing of the instrument. They are not enclosed with this manual, nevertheless they are part of the service documentation.

Document type Valid for …/document title Doc ID

Operating Manual Genesis RSP and NPS

Genesis RMP

Genesis RWS

Carousel

Columbus Washer

Sunrise Reader

Spectra & Rainbow Readers

Instrument Software Manual

Installation Manual Lower DiTi eject option 2

Genesis Instrument Doc ID 390 791

Low volume option 1: tube fastening

Access option/Signal lamp (RSP, RWS)

Doc ID 390 783

I 119 100

Doc ID 391 197

Doc ID 391 209

I109004

I137301

I139003

Doc ID 391 276

Doc ID 391 228

Doc ID 392 330

Door lock V2 (RMP)

Alarm device V2 (RMP)

Form or Checklist Decontamination Declaration

Genesis Maintenance and Service Logbook, including:

• Installation Qualification

• Operation Qualification

• Acceptance Protocol

• Daily/Weekly Maintenance Checklist

• Preventive Maintenance Checklist

• Service Checklist

Furthermore, you may find following Application Software Manuals useful:

Area of application Application software Doc ID

Diagnostics TOPS

Doc ID 391 260

Doc ID 391 255

Doc ID 390 901

Doc ID 390 924

Doc ID 391 180

Doc ID 391 182

Doc ID 391 825

Doc ID 391 193

Doc ID 391 181

Doc ID 391 183

I 117 578

Logic

Life Science FACTS

Gemini

1 – 2 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 August 2002

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Doc ID 391 252

Doc ID 391 201

Page 11

1 – About This Manual

Symbols Used in This Manual

Instrument Overviews

Safety Symbols

The safety symbols are explained in Chapter 2, ‘Safety’.

Useful Notes

Useful notes appear as follows:

Note

Gives helpful information about the equipment or regarding proceedings, tentative clarifications etc.

In Chapter 8, ‘Instruments at a Glance’ you will find useful illustrations of the instruments giving an overview of the main components.

On the detail drawings and the text passages in this document (mainly in Chapter 6,

‘Replacement of Spare Parts, Repair’), one main part is always designated with the

identical item number – for example (8) for LiHa – as on the relevant illustration in chapter 8. Item numbers of their components consist always of the main part item number, a dash and the item number of the component – for example (8-04) for LiHa backplane.

Abbreviations and Acronyms Used in This Manual

FaWa Fast wash pump

FSE Field service engineer

FWO Fast wash option

ILID Integrated liquid detection

LICOS Liquid container supervisor

LiHa Liquid handling arm

MP Micro plate

MPO Monitored pump option

PCB Printed circuit board

PosID Positive identification option, barcode reader

RMP Robotic microplate processor

RoMa Robotic manipulator arm

RSP Robotic sample processor

RWS Robotic workstation

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1 – About This Manual

1 – 4 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 August 2002

Page 13

2 Safety

2 – Safety

Purpose of This Chapter

Significance of These Safety Instructions

This chapter contains specific rules of behavior and warnings from hazards with regard to installation, setup, maintenance and repair of the Genesis RSP, RMP or RWS instruments.

The safety of users and personnel can only be ensured if these safety instructions and the safety-related warnings in the individual chapters are strictly observed and followed.

Therefore, the Service Manual must always be available to all persons performing the tasks described herein.

In addition to the safety instructions given in this Service Manual, the safety instructions pointed out in the Operating Manuals of the Genesis RSP, RMP or RWS instruments apply as well.

2.1 User Qualification

FSE Authorization The field service engineers (FSE) are specially trained personnel. Exclusively FSEs are

entitled to perform the maintenance and service work described in this Service Manual.

The manufacturer Tecan authorizes the FSEs if they fulfill the following particular qualifications:

WARNING Symbols

• They must have received appropriate service and operator training from Tecan.

• They must be familiar with the good laboratory practice guidelines.

• They must have read and understood the instructions in this Service Manual.

2.2 Notices and Symbols

2.2.1 Warning Notices Used in This Manual

The symbols used for safety-related notices have the following significance:

WARNING

Generally, the triangular warning symbol indicates the possibility of personal injury or even loss of life if the instructions are not followed.

Whenever possible, the symbol indicates the hazard a person is exposed to more specifically. The symbols used in this Service Manual have the following significance:

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2 – Safety

WARNING

Biological hazard

WARNING

Chemical hazard

WARNING

Radioactive radiation

WARNING

Electrical danger

WARNING

Laser radiation

ATTENTION Symbols

ATTENTIONS appear as follows:

ATTENTION

With the general “STOP” symbol, ATTENTIONs indicate the possibility of equipment damage, malfunctions or incorrect process results, if instructions are not followed.

Other symbols indicate the significance of the ATTENTION more specifically.

ATTENTION

Damage to electronics by electrostatic discharge. Always follow ESD safety practices.

ATTENTION

Disturbance of functions by electromagnetic RF waves. Do not use a cellular phone.

2.2.2 Warning Notices Attached to the Product or Its Surroundings

Cellular Phones Prohibited

Do not use cellular phones in the proximity of the instrument.

This symbol is attached to the safety panel of the instrument. The symbol must also be attached to the laboratory door.

Damaged or fallen off symbols (notices or stickers) must be replaced immediately.

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2 – Safety

2.3 Use of the Product

Intended Use The Genesis RSP, RMP or RWS instruments are to be applied and used exclusively in

the following application fields. Any other use is considered improper and is strictly forbidden.

• The Genesis RSP is intended for liquid pipetting for generally known laboratory methods according to common safety precautions.

• The Genesis RMP is intended for fully automated processing of 96-well microplate based ELISA (Enzyme Linked Immuno Sorbent Assay) and ELISA-like tests, starting from sample pipetting and ending with result reading. All ELISA test procedures have to be validated prior to performing routine tests.

• The Genesis RWS Logistics is intended for pipetting tasks as well as storage, identification and transfer of microplates. It is to be applied for research only. The Genesis RWS Logistics is intended to be part of a liquid handling system and as such installed and put into operation by a trained Tecan or Tecan authorized system integrator.

• The Genesis RWS Assay is intended for processing of microplate based tests, including liquid handling, incubation, wash, read and data acquisition. It is to be applied for research only. The Genesis RWS Assay is intended to be part of a liquid handling system and as such installed and put into operation by a trained Tecan or Tecan authorized system integrator.

All Genesis instruments are intended for indoor operation and storage only.

Improper Use Due to their open architecture, the Genesis RWS Assay and Logistics are not intended

for clinical and diagnostic applications. These applications would be carried out by less qualified people, exposing them to dangerous liquids in case of instrument malfunction.

Incorrect use of the Genesis RMP may lead to false test results and may cause exposure of the operator to potentially dangerous compounds.

Do not attempt to use liquids with undissolved particles as this could result in liquid not being dispensed due to clogged tips.

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2 – Safety

2.4 Product Safety

Principle The Genesis RSP, RMP or RWS instruments are designed and built in accordance with

the present state-of-the-art technology and the recognized technical safety regulations.

Nevertheless, risks to users, property, and the environment can arise when the instrument is used carelessly or improperly.

The manufacturer has determined all residual dangers emanating from the instrument in all life phases and from the process.

Appropriate warnings in the Operating Manuals of the Genesis RSP, RMP or RWS instruments and in this Service Manual serve to make the user alert to these residual dangers.

2.4.1 Instrument-Related Hazards and Safety Measures

Pay attention to the following safety notices:

WARNING

Electrical shock hazard. Switch the instrument off and disconnect from mains whenever no power is required to perform service tasks.

ATTENTION

Crimping of the tubing between top cover and case possible. Secure the top cover from falling down during inspection work.

ATTENTION

Damage to the electronic boards due to electrostatic discharge (ESD). Always wear a wrist strap when handling the boards.

2.4.2 Other Hazards and Safety Measures

WARNING

• Chemical, biological and radioactive hazards can be associated with the substances used or the samples processed with the Genesis RSP, RMP or RWS instrument.

• The same applies to waste disposal.

Always be aware of possible hazards associated with these substances.

Request a filled out and signed Decontamination Declaration prior to performing any maintenance or repair tasks.

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Page 17

2.4.3 Safety Elements

2 – Safety

Removal of Protective Devices

When to Decontaminate

The protective and safety devices installed on the Genesis RSP, RMP or RWS instrument must be neither removed nor disabled during operation.

If such elements were removed, e.g. for maintenance work, operation may only be resumed when all protective and safety devices have been completely installed and checked.

2.5 Decontamination

Apart from regular decontamination, the user must thoroughly decontaminate the instrument according to standard laboratory regulations in the following cases:

• Before any maintenance or service work is performed on the instrument

• Before a Tecan field service engineer (FSE) performs any in-site work on the instrument

• Before the instrument is returned to Tecan (e.g. for repair)

• Prior to storage of the instrument

• Prior to disposal of the instrument or parts of it

• Generally before the instrument or parts of it leave the user’s site.

Decontamination Method

Decontamination Declaration

The decontamination method must be adapted to the respective application and the substances associated with it. The user takes the full responsibility for the appropriate decontamination of the entire equipment.

WARNING

Biological or chemical hazard and/or radioactive radiation.

• Contamination hazard due to parts of the instrument which are not completely decontaminated.

• Mind that not only the parts having direct contact with chemicals or biological material must be treated, but also the tubing system as well as the whole upstream equipment.

Before a Tecan FSE carries out any work on the instrument, or before the instrument is returned to Tecan, the owner of the instrument must confirm in writing that the decontamination has been performed properly and in accordance with good laboratory practice guidelines. For this, the owner must enclose a Decontamination Declaration form (Doc ID 390 901), which can be provided by Tecan.

Note: Tecan will refuse any instrument or a part of it, if the decontamination form is not filled in and duly signed.

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2 – Safety

2.6 General Safety Rules

Legal Regulations Legal regulations, such as local, state and federal laws which prescribe the use or

application as well as the handling of dangerous materials in connection with the Genesis RSP, RMP or RWS instrument must be strictly followed.

Duty of Maintenance and Care

Appropriate Behavior

Spare Parts to Be Used

Modifications Modifications to the Genesis RSP, RMP or RWS instrument are only permitted with the

The user is responsible for ensuring that the Genesis RSP, RMP or RWS instrument is operated in proper condition only, and that maintenance, service, and repair jobs are performed with care and on schedule.

Use exclusively tools suitable for the respective work sequence. Ensure that the tools are in sound condition.

Handling and disposing of waste has to be in accordance with all local, state and federal environmental, health, and safety laws and regulations.

Use only genuine spare parts for maintenance and repair.

written approval of the manufacturer. Modifications and upgrades shall only be carried out by an authorized field service engineer. The manufacturer will decline any claim resulting from unauthorized modifications.

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3 Product Description

3 – Product Description

Purpose of This Chapter

Chapter Overview This chapter consists of the following sections:

This chapter summarizes the technical data of the Genesis instruments and contains an overview of requirements, hardware, software and firmware compatibilities.

Note

For detailed information concerning optional modules as reader, washer, carousel etc., refer to their respective manuals.

Section Title Page

3.1 Technical Data and Requirements 3 – 2

3.1.1 Dimensions and Weights 3 – 2

3.1.2 Supply Ratings 3 – 6

3.1.3 Environmental Conditions 3 – 7

3.1.4 Computer and Software Requirements 3 – 8

3.1.5 Additional Data for System Modules 3 – 8

3.2 Compatibility Matrix 3 – 9

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3 – Product Description

3.1 Technical Data and Requirements

3.1.1 Dimensions and Weights

RSP Instrument Dimensions

830 mm

(32.7")

Genesis RSP 100: 1051 mm (41.4") Genesis RSP 150: 1426 mm (56.1") Genesis RSP 200: 2026 mm (79.8")

1200 mm

(47.25")

1000 mm

(39.4")

RMP Instrument Dimensions

front view

Genesis RSP 100: 1501 mm (59.1") Genesis RSP 150: 1876 mm (73.9") Genesis RSP 200: 2476 mm (97.5")

top view

RMP 100: 1405 mm (55.3") RMP 150: 1780 mm (70.1") RMP 200: 2380 mm (93.7")

805 mm (31.7")

780 mm (30.7")

1230 mm (48.4")

left side view

840 mm

(33.1")

1000 mm (39.4")

870 mm (30.7")

1230 mm (48.4")

RMP 100: 1856 mm (73.1") RMP 150: 2230 mm (87.8") RMP 200: 2830 mm (111.45")

840 mm (33.1")

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RWS Logistics Workstation Dimensions

830 mm

(32.7")

Logistics WS 100: 1051 mm (41.4") Logistics WS 150: 1426 mm (56.1") Logistics WS 200: 2026 mm (79.8")

3 – Product Description

1200 mm

(47.25")

RWS Assay Workstation Dimensions

830 mm

(32.7")

Front View

Logistics WS 100: 1501 mm (59.1") Logistics WS 150: 1876 mm (73.9") Logistics WS 200: 2476 mm (97.5")

Top View

Assay WS 150: 1796 mm (70.7") Assay WS 200: 2396 mm (94.4")

780 mm (30.7")

840 mm (33.1")

Left Side View

1200 mm

(47.25")

Front View

Assay WS 150: 1970 mm (77.6") Assay WS 200: 2570 mm (101.2")

Top View

840 mm

(33.1")

780 mm (30.7")

Left Side View

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3 – Product Description

Worktable Dimensions

Genesis RSP

Accessible X-range (X-travel) mm

Accessible Y-range (Y-travel) mm

Grid positions on worktable pcs. 30 45 69

Genesis RMP

Accessible X-range (X-travel) mm

inch

RSP 100 RSP 150 RSP 200

745

29.3

418

16.5

RMP 100 RMP 150 RMP 200

550

21.6

1120

44.1

418

16.5

925

36.4

1720

67.7

418

16.5

1525

Accessible Y-range (Y-travel) mm

inch

Grid positions on worktable pcs. 24 39 63

Genesis RWS

RWS Logistics 100 150 200

Accessible X-range (X-travel) mm

inch

Accessible Y-range (Y-travel) mm

inch

Grid positions on worktable pcs. 30 45 69

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418

16.5

745

29.3

418

16.5

418

16.5

1120

44.1

418

16.5

418

16.5

1720

67.7

418

16.5

Page 23

3 – Product Description

RWS Assay 150 200

Accessible X-range (X-travel) mm

Accessible Y-range (Y-travel) mm

Grid positions on worktable pcs. 43 67

Weights Genesis RSP

Platform with 4-tip/8-tip LiHa 2 kg

RoMa 2 kg

PosID 2 option kg

MPO or FWO kg

inch

lb.

925

36.4

418

16.5

RSP 100 RSP 150 RSP 200

96/103

212/227

4.4

115/122

253/269

4.4

1525

418

16.5

165/172

364/379

4.4

Packing kg

lb.

Genesis RMP

RMP 100 RMP 150 RMP 200

Platform with LiHa 2, RoMa 2 and PosID 2

FWO kg

Packing kg

Genesis RWS

Logistics 100 150 200

Platform with 4-tip/8-tip LiHa 2 and RoMa 2

lb.

166

366

4.4

104/111

229/245

104

188

414

4.4

123/130

271/287

156

241

531

218

173/180

381/397

4.4

PosID 2 option kg

lb.

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3 – Product Description

Logistics 100 150 200

MPO or FWO kg

lb.

Packing kg

lb.

4.4

104

4.4

156

Assay 150 200

Platform with 4-tip/8-tip LiHa 2 and RoMa 2

PosID 2 option kg

MPO or FWO kg

Packing kg

lb.

131/138

289/304

4.4

110

181/188

397/414

4.4

163

3.1.2 Supply Ratings

Genesis RSP

Genesis RMP

Supply ratings RSP 100 RSP 150/200

Primary voltage V AC 100–240 100–240

Frequency Hz 50/60 50/60

Power VA 800 800

Module type

(for power module supplied as of September 2001)

PM 1 PM 4

Supply ratings RMP 100/150/200

Primary voltage V AC 100–240

Frequency Hz 50/60

Power VA 1000

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Genesis RWS

Supply ratings RWS 100

3 – Product Description

RWS 150/200

Operating Conditions

Primary voltage V AC 100–240 100–240

Frequency Hz 50/60 50/60

Power VA 800 1200

Module type

(for power module supplied as of September 2001)

3.1.3 Environmental Conditions

The Genesis RSP, RMP or RWS instruments are intended for indoor operation and

storage only.

Operating temperature °C

Operating humidity relative (non condensing) at 30 °C/86 °F or below

Logistics

Assay/Logistics

VA PM 1 PM 2

RSP RMP RWS

°F

15–32

59–90

18–30

65–86

% 30–80 30–80 30–80

18–30

65–86

Storage Conditions

Pollution degree 2 2 2

Over voltage category class 2 2 2

Protect the instrument against dust and debris with a cover.

Recommendation: store the instrument in its original packaging. Store all manuals and the Service and Maintenance Logbook with the instrument.

RSP RMP RWS

Storage temperature °C

°F

Storage humidity

% 30–80 30–80 30–80

1–60

34–140

1–60

34–140

1–60

34–140

relative (non condensing) at 30 °C/86 °F or below

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3 – Product Description

3.1.4 Computer and Software Requirements

Computer Hardware

Software It is strongly recommended to use the latest software versions. Please contact your

Refer to the Genesis Instrument Software Manual for details on minimum computer requirements.

nearest Tecan representative for more information.

Software RSP RMP RWS

Logistics

Operating System X

Genesis Instrument SoftwareXXXX

Logic (Clinical Diagnostics)

Gemini (Life Science) X X X

TOPS (Operating SW)

FACTS (Event scheduling SW)

RWS

Assay

TAURUS (Database for Clinical Diagnostics)

Magellan (Data reducing SW)

X = required or available for respective instrument

3.1.5 Additional Data for System Modules

LiHa 2 • 4 or 8 tips (diluters) acting independently

• Variable tip spacing: 9–38 mm

• Arm movement speed: 300–500 mm/s

• Positioning precision: better than 0.4 mm

RoMa 2 • Transports any rack in MP-format

• Arm movement speed: 400 mm/s

• Rotation: 270°

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• Lifting force: up to 4 N (transportable mass up to 0.4 kg

• Software adjustable gripper force: 1–4 N

• Gripper space range 55 to 140 mm

PosID 2 • Laser class 2

• Wave length: 670 nm

• Distinction between sample barcode/no barcode/no tube

• Reads vertically and horizontally

• Movement speed: 400 mm/s

• Barcode types: Code 39 (length 0...32) Code 39 full ASCII Codabar (length 0...32) Code 128 (length 0...32) 2/5 Interleaved (length 0...30, even only) UPC-A (length not setable: 12) UPC-E (length not setable: 8) EAN-8 (length not setable: 8) EAN13 (length not setable: 13)

3 – Product Description

3.2 Compatibility Matrix

Tecan customer support provides a compatibility maxtrix which displays the most common configurations that may be installed presently on your customer’s systems. Please request your up-to-date copy via expertline-eu@tecan.com.

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3 – Product Description

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4 Transport and Installation

4 – Transport and Installation

Purpose of This Chapter

Chapter Overview This chapter consists of the following sections:

This chapter summarizes the procedures needed for installation of a Genesis RSP, RMP or RWS instrument from site inspection to site acceptance.

Section Title Page

4.1 Site Inspection 4 – 1

4.2 Transport 4 – 2

4.3 Installation 4 – 3

4.3.1 Unpacking and Positioning 4 – 3

4.3.2 RMP Specific Installation Tasks 4 – 3

4.3.3 RWS Specific Installation Tasks 4 – 13

4.3.4 Further Options and Modules for RSP/RWS 4 – 14

4.3.5 Computer, Software 4 – 15

4.4 Commissioning 4 – 16

4.5 Conformity Assessment and CE Marking for RWS 4 – 18

4.6 Site Acceptance 4 – 18

4.1 Site Inspection

Site Requirements Check the customer’s site for site requirements suitable concerning the respective

instrument:

Notice the dimensions and weights of the different instruments (see section 3.1.1).

Delivery Route

• Loading dock present?

• Load capacity and size of elevator sufficient?

• Door and entrance openings, passageway corners: big enough?

Environmental Requirements

• Check according to Section 3.1.3, ‘Environmental Conditions’.

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4 – Transport and Installation

Space

• Enough space to place instrument and possible extensions?

• Enough space to open safety panels and access doors of the instrument?

• Enough walking space around the instrument?

• Space for placing system liquid/waste bottles?

• Enough space for the control computer?

Supply

Notice the power supply requirements (refer to section Section 3.1.2, ‘Supply Ratings’)

Check presence of power sockets for

• Instrument

•Computer

• Other modules

Date of Delivery • Determine the date of delivery.

4.2 Transport

General Notes • The Genesis RSP, RMP and RWS are precision instruments. Handle with care. Do

not expose to excessive shock.

• Always use original packaging for shipping the instrument.

Visual Check • Visually check the crate(s) for damage sustained during transportation. If such are

found, the customer must immediately file a complaint with the transport agency.

• Tecan instrument packaging is designed to avoid damage during transportation. Please inform Tecan about all occurrences of transportation damages. Such information is important for further improvements.

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Page 31

4.3 Installation

4.3.1 Unpacking and Positioning

Transport handles

Figure 4-1 Transport handles – seen from below

• For exact positioning: always lift the instrument; do not shift it.

4 – Transport and Installation

1 Unpack all components and visually

check for any damage. Leave transport paddings and moorings in place.

2 Check if the shipment is in compliance

with the packing list.

3 Lift the instrument onto the assigned

work bench and place it as required.

• Because of the considerable weight of the instrument (see Section 3.1.1,

‘Dimensions and Weights’), up to four people are required for lifting the instrument.

The center of gravity is at the rear right side of the instrument. Make sure that the two strongest persons lift the rear of the instrument.

• Use the optional transport handles (see Figure 4-1). Never lift the instrument by the

lateral worktable covers. The screws holding the covers are not designed to support the instrument weight.

4 Remove all transport paddings and moorings.

Packing material shall be stored for possible shipment of parts to be repaired by manufacturers.

4.3.2 RMP Specific Installation Tasks

Add-On Module Only the RMP 200 has a separate add-on module. RMP 100 and 150 consist of one-

piece frames. Therefore, following procedure applies to RMP 200 only.

Refer to Figure 4-2, ‘RMP 200’ and Figure 4-3, ‘Add-on module assembly’.

1 Place a spirit level onto the RMP worktable and level horizontally by means of the

supports below the instrument frame.

2 Connect the add-on module (15) to the right side of the RMP 200.

There are two positioning pins (15-01) in the add-on module frame and two positioning holes in the instrument frame.

While positioning the add-on module, lead the cables for the mains power switch and the control lamp trough the upper left part of the add-on module.

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4 – Transport and Installation

Control lamp cable

Figure 4-2 RMP 200

3 Turn the two left supports (15-02) to their topmost positions, so that they do not

touch the work bench. The add-on module is now sitting on its two right supports with the two positioning pins connected to the RMP 200.

Mains power switch cable

Uniport cable

Incubator/shaker cable

4 Turn the two left supports down until they touch the work bench.

5 Insert the module worktable (15-03).

15-01

15-02

15-03

Figure 4-3 Add-on module assembly

15 Add-on module

15-01 Positioning pin

15-02 Support

15-03 Module worktable

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4 – Transport and Installation

6 Insert the fixing screws and the two

distance washers (15-04) according to

Figure 4-4. Tighten the fixing screws.

7 Check horizontal alignment with a spirit

M4x12

6x M4x20

15-03

4x M4x16

level; if necessary, adjust by means of

M4x6

15-04

Figure 4-4 Module worktable

the two right supports (15-02).

15-03 Module worktable

15-04 Distance washer

Set the mains power switch to off and disconnect the mains power connection of the instrument before performing any further work!

Observe precautions for handling electrostatic discharge sensitive devices. Wear a wrist strap.

8 Open the right access door (6) and

install the mains power switch (33-02)

33-07

into the add-on module.

Note the correct orientation of the switch according to Figure 4-5!

9 Connect the mains power cable (33-07)

to the power switch (33-02) according to the installation diagram (33-06) on

33-02

correct

P2P1

view A

33-06

33-05

the housing.

33-08

33-06

Washer

Figure 4-5 Electric connections for RMP

33-07

33-05

10 Fix the earth cable (33-05) to the add-

on module frame as shown in Figure

4-5.

11 Connect the control lamp cable (33-08)

to the power control lamp in the add-on module.

12 Connect the Uniport cable coming from

the Optibo to the Uniport (see Figure

4-6, ‘Cable connections on Supervisor and Uniport board’).

The Uniport is located in the rear part of the add-on module.

33-02 Power switch

33-05 Earth cable

33-06 Installation diagram

33-07 Mains power cable

33-08 Control lamp cable

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4 – Transport and Installation

Alarm device J25

2nd RT incubator J16, J17, J12

RT incubator

Balance

OEM

Washer

Reader

from Optibo

Figure 4-6 Cable connections on Supervisor and Uniport board

Supervisor board

Waste (LICOS)

System Liquid (LICOS)

J5 Niveau (H-sensor)

Uniport board

33-09

Figure 4-7 Connector sheet

13 Fix the connector sheet (33-09).

The connector sheet guarantees a proper electromagnetic compatibility (EMC).

14 Insert and fix the module cover (15-05).

15-05

Figure 4-8 Module cover

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Page 35

Reader (Option)

19-02

16-06

15-07

4 – Transport and Installation

1 Remove the frame cover (15-07) from

the add-on module in order to get easier access.

2 For RMP 200 only:

Lock the adjusting bracket (16-06) in designated place (positioning pins) onto the module worktable (15-03) and fix it with the knurled screws.

3 Place the reader (19) onto the module

worktable.

4 Set selection switch (19-02) into correct

position, according to the label (19-01) on the adjusting bracket:

• TOPS V3.0 and earlier: set switch to “RMP mode”.

• TOPS V4.0 and later: set switch to “Stand-alone mode”.

15-06

15-03

Figure 4-9 Reader assembly

19-03

3x M4x12

19-01

5 Put a spirit level in X-direction onto the

reader housing. If necessary, level horizontally by means of the adjusting wheel (15-06).

6 Connect the reader cable (19-03) to the

connection cable on the Uniport (TOPS V3.0 and earlier) or to the second PCcom port (TOPS V4.0 and later).

15-03 Module worktable

15-06 Adjusting wheel

15-07 Frame cover

16-06 Adjusting bracket

19 Reader

19-01 Label

19-02 Selection switch

19-03 Reader cable

August 2002 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 4 – 7

Page 36

4 – Transport and Installation

Washer (Option)

16-01

1 If not yet done: remove the frame cover

(Figure 4-9, 15-07) from the add-on module in order to get easier access.

2 For RMP 200 only:

Screw the positioning rack (16-01) to the adjusting bracket (16-06).

16-02

16-05

Figure 4-10 Washer assembly

16-06

16-04

3x M4x10/ washer

16-03

3 Place the washer (16) on the

positioning rack.

4 Check horizontal alignment with a spirit

level. If necessary, adjust by means of the adjusting wheel (16-02).

16 Washer

16-01 Positioning rack

16-02 Adjusting wheel

16-03 Waste tubing positioning rack

16-04 Waste tubing washer

16-05 Washer cable

16-06 Adjusting bracket

5 Attach the washer cable (16-05) –

which is connected to the Uniport – to the washer.

6 Lead the waste tubing (16-03, 16-04)

through the module frame.

4 – 8 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 August 2002

Page 37

Heated Incubator (Option)

4 – Transport and Installation

Installation of One Heated Incubator

1 Connect the incubator cable (20-01) to

the incubator 1 (20-A) and the Optibo.

2 Place the incubator 1 (20-A) into the

respective recesses on the module worktable.

20-01

20-A

Figure 4-11 Heated incubator 1

20-A

20-B

20-01

20-02

3 Check horizontal alignment with a spirit

level. If necessary, adjust by means of the supplied special key (see 17-05 in

Figure 4-13).

20-A Heated incubator 1

20-01 Incubator cable

Installation of Two Heated Incubators

1 Connect the incubator cable (20-01) to

the incubator 1 (20-A) and the Optibo.

2 Join the two incubators with the

connection cable (20-02).

3 Change address switch of incubator 2

(20-B) from #2 (= standard setting) to #3.

4 Place the incubator 1 (20-A) into the

respective recesses on the module worktable.

20-A

20-B

20-03

Figure 4-12 Installation of two heated incubators

5 Insert adapter plate (20-03) beneath

incubator 1 onto the worktable.

6 Place the incubator 2 (20-B) into the

recesses on the adapter plate.

7 Check horizontal alignment with a spirit

level. If necessary, adjust by means of the supplied special key (see 17-05 in

Figure 4-13).

20-A Heated incubator 1 (address #2)

20-B Heated incubator 2, with shaker

(address #3)

20-01 Incubator cable

20-02 Connection cable

20-03 Adapter plate

August 2002 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 4 – 9

Page 38

4 – Transport and Installation

Room Temperature Incubator

Installation of One RT Incubator

1 Fix the mounting bracket (17-01) with

the knurled nuts to the module worktable.

2 Place the RT incubator 1 into the

recesses on the module worktable and screw it to the mounting bracket.

17-02

17-01

17-03

17-02

17-A

17-04

17-01

17-A

17-B

M4x8/ washer

17-04

3 Check horizontal alignment with a spirit

level. If necessary, adjust by means of the supplied special key (17-05).

4 Attach the incubator cable (17-02) –

which is connected to the Supervisor board – to the incubator 1 (17-A).

17-A Room temperature incubator 1

17-B Room temperature incubator 2

17-01 Mounting bracket

17-02 Incubator cable RT1

17-03 Incubator cable RT2

17-04 Adapter plate

17-05 Special key

Installation of Two RT Incubators (Option)

1 Place the adapter plate (17-04) onto

the worktable.

2 Fix the mounting bracket (17-01) with

the knurled nuts to the module worktable and the adapter plate.

17-B 17-A

3 Place the RT incubator 1 into the

recesses on the module worktable and screw it to the mounting bracket.

4 Place the RT incubator 2 into the

recesses on the adapter plate and screw it to the mounting bracket.

5 Check horizontal alignment with a spirit

level. If necessary, adjust by means of the supplied special key (17-05).

6 Attach the incubator cables (17-02,

17-05

17-03) – which are connected to the Supervisor board – to the incubators.

Figure 4-13 Room temperature incubators

4 – 10 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 August 2002

Page 39

Wash Bottle Rack

18-01

4 – Transport and Installation

Recommendation: As the fixing screws (18-01) might get into contact with spilled wash liquid, grease them to prevent from stucking.

1 For RMP 200 only:

• Place the wash bottle rack (18) on the module worktable and insert the fixing screws (18-01), but do not tighten yet.

• Mount the add-on module safety panel.

• Make sure the wash bottle rack is aligned parallel to the closed safety panel.

• Tighten the fixing screws (18-01).

18-05

18-02

18-04

18-03

• Place the bottles (18-02) in the wash bottle rack.

16 Washer

18 Wash bottle rack

18-01 Fixing screws

18-02 Bottle

18-03 Wash liquid tubing

18-04 Tubing clip

18-05 Cable

2 Connect the wash liquid tubing (18-03)

to the bottles and their respective channels at the washer (16).

Make sure for each tubing that the number printed on the wash bottle rack corresponds with the one printed on the rear of the washer.

3 Fix the tubing into tubing clip (18-04).

4 Attach the cable (18-05) marked

“Niveau” – which is connected to the Supervisor board – to the wash bottle rack.

5 Install the frame cover (15-07) on the

15-07

Figure 4-14 Installation of wash bottle rack

August 2002 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 4 – 11

add-on module.

Page 40

4 – Transport and Installation

LICOS

15-08

1 For RMP 200 only:

• Insert the print cover (15-08) and fix it with the knurled nuts.

• Place the system liquid container (15-09) in the compartment and connect the system liquid tubing (white connector, leading to FWO) and the LICOS tubing (blue connector, leading to Supervisor board) to the container.

• Lead the fill tubing into the system liquid container.

LICOS

15-09

Waste liquid

System liquid

2 Connect waste liquid tubing, leading to

the Supervisor board, to LICOS sensor rod. Place LICOS sensor rod into the waste container.

15-08 Print cover

15-09 System liquid container

Figure 4-15 Installation of LICOS

Alarm Device Please refer to Installation Instructions for Alarm Device V2, Doc ID 391 255.

4 – 12 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 August 2002

Page 41

Workstation Extension (RWS Assay)

4.3.3 RWS Specific Installation Tasks

4 – Transport and Installation

The workstation extension is an option for RWS Assay instruments only. It is used as support for reader and washer.

Figure 4-16 RWS Assay workstation extension

25-01

1 Install the workstation extension (25) at

the right side of the cut out worktable (12).

2 Check horizontal alignment with a spirit

level; if necessary, adjust by means of the two right supports (25-01).

12 Cut out work table

16 Washer

19 Reader

24 Mounting assembly for washer

25 Workstation extension

25-01 Support

Variable Extension Deck (RWS Logistics)

The variable extension deck is an option for RWS Logistics instruments only. It is used as support for Ultra reader and further external devices.

The variable extension deck can either be placed on the right or on the left side of the instrument.

Reader (Option) 1 For RWS Assay:

• Place the reader (19) onto the workstation extension (25).

For RWS Logistics:

• Install the positioning plate on the variable extension deck.

• Place the Ultra reader onto the positioning plate.

2 Connect the reader to the power supply and to PC-com port.

Washer (Option) For RWS Assay only.

1 Install the mounting assembly for washer (24) onto the workstation extension (25).

August 2002 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 4 – 13

Page 42

4 – Transport and Installation

2 Place the washer (16) on top of the mounting assembly.

3 Check horizontal alignment with a spirit level. If necessary, adjust by means of the

mounting assembly legs.

4 Connect the washer to the power supply and to PC-com port.

5 Connect wash liquid tubing and waste tubing to the washer and respective liquid

containers.

Heated Incubator (Option)

4.3.4 Further Options and Modules for RSP/RWS

Installation of One Heated Incubator

1 Install adapter plate onto worktable.

2 Place incubator into respective recesses on the adapter plate.

3 Connect the incubator cable to the Optibo/Optibo Power.

4 Check horizontal alignment with a spirit level. If necessary, adjust by means of the

supplied special key (see 17-05 in Figure 4-13).

Installation of Up To Four Heated Incubators

Corresponding to the workstation configuration, up to four incubators can be placed at the rear of the worktable.

1 Install each incubator as described under Installation of One Heated Incubator.

It depends on the application software, if it is also possible to connect maximal two incubators in series.

2 Assure proper address setting for each incubator in compliance with possibly other

options (Refer to Section 6.2.2 Jumper and Address Settings Overview).

Standard setting for one incubator is address #2.

Connecting Options and Modules

LICOS 1 Connect LICOS sensor tubing, leading to MPO board, to the LICOS sensor rods.

4 – 14 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 August 2002

1 Make sure all options and modules are compatible (Refer to Section 3.2

Compatibility Matrix).

2 Assure proper address settings (Refer to Section 6.2.2 Jumper and Address

Settings Overview).

3 Prepare all options and modules according to manufacturers instructions and

connect them to Optibo/Optibo Power or Uniport or CANDI board.

2 Place LICOS sensor rods into respective containers:

• Tube 1: system liquid container

• Tube 2: waste container

3 Place system liquid container on worktable level to avoid pressure differences within

tubing system.

Page 43

4 – Transport and Installation

Access Option/ Signal Lamp

4.3.5 Computer, Software

Please refer to Installation Manual ID 392 330

1 Place the computer on the left side of the instrument. Install the computer according

to manufacturer’s instructions.

2 Make sure the instrument is switched off. Install communication cable between

computer (COM 2) and instrument (Optibo or Optibo Power).

3 Install Genesis instrument software and – if necessary – perform firmware download

(refer to Genesis Instrument Software Manual Doc ID 390 791).

4 Install respective application software.

August 2002 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 4 – 15

Page 44

4 – Transport and Installation

4.4 Commissioning

Mechanical Checks

Quick Jumper Settings Test

Retightening Screws

Manually check smooth movement of the LiHa 2 and – if installed – RoMa 2 and PosID 2.

If there is any resistance in the movement, check for dirt residue and clean thoroughly.

Control CAN-bus resistance to check correct jumper settings (see Section 6.2.3, ‘CAN-

Bus Resistance Test’).

1 Tighten all power cable screws on the

Optibo/Optibo Power (left access door).

2 Tighten all ILID plug fixing screws.

Make Liquid System Ready for Use

Figure 4-17 Retightening screws

1 Tighten tubing connections and the

syringe screw on diluters.

For these tasks, a better result is achieved when the valves with syringes are removed from the diluters.

2 Tighten tubing connections on

distributors (top cover).

3 Mount tips.

4 Open worktable front cover (10),

remove sealing strip. Place wash station on the worktable. Cut the sealing strip at the appropriate length and reinsert.

Figure 4-18 Diluter

Power-on 1 Connect the instrument to the mains.

2 Set mains power switch to on.

4 – 16 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 August 2002

Page 45

4 – Transport and Installation

Check Readiness for Operation

Cleaning Check the whole system for dirt residue resulting from transport and installation.

1 According to the document Installation Qualification, Doc ID 391 180, perform Setup

& Service software module.

2 Perform calibration process according to document Operation Qualification, Doc ID

391 182.

Observe appropriate sections in the Operating Manual.

August 2002 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 4 – 17

Page 46

4 – Transport and Installation

4.5 Conformity Assessment and CE Marking for RWS

Legal Situation Genesis RWS is an open and flexible platform providing our clients with many

configuration possibilities. A Genesis RWS instrument is considered as sub-assembly that must be integrated into a complete system. Each system has to be assessed and investigated to comply with particular local requirements.

The openness of the Genesis RWS system makes it impossible to declare it as CE conform and affix the corresponding label.

Responsibility A system integrator is a legal person (e.g. a RO within Tecan group or a distributor) who

acts in legal sense between Tecan Schweiz AG (manufacturer of sub-assembly) and the end-user of the system. The system integrator takes the responsibility of a remanufacturer for the whole system and must fulfill the following points:

1 Description of complete system (product)

2 Draw up (technical file)

3 Assure conformity to local regulations

4 Declare Conformity

5 Affix CE-marking (within EU-region only)

Tecan Schweiz AG can provide support to help system integrators with points 2, 3, 4 and 5 above.

Safety Standards Please note that Genesis RWS Instruments meet the following:

• Safety requirements for laboratory equipment EN 61010-1 / UL 3101-1 / CSA C22.2 No 1010-1 except Part 5 and 7, which are met only in part due to the open nature of the instrument

• EMC requirements for laboratory equipment EN 50081-1, part 1 EN 50082-1, part 1

The above is stated in the manufacturer’s declaration.

4.6 Site Acceptance

Completion 1 In case of a RWS instrument: make a conformity declaration.

2 Fill out the Acceptance Protocol (Doc ID 391 825) and have it signed by the

customer.

4 – 18 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 August 2002

Page 47

5 Maintenance

5 – Maintenance

Purpose of This Chapter

This chapter summarizes the preventive maintenance activities intended to retain the Genesis RSP, RMP or RWS instrument in a state in which it maintains the required or specified performance.

5.1 Concerning Your Safety

Decontamination Depending on the application, the instrument may be contaminated with compounds

hazardous to your health.

WARNING

The instrument may be contaminated. Before performing any maintenance or repair tasks:

• Make sure that the instrument has been decontaminated by an expert according to standard laboratory regulations.

• Request a filled out and signed Decontamination Declaration (Doc ID 390 901)

Unless otherwise noted, always switch off power and disconnect from mains before carrying out any maintenance tasks.

5.2 Consumables

Cleaning Agents

ATTENTION

Strong detergents may dissolve carrier and worktable surface coatings. Use only cleaning agents that are recommended by Tecan and according to table

Cleaning in Section 5.3.2.

Alcohol

Use ethyl-alcohol or 2-Propanol (Isopropanol).

Water

Use distilled or de-ionized water.

Bleach

Use sodium hypochlorite solution, max. 6 %.

Detergent

Use a weak detergent like

• RoboScrub

, order through Tecan US (order number 70-736 for 16 oz. bottle) or

August 2002 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 5 – 1

Page 48

5 – Maintenance

• CLEAN SYSTEM, order through Tecan-D: Daily System Clear = to clean the system daily = order number 30000938 (250 ml), Setup Clean = to clean contaminated systems = order number, 30000937 (500 ml), Protolyse = to clean the system from proteins = order number 30000939 (1000 ml), Carrystop = against carryover = order number 30000940 (1000 ml).

Cleaning Material Use lint-free tissue only.

5.3 Maintenance Schedule

Spare Parts For spare parts list with part numbers refer to Chapter 7, ‘Check Lists Spare Parts’.

• Use original Tecan spare parts only.

General

Note

Spare parts must correspond to the technical requirements laid down by the manufacturer.

5.3.1 Daily/Weekly Maintenance

For daily and weekly maintenance please follow the descriptions in the document Daily/ Weekly Maintenance Checklist, Doc ID 391 193. Check off the appropriate boxes as you go through the maintenance tasks.

5.3.2 Half-Yearly Maintenance

Refer to document Preventive Maintenance Checklist, Doc ID 391 181 and check off the appropriate boxes as you go through the maintenance tasks.

Task

Print out system information

Run counter read out

5 – 2 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 August 2002

Page 49

Parts to Be Replaced

5 – Maintenance

Part Interval: 6 month or … Refer to …

ILID cables after 250,000 Z-moves Section 6.6.4

DiTi cone and tubing extension

Washer tubing

Adjustment

Part Interval: 6 month or … Refer to …

RoMa 1 Z-brake Section 6.7.12

Cleaning Clean every 6 month or when necessary:

Instrument part Cleaning agent/material

Liquid system, waste system Water, alcohol, weak detergent

Worktable Alcohol, weak detergent, bleach 6 %

Metal parts Alcohol

Arm guide rail, guide rollers of LiHa, RoMa Alcohol

Z-rods RoMa Lint-free tissue (do not use any agent)

after 250,000 Z-moves

Test to Be Performed

Z-rods LiHa Lint-free tissue (do not use any agent)

Carriers Alcohol, weak detergent, bleach 6 %

Racks Alcohol, weak detergent, bleach 6 %

Tips Alcohol, bleach 6 %

DiTi cones Alcohol

PosID scanner head laser beam output window

Washer manifold Supplied cleaning needles, water

Reader optic (filter) Optical cleaning solution (lens tissue

Perform every 6 month:

Tes t

Reference position LiHa

Alcohol

or Ultrasonic bath, water

recommended)

Reference position RoMa (for RSP and RWS only)

Check tip adapter function

August 2002 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 5 – 3

Page 50

5 – Maintenance

5.3.3 Yearly Maintenance

Fill/flush system

Disposable tips

Liquid detection test

LICOS test

PosID test

Washer: prime each washer channel

Reader: QC test

Door lock test

Refer to document Preventive Maintenance Checklist, Doc ID 391 181 and check off the appropriate boxes as you go through the maintenance tasks.

General Perform the half-yearly maintenance tasks as listed in Section 5.3.2.

Parts to be Replaced

Test to Be Performed

Part Interval: 12 month or … Refer to …

Syringes after 1 million moves Section 6.4.3

3-way valve of diluter after 1 million moves Section 6.4.3

Tips

Aspirating tubing Section 6.4.2

Interconnecting tubing Section 6.4.2

Pipetting tubing Section 6.4.2

Waste tubing Section 6.4.2

Perform every 12 month:

Test

Precision test

5 – 4 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 August 2002

Page 51

6 – Replacement of Spare Parts, Repair

6 Replacement of Spare Parts, Repair

Purpose of This Chapter

Chapter Overview This chapter consists of the following sections:

This chapter describes the activities carried out after a failure has occurred, intended to restore an item to a state in which it can perform its required function.

Section Title Page

6.1 General Notes on Repair 6 – 4

6.1.1 Concerning Your Safety 6 – 4

6.1.2 General Repair Tasks 6 – 5

6.1.3 Operating Tests after Repair 6 – 6

6.2 Abstract of Important Data 6 – 7

6.2.1 Special Tools 6 – 7

6.2.2 Jumper and Address Settings Overview 6 – 8

6.2.3 CAN-Bus Resistance Test 6 – 10

6.2.4 Software Error Messages 6 – 11

6.3 Instrument – Disassembly and Assembly Procedures 6 – 22

6.3.1 Worktable 6 – 22

6.3.2 Door Locks 6 – 24

6.3.3 X-Drive Assembly 6 – 25

6.3.4 Power Modules 6 – 34

6.3.5 Electronic Boards 6 – 37

6.4 Liquid System – Disassembly and Assembly Procedures 6 – 46

6.4.1 Overview 6 – 46

6.4.2 Tubing System 6 – 47

6.4.3 Diluter and Dilback 6 – 50

6.4.4 MPO/FWO 6 – 54

6.4.5 Low Volume Option 6 – 62

6.4.6 6-Way Valve Option 6 – 69

6.5 LiHa 1 – Disassembly and Assembly Procedures 6 – 73

6.5.1 Overview 6 – 73

6.5.2 Complete LiHa 1 Assembly 6 – 75

6.5.3 X-Flex Cable 6 – 76

6.5.4 ILID Cable 6 – 76

6.5.5 ILID Flat Cable 6 – 76

6.5.6 Electronic Boards for LiHa 1 6 – 78

August 2002 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 6 – 1

Page 52

6 – Replacement of Spare Parts, Repair

Section Title Page

6.5.7 Y-Belt and Y-Spreading Belt 6 – 79

6.5.8 Y-Motor and Y-Spreading Motor 6 – 80

6.5.9 Tip Adapter 6 – 81

6.5.10 Ensure Operating Readiness 6 – 81

6.6 LiHa 2 – Disassembly and Assembly Procedures 6 – 83

6.6.1 Overview 6 – 83

6.6.2 Complete LiHa 2 Assembly 6 – 85

6.6.3 X-Flex Cable 6 – 88

6.6.4 ILID Cable 6 – 89

6.6.5 ILID Flat Cable 6 – 90

6.6.6 Electronic Boards for LiHa 2 6 – 91

6.6.7 Y-Belt and Y-Spreading Belt 6 – 95

6.6.8 Y-Motor and Y-Spreading Motor 6 – 97

6.6.9 Tip Adapter 6 – 98

6.6.10 Lower DiTi Eject Option 6 – 99

6.6.11 Ensure Operating Readiness 6 – 104

6.7 RoMa 1 – Disassembly and Assembly Procedures 6 – 106

6.7.1 Overview 6 – 106

6.7.2 Complete RoMa 1 Assembly 6 – 109

6.7.3 Gripper Fingers 6 – 109

6.7.4 Gripper Module Head, Gripper Board 6 – 109

6.7.5 Rotator Motor 6 – 110

6.7.6 X-Flex Cable 6 – 110

6.7.7 Gripper/Rotator Flex Cables 6 – 110

6.7.8 Y/R- and Z/G-DC-Servo Board 6 – 110

6.7.9 RoMa 1 Backplane 6 – 111

6.7.10 Y-Belt 6 – 111

6.7.11 Y- and Z-Motor 6 – 111

6.7.12 Z-Brake 6 – 112

6.7.13 Ensuring Operating Readiness 6 – 113

6.8 RoMa 2 – Disassembly and Assembly Procedures 6 – 114

6.8.1 Overview 6 – 114

6.8.2 Complete RoMa 2 Assembly 6 – 117

6.8.3 Mechanical Adjustment After Reinstallation 6 – 118

6.8.4 Gripper Fingers 6 – 121

6.8.5 Gripper Module Head, Gripper Board 6 – 122

6.8.6 Rotator Motor 6 – 125

6 – 2 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 August 2002

Page 53

6 – Replacement of Spare Parts, Repair

Section Title Page

6.8.7 X-Flex Cable 6 – 126

6.8.8 Gripper/Rotator Flex Cables 6 – 129

6.8.9 Y/R- and Z/G-DC-Servo Board 6 – 131

6.8.10 RoMa 2 Backplane 6 – 132

6.8.11 Y-Belt 6 – 133

6.8.12 Y-Motor 6 – 135

6.8.13 Z-Motor 6 – 136

6.8.14 Z-Brake 6 – 137

6.8.15 Ensuring Operating Readiness 6 – 138

6.9 PosID 1 – Disassembly and Assembly Procedures 6 – 139

6.9.1 Complete PosID 1 Assembly 6 – 139

6.9.2 X-Drive Assembly (X-Belt, X-Motor, X-Flex Cable) 6 – 140

6.9.3 Electronic Boards for PosID 1 6 – 141

6.9.4 Scanner Assembly (Scanner Head, B-Motor) 6 – 144

6.9.5 Y-Belt Assembly (Y-Belt, Y-Motor) 6 – 146

6.9.6 No Tube Sensor 6 – 147

6.9.7 Ensure Operating Readiness 6 – 148

6.10 PosID 2 – Disassembly and Assembly Procedures 6 – 149

6.10.1 Complete PosID 2 Assembly 6 – 150

6.10.2 X-Drive Assembly (X-Belt, X-Motor, X-Flex Cable) 6 – 153

6.10.3 Electronic Boards for PosID 2 6 – 155

6.10.4 Scanner Assembly (B-Motor, Scanner Head and Cable)

6.10.5 Y-Drive Assembly (Y-Belt, Gripper Assembly, YMotor)

6.10.6 No Tube Sensor 6 – 161

6.10.7 Ensure Operating Readiness 6 – 162

6 – 157

6 – 159

August 2002 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 6 – 3

Page 54

6 – Replacement of Spare Parts, Repair

6.1 General Notes on Repair

Useful References • Refer to Chapter 8, ‘Instruments at a Glance’ for an overview concerning the

location of the most common parts.

• For spare parts list with part numbers refer to Chapter 7, ‘Check Lists Spare Parts’.

•As Chapter 7 is structured in the sequence of disassembly of an item, it can also be used by experienced FSEs as brief instructions.

• For electrical diagrams refer to Chapter 9, ‘Diagrams’.

Spare Parts • Use original Tecan spare parts only.

Note

Spare parts must correspond to the technical requirements laid down by the manufacturer.

Disposal of Waste • Dispose used items and consumables according to the relevant national

environmental, health and safety laws and regulations.

6.1.1 Concerning Your Safety

Chemical, Biological and Radioactive Hazards

Decontamination For your own and any other affected person’s safety, make sure the instrument or parts

Depending on the applications, parts of the instrument may have been in contact with biohazardous, poisonous or even radioactive materials. A potential risk may arise from the liquids that have been handled on the instrument.

• Strictly apply appropriate safety precautions according to general laboratory and applicable local, state and federal regulations.

WARNING

Potential Biohazard. The instrument might be contaminated! For servicing, use appropriate personal protective equipment!

have been thoroughly decontaminated prior to carrying out any maintenance and repair task on the instrument or before sending it or parts of it for repair:

• Thoroughly clean and decontaminate all relevant parts.

• Provide a filled-out and signed Decontamination Declaration (Doc ID 390 901).

6 – 4 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 August 2002

Page 55

Electrical Shock Hazard

6 – Replacement of Spare Parts, Repair

WARNING

Unless otherwise noted, always switch off power and disconnect from mains before carrying out any tasks described in this chapter.

Electrostatic Sensitive Devices

Discharge static electricity from your body by wearing a wrist strap to protect yourself and sensitive control electronics installed:

• Wear a wrist strap during all installation and maintenance tasks, e.g. when exchanging components.

ATTENTION

Observe precautions for handling electrostatic discharge sensitive devices.

6.1.2 General Repair Tasks

Loctite® 638 • Several set screws are glued with Loctite 638. Use a hot-air apparatus to soften the

adhesive before unscrewing these screws.

Disconnecting Cables

• When disconnecting cables, always mark designation (Jxx) on connector using a water resistant pen.

If due to insufficient space, designations are not marked on the PCB use electrical diagrams instead.

Figure 6-1 Connector designation

When replacing any PCB …

Cleaning • Wipe off grease residue and thoroughly clean affected instrument parts after any

• Make sure the jumpers for CAN-bus resistance are set identically to the replaced PCB (see also Section 6.2.2, ‘Jumper and Address Settings Overview’).

• Control if address switch is set correctly (see Section 6.2.2, ‘Jumper and Address

Settings Overview’).

• Check CAN-bus resistance (see Section 6.2.3, ‘CAN-Bus Resistance Test’).

repair task.

August 2002 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 6 – 5

Page 56

6 – Replacement of Spare Parts, Repair

6.1.3 Operating Tests after Repair

Service Checklist • After replacing or removing and reinstalling modules or spare parts, carry out the

appropriate tests according to Service Checklist Doc ID 391 183 (included in the Genesis Maintenance and Service Logbook).

6 – 6 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 August 2002

Page 57

6.2 Abstract of Important Data

6.2.1 Special Tools

LiHa reference tip Part No. 612 503

384 well tip adjustment tool Part No. 613 103

6 – Replacement of Spare Parts, Repair

RoMa calibration tool Part No. 612 622

RoMa teach plate Part No. 613 101

PosID service rack Part No. 613 100

August 2002 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 6 – 7

Page 58

6 – Replacement of Spare Parts, Repair

6.2.2 Jumper and Address Settings Overview

The following communication overview shows …

• the default address settings on the electronic boards of the different modules,

• on which modules the jumpers have to be set/switched on, or removed/switched off according to the configuration of the instrument:

Communication Overview

RS 232

RS 232 / RS 232

Multiport 8x RS232

Washer

Reader

Z/R

Liconic Carousel

Stepper Drive / Scanner

Option-Can

Te-Shake #6

Option-Can

Te-Mags #5

Option-Can

Te-Vacs #4

Option-Can

Te-Sonic #3

Option-Can

Incubator #2

3 2

SMIO #1

Option-Can

MPO #0

Option-Can

Can

DC-

ST5

Local-

Servo

Option-Can

T1..T6

TEMPO #8..D

Option-Can

Te-Flow #1

Option-Can

LOW-VOLUME

U1..4

Q1...8 S1..8

...4

7 2

RMP 4

RSP 9

Option-Can

Local-

Option-Can

Te-Stack #0...F

WRC (2) #6

6-way valve

Supervisor #1

Uniport

position)

(depending on

TeMo #0

Can

DC-

Servo

Can

DC-

Servo

Local-

T3TR6

Can

The Device default number and name, i.e. O5 as device is identified in FW

The Device default adress, i.e. #4. Setting for the adress switch

Some configurations may require different adress settings.

DC-

Servo

Option-Can

WRC (1) #6

= always open (Switch off or Jumper not set)

= always terminated if the module is installed (Switch on or Jumper set)

The termination of the option-CAN and the system-CAN is priorized

depending on configuration:

Option-Can

The two installed modules with the lowest numbers / letters within the box

have to be terminated:

{

Vacs #4

= priorized termination of Option CANA= priorized termination of System CAN

RS-232

Can

DC-

System-

Optibo

MO2

D 9

System-Can Option-Can

Can

Diluter

System-

Can

Diluter

System-

Can

Diluter

System-

Can

Diluter

System-Can

Diluter Backplane

System-

Can

Diluter

System-

Can

Diluter

System-

Can

Diluter

System-

Can

Diluter

System-

E 9

Servo

Option-Can

CU PosID2

Can

DC-

MO1

Local-

Servo

Can

DC-

MO5

Servo

System-

Can

DC-

MO4

Servo

System-

System-Can

Backplane (LiHa)

Can

System-

Can

System-

Can

System-

DC-

MO3

Servo

MO2

Servo

MO1

Servo

Scanner

Y/B PosID

Local-Can / RS232

Can

DC-

MO2

Local-

Servo

Can

DC-

MO1

Servo

RoMa

Backplane

System-

Can

System-

DC-

MO2

Servo

System-Can

6 – 8 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 August 2002

Page 59

Jumper Allocation

6 – Replacement of Spare Parts, Repair

PCP System

CAN-bus

Optibo, Optibo Power J12 J13 —

CU board J1 J22

Option CAN-bus

Local CAN-bus

MPO board V2.0 MPO board V3.1/V4.0

LiHa backplane J14 — —

Dilback J10 — —

RoMa 1 backplane

RoMa 2 backplane

PosID 1/PosID 2 CU board — J8 J6

— —

J4 J2

—

— —

—

August 2002 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 6 – 9

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6 – Replacement of Spare Parts, Repair

6.2.3 CAN-Bus Resistance Test

Purpose of this test is to verify whether bus end jumper settings on control electronics are correct.

Will Be Applicable • When commissioning a new instrument.

• After exchange or new installation of a LiHa 1/LiHa 2, RoMa 1/RoMa 2, PosID 1/ PosID 2 or other options as e.g. Te-VacS etc.

• After exchange or supplemental installation of PCBs.

Required Special Tools

Test Procedure 1 Switch off the instrument.

•Multimeter

2 On the Optibo or Optibo Power (left access door) check the CAN-bus resistance

between the respective check points:

Figure 6-2 Check points for System CAN-bus

• System CAN Measure resistance between CAN_L and CAN_H.

• Option CAN Measure resistance between CANO_L and CANO_H.

Figure 6-3 Check points for Option CAN-bus

3 Correct CAN-bus resistance:

50–65 Ω: correct number of jumpers < 50 Ω: too many jumpers are set ~ 40 Ω: 1 jumper too much > 65 Ω: too few jumpers are set ~ 120 Ω: 1 jumper too few

If CAN-bus resistance is not between 50 an 65 Ω: compare jumper settings and

CAN-bus connections with ‘Communication Overview’ in Section 6.2.2, ‘Jumper and

Address Settings Overview’ and correct.

6 – 10 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 August 2002

Page 61

6.2.4 Software Error Messages

Toolbox General Errors

6 – Replacement of Spare Parts, Repair

Toolbox error code

0 OK (no error)

1 Toolbox not initialized (from V2.1 on: not opened)

2 Toolbox already initialized (from V2.1 on: already open)

3 Toolbox init error (from V2.1 on: error in opening)

4 Communication driver error

5 Incorrect answer string format (cannot extract)

6 Illegal command parameter value

7 Error list contains at least one error

8 No such worktable

Explanation

9 Open rack database failed

10 Worktable access error (carrier/rack)

11 Evaluation access (not a single position defined)

12 Evaluation access (not a single position is accessible due to Y)

13 Evaluation access (position out of range)

14 Accessing all selected positions not possible

15 No carrier/rack defined

16 Worktable access error (tube)

17 Open comm log file failed

18 No carrier on specified grid position

19 Worktable object creation error

20 Open communication driver failed

21 Close communication driver failed

22 Evaluation access (not a single position is accessible due to X)

23 Genesis DB not open

24 Communication driver not open

25 Plate stuck on gripper

26 Balance initialization error

27 Balance isn't initialized

28 Balance isn't correct tared

29 Measurements not enough linear. Preparing/weighing not possible.

30 Wrong machine type. No balances available.

31 Balance not prepared. Weighing not possible.

32 Error while getting a balance value. Weighing not possible.

August 2002 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 6 – 11

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6 – Replacement of Spare Parts, Repair

Toolbox error code

33 Wrong machine type. No low volume support.

34 This machine has no pinch valves

35 No installable easy option available

36 Easy option slot occupied

37 Defined Easy Option module not available

38 The initialization of the serial communication port failed

39 Sending through the serial communication port failed

40 Receiving through the serial communication port failed

41 Command not implemented (for the PosID 1)

42 Command not implemented (for the PosID 2)

43 Difference too big between “prepare weigh” and “weigh” in

44 Worktable View: nothing selected

45 Worktable View: index out of range

46 Worktable View: …

Explanation

evaporation

Toolbox User Interactions

Toolbox Data Errors

47 Worktable View: object not created

Toolbox error code

90 Abort from user

91 Retry from user

92 User (calling application) handles error

93 Ignore from user

94 “Go to ZBottom” from user

Toolbox error code

101 Incorrect tip number

102 Data pointer is NULL

103 Individual tip data set (no global data available)

Explanation

104 Incorrect liquid index

105 Data set not defined

106 Selector out of bounds

107 Not enough space (for complete report)

6 – 12 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 August 2002

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6 – Replacement of Spare Parts, Repair

Toolbox Communication Errors

Toolbox Device Errors (Ranges)

Toolbox

Explanation

error code

108 Invalid diluter number

109 Parameter value(s) out of range

110 Invalid arm ID

111 Invalid number of tips

112 Invalid number of diluters

Toolbox

Explanation

error code

201 COM unknown error

202 COM device still busy

203 COM device time-out

Toolbox error code range

Device Address

Explanation

Common Errors for All Devices

300 Common

400 M CU

500 A LiHa

527 A LiHa (tip mounted)

600 O MPO, Incubator, Supervisor

700 D Diluter

800 P PosID

900 R RoMa

1000 V Low Volume Option

1100 U Uniport

10,000 P PosID extended errors

Toolbox error code = Toolbox error code range + Communication driver error code

Examples:

Toolbox error code 807 = 800 + 7 = PosID not initialized Toolbox error code 528 = 527 + 1 = LiHa (tip mounted) initialization error

Communication

Explanation

driver error code

1 Initialization error

August 2002 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 6 – 13

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6 – Replacement of Spare Parts, Repair

Communication driver error code

2 Invalid command

3 Invalid operand

4 Invalid command sequence

5 Device not implemented

6 Time-out error

7 Device not initialized

8 Command overflow of CU

15 Command overflow of subdevice

CU Error Codes Toolbox error code = Toolbox error code range (= 400 for CU) + Communication driver

error code

Communication driver error code

13 413 No access to serial EEPROM

Explanation

Toolbox error code

Explanation

16 416 Power fail circuit error

17 417 Arm collision avoided between LiHa and

RoMa

18 418 Door lock 1 failed

19 419 Door lock 2 failed

20 420 No new device #V node detected

21 421 Device #V node already defined

LiHa Error Codes Toolbox error code = Toolbox error code range + Communication driver error code

First number = LiHa (range 500), second number = LiHa tip mounted (range 527)

Communication driver error code

9 509/536 No liquid detected (MDT, MET)

10 510/537 Drive no load

11 511/538 Not enough liquid (MDT)

Toolbox error code

Explanation

12 512/539 Not enough liquid (MET)

13 513/540 Arm collision avoided with PosID

16 516/543 Power fail circuit error

17 517/544 Arm collision avoided with RoMa

18 518/545 Clot limit passed (MCT)

6 – 14 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 August 2002

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6 – Replacement of Spare Parts, Repair

Communication driver error code

19 519/546 No clot exit detected (MCT)

20 520/547 No liquid exit detected (MDT, MET)

23 523/550 Not yet moved (MDT, MET)

24 524/551 ILID pulse error (MDT, MET, MCT)

25 525/552 Tip not fetched (AGT, ADT)

26 526/553 Tip not mounted (AGT, ADT)

27 527/554 Tip mounted (AGT, ADT)

RoMa Error Codes Toolbox error code = Toolbox error code range (= 900 for RoMa) + Communication

driver error code

Communication driver error code

9 909 Plate not fetched (AGR)

10 910 Drive no load

Toolbox error code

Explanation

16 916 Power fail circuit error

17 917 Arm collision avoided with LiHa

XP Error Codes Toolbox error code = Toolbox error code range (= 700 for Diluter) + Communication

driver error code

PosID 1 Common Errors

Communication driver error code

9 709 Plunger overload

10 710 Valve overload

11 711 Valve in bypass

13 713 No access to EEPROM

Toolbox error code = Toolbox error code range* + Communication driver error code

*= 800 for Communication driver error codes up to 31 and 10,000 for Communication driver error codes beyond 31

Toolbox error code

Explanation

Communication driver error code

14 814 Extended error in device occurred (REE

36 10,036 EEPROM failure

August 2002 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 6 – 15

Toolbox error code

Explanation

reports the extended error code)

Page 66

6 – Replacement of Spare Parts, Repair

PosID 1 Axis Errors (Ranges)

Communication driver error code

37 10,037 EEPROM no access (hardware problem; e.g.

38 10,038 EEPROM data invalid (e.g. chip empty or

39 10,039 EEPROM special error (trap for rare error;

40 10,040 Invalid mnemonics

41 10,041 Invalid argument (parameter out-of-range)

42 10,042 Invalid parameter number

43 10,043 Invalid device address

44 10,044 Invalid frame type

45 10,045 Invalid message length

Communication driver error code ranges

Toolbox error code

Explanation

no chip available)

invalid data, system adjustment required!)

data is valid!)

PosID 1 Common Axis Errors

100 X-axis offset (arm movement)

200 Y-axis offset (grip movement)

300 B-axis offset (barcode scanner movement)

Communication driver error code: x = communication driver error code range

Examples:

Communication driver error code 263 = 200 + 63 = Y-axis target not reached

Communication driver error code 1324 = 300 + 1024 = B-axis overload detected

Toolbox error code = Toolbox error code range (10,000 for PosID) + Communication driver error code

Communication driver error code

x50 10,x50 Unknown axis mnemonic

x51 10,x51 Invalid axis identifier

Toolbox error code

Explanation

x52 10,x52 # of sub-axis is out of limit

x55 10,x55 Collision detection is active

x58 10,x58 Time-out calculation error

6 – 16 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 August 2002

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6 – Replacement of Spare Parts, Repair

Communication driver error code

x59 10,x59 Dynamic read calculation error

x61 10,x61 Initialization: target not reachable

x62 10,x62 Target out-of-range

x63 10,x63 Target not reached

x65 10,x65 Axis movement time-out

1x20 11,x20 CAN over run

1x21 11,x21 No load

1x22 11,x22 No liquid detected

1x23 11,x23 Break point not reached

1x24 11,x24 Overload detected

1x25 11,x25 Delayed action pending (ready to execute)

1x26 11,x26 Delayed action pending (ready to execute)

1x27 11,x27 Command not yet implemented

1x29 11,x29 DC-Servo multiple error

Toolbox error code

Explanation

PosID 1 Miscellaneous Errors

Toolbox error code = Toolbox error code range (10,000 for PosID) + Communication driver error code

BCS = Barcode Scanner; HOST = PosID CU

Communication driver error code

401 10,401 BCS initialization: no ID REQUEST from BCS

405 10,405 Unexpected response from BCS after START

411 10,411 No decoded barcode from BCS

412 10,412 Barcode string length out-of-range

413 10,413 NR (No Read) message from BCS

421 10,421 CMNDNAK (CoMmaND Not Acknowledge)

422 10,422 No ACK or NAK respond from BCS

425 10,425 No respond from BCS

426 10,426 Checksum error detected by BCS

Toolbox error code

Explanation

after ATTENTION from HOST

DECODE

respond from BCS

427 10,427 Unexpected respond from BCS

435 10,435 No respond from BCS

August 2002 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 6 – 17

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6 – Replacement of Spare Parts, Repair

Communication driver error code

436 10,436 Checksum error detected by HOST

437 10,437 Unexpected respond from BCS

438 10,438 No complete respond from BCS

441 10,441 HOST received message from wrong

451 10,451 BC type out-of-range

452 10,452 Verify mode out-of-range

455 10,455 Unexpected character in BC string

456 10,456 BC check digit error

460 10,460 Invalid test number

470 10,470 Parameter out-of-range

501 10,501 Invalid field id

502 10,502 Invalid parameter

510 10,510 Invalid sector id

511 10,511 Sector already active

Toolbox error code

Explanation

message source

512 10,512 Sector not yet active

513 10,513 Sector parameter out-of-range

514 10,514 Sector limit reached

520 10,520 Invalid fixed field id

521 10,521 Fixed field already active

522 10,522 Fixed field not yet active

523 10,523 Fixed field parameter out-of-range

530 10,530 Unknown carrier state

531 10,531 Invalid carrier code

532 10,532 Invalid carrier code string length

533 10,533 Invalid carrier code type

534 10,534 Invalid carrier placement

535 10,535 Invalid carrier id

536 10,536 Carrier id already active

537 10,537 Carrier id not yet active

538 10,538 Invalid carrier code format

545 10,545 Invalid carrier type

546 10,546 Carrier type already active

547 10,547 Carrier type not yet active

548 10,548 Invalid carrier data id

549 10,549 Carrier is at remove position

6 – 18 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 August 2002

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6 – Replacement of Spare Parts, Repair

Communication driver error code

550 10,550 Unknown rack/sample state

555 10,555 Invalid rack/sample type

556 10,556 Rack/sample type already active

557 10,557 Rack/sample type not yet active

558 10,558 Invalid rack/sample data id

560 10,560 Move right carrier locked

601 10,601 Invalid port number

602 10,602 Invalid bit number

701 10,701 BC scan task not started

710 10,710 No carrier present

711 10,711 Expected carrier not found

720 10,720 Calibration Y max read

741 10,741 Reload of same carrier

742 10,742 Comparison of 1st rack/sample impossible

743 10,743 Illegal removal of carrier detected

Toolbox error code

Explanation

744 10,744 Illegal movement of carrier detected

750 10,750 Previous BC read was equal

PosID 2 Errors Toolbox error code = Toolbox error code range (= 800 for PosID) + Communication

driver error code

Communication driver error code

9 809 No liquid detected by DC-Servo

10 810 Drive with no load detected

11 811 Break point reached

12 812 No access to parameter block

13 813 Collision between LiHa and PosID avoided

14 814 Extended error

16 816 Power fail circuit failure

17 817 Not locked to grid

Toolbox error code

Explanation

(error code currently not used)

18 818 Sector not defined

20 820 Barcode scanner failure (communication

problem, e.g. wrong answer to ESC sequence)

August 2002 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 6 – 19

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6 – Replacement of Spare Parts, Repair

Communication driver error code

21 821 Barcode scanner communication error

22 822 Carrier not movable

23 823 Break point not reached

24 824 Carrier not defined

25 825 Rack/sample not defined

26 826 Carrier not loaded

27 827 Invalid carrier id barcode

28 828 Carrier not present

29 829 Illegal BCS movement

30 830 BCS failed during initialization

Toolbox error code

Explanation

(transmission errors upon OV, FE, PT, VRC cmds)

(error code currently not used)

Low Volume Option Errors

Incubator Errors Toolbox error code = Toolbox error code range (= 600 for incubator) + Communication

Toolbox error code = Toolbox error code range (= 1000 for Low Volume Option) + Communication driver error code

Communication driver error code

9 1009 Selected valve not installed

10 1010 Endless mode not possible

11 1011 Wrong node defined

driver error code

Communication driver error coder

9 609 Shaker not installed

10 610 Shaker position initialization error

11 611 Close door solenoid short or open circuit

12 612 EEPROM checksum error

Toolbox error code

Explanation

13 613 EEPROM access error

16 616 Slot temperature overrun

17 617 Temperature sensor short- or open circuit, or

suspect

18 618 Shaker fail

6 – 20 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 August 2002

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6 – Replacement of Spare Parts, Repair

Supervisor Errors Toolbox error = Toolbox error range (= 600 for Supervisor) + Communication driver error

Communication driver error coder

12 612 LICOS not calibrated

13 613 EEPROM access error

16 616 Door already open

17 617 Hall sensors not calibrated

Uniport Errors Spectra/Sunrise Errors

Toolbox error = Toolbox error range (= 1100 for Uniport) + Communication driver error

Communication driver error coder

16 1116 Lamp low

17 1117 Lamp high

18 1118 Transport error

19 1119 Filter error

20 1120 Checksum error

Toolbox error code

Explanation

21 1121 No data uploaded by “D” or “D2” cmd.

August 2002 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 6 – 21

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6 – Replacement of Spare Parts, Repair

6.3 Instrument – Disassembly and Assembly Procedures

This section describes mechanical and electronic exchange routines on instrument level.

6.3.1 Worktable

Spare Parts Worktable

Required Special Tool

Removal of Worktable

For spare parts list with part numbers refer to Section 7.1.1, ‘Spare Parts Worktable’.

Following items can be replaced as spare parts:

• Worktable

• Positioning pins

• Sealing strip

• Reference tip for LiHa

Will Be Applicable …

• If a new or another type of worktable has to be installed.

• If you need to access the PosID/PosID 2 or an older version of PosID/PosID 2 CU board (located underneath the worktable).

Removal

For more information refer to Section 4.3, ‘Installation’, inverse order of installation instructions.

1 Empty the worktable completely.

2For RMP: detach the module worktable.

3 Open the front worktable cover (10).

• For RMP: remove the door locks (21).

• For RWS: remove magnet holders.

4 Remove all screw caps (tip: use a watch maker screwdriver) and all fixing screws

from the worktable.

5 Remove the worktable by carefully lifting and pulling forward.

Installation of Worktable

6 – 22 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 August 2002

1 Carefully install the worktable.

2 RSP and RWS: insert the 4 countersunk screws on the rear right and rear left but do

not tighten them yet.

RMP: insert the 2 countersunk screw on the rear left but do not tighten them yet.

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6 – Replacement of Spare Parts, Repair

3 Insert but only slightly tighten the oval head screws.

4 Manually align the worktable, then tighten the front left screw.

This screw will act as a pivot point during the following alignment.

5 Install the reference tip onto the LiHa:

• 4-Tip LiHa: mount reference tip on position 1 (first tip from behind).

• 8-Tip LiHa: mount reference tip on position 3 (third tip from behind).

6 Manually position the reference tip at the edge of the foremost positioning pin in grid

position 1 (most left grid). Check the gap between pin and reference tip.

7 Manually move the LiHa to the

rightmost grid position and check the gap between pin and reference tip.

The gap must be the same on either side of the worktable.

Ensure Operating Readiness

Figure 6-4 Gap between reference tip and positioning pin

8 When the worktable is positioned: tighten the fixing screws and insert the screw

caps.

9 Reinstall all previously removed parts. For detailed information about installing …

• RMP door locks: refer to Section 6.3.2.

• RMP 200 add-on module: refer to Section 4.3, ‘Installation’.

• Reader, washer and incubators: refer to Section 4.3, ‘Installation’.

10 Ensure Operating Readiness as described later in this section.

For detailed information refer to the Genesis Instrument Software Manual.

After replacing or reinstalling the worktable or replacing the positioning pins, control – and if necessary carry out – following settings:

Step Test or Setup

1LiHa

• Check reference positions

• Adjust scale factors

Only necessary if check failed

• Adjust reference positions

Only necessary if check failed

• Set absolute Z

• Set individual Z

August 2002 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 6 – 23

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6 – Replacement of Spare Parts, Repair

2PosID

•Test

• PosID adjustment

Only necessary if test failed

3RoMa

• Check reference positions

• RoMa setup

Only necessary if check failed

6.3.2 Door Locks

RMP For the description of disassembly and assembly procedure for the Genesis RMP door

locks, please refer to the document Doc ID 391 260.

RSP, RWS The door lock is part of the access option for RSP and RWS instruments. Please refer

to document Doc ID 392 330 for further information.

6 – 24 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 August 2002

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6 – Replacement of Spare Parts, Repair

6.3.3 X-Drive Assembly

The X-drive assembly is installed in the X-bay (5) of the instrument. It consists of one Xmotor and a X-belt which drives the LiHa. If the instrument is equipped with a RoMa, a second X-drive assembly is installed which drives the RoMa.

The X-DC-Servo board – which controls the X-motors of the LiHa and RoMa – is described in Section 6.3.5, ‘Electronic Boards’.

Spare Parts For spare parts list with part numbers refer to Section 7.1.3, ‘Spare Parts X-Drive

Assembly’.

Following items can be replaced as spare parts:

• Belt tensioner

• X-belt (5.5 m)

• X-DC-Servo motor with cable and bracket

Overview X-Drive Assembly for LiHa

5-01

5-10

2x M4x10

5-02

5-03 5-04

5-11

5-06

2x M4x10

5-07

5-08

M4x10

5-01 5-03 5-07

5-09

3x M4x8

5-05

M4x60

Figure 6-5 X-drive assembly for LiHa

5-01 X-motor LiHa 5-06 Fixing screw/washer for belt take-up

5-02 X-motor cable LiHa (J13) 5-07 X-slide LiHa

5-03 X-belt LiHa 5-08 Fixing screw for X-belt LiHa

5-04 Belt take-up LiHa 5-09 Fixing screw for X-motor LiHa

5-05 Belt tensioner (belt tensioning screw/ 5-10 Fixing screw for X-motor LiHa

washer/pressure spring) 5-11 Driver LiHa

August 2002 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 6 – 25

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6 – Replacement of Spare Parts, Repair

Overview X-Drive Assembly for RoMa

5-15

5-16

5-14

5-13

5-12

5-01

5-23

5-22

M4x8

5-21

M4x10

5-10

2x M4x10

5-09, 5-20

5x M4x8

Figure 6-6 X-drive assembly for RoMa

5-07

5-24

5-12

5-19

5-14

5-18

2x M4x10

5-17

M4x60

5-19

5-01 X-motor LiHa 5-17 Belt tensioner (belt tensioning screw/

5-07 X-slide LiHa washer/pressure spring)

5-09 Fixing screw for X-motor LiHa 5-18 Fixing screw/washer for belt take-up

5-10 Fixing screw for X-motor LiHa 5-19 X-slide RoMa

5-12 X-motor RoMa 5-20 Fixing screw for X-motor RoMa

5-13 X-motor cable RoMa (J09) 5-21 Fixing screw for belt lock

5-14 X-belt RoMa 5-22 Fixing screw for X-motor RoMa

5-15 Fixing screw for X-belt RoMa 5-23 Belt lock RoMa

5-16 Belt take-up RoMa 5-24 Driver RoMa

Removal of X-Belt For LiHa and RoMa X-Belt

The item numbers mentioned refer to Figure 6-5, ‘X-drive assembly for LiHa’ and Figure

6-6, ‘X-drive assembly for RoMa’.

Note

In case the instrument is not yet equipped with the new belt tensioner (5-05 or 5-17), we recommend to upgrade the instrument when removing the X-belt.

6 – 26 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 August 2002

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6 – Replacement of Spare Parts, Repair

1 Remove the arm of the relevant X-drive.

For LiHa 1 see Section 6.5.2, ‘Complete LiHa 1 Assembly’, for LiHa 2 see Section 6.6.2, ‘Complete LiHa 2 Assembly’, for RoMa 1 see Section 6.7.2, ‘Complete RoMa 1 Assembly’ for RoMa 2 see Section 6.8.2, ‘Complete RoMa 2 Assembly’.

2 Unscrew and remove the X-bay covers, open right access door (6).

3 For RMP instruments only:

• Remove system liquid container.

• Unscrew the steel plate supporting the Supervisor/Uniport board (41, 37) in order to get access to the belt tensioning screw (5-17).

4 From below the X-bay loosen the respective belt take-up fixing screws (5-06 or

5-18).

5 Loosen the respective belt tensioning screw (5-05 or 5-17) to slacken the X-belt

tension.

6 For LiHa X-belt:

• Open X-belt fixing screw (5-08), remove X-belt (5-03).

Installation of X-Belt

For RoMa X-belt:

• Open belt lock (5-23) and X-belt fixing screws (5-15), remove X-belt (5-14).

For LiHa X-Belt

5-04

5-03

5-11

5-08

M4x10

2x M4x10

5-07

5-05

M4x60

5-06

Figure 6-7 Installing X-belt LiHa

5-03 X-belt LiHa 5-06 Fixing screw/washer for belt take-up

5-04 Belt take-up LiHa 5-07 X-slide LiHa

5-05 Belt tensioner (belt tensioning screw/ 5-08 Fixing screw for X-belt LiHa

washer/pressure spring) 5-11 Driver LiHa

1 Cut the new belt to required size according to the replaced one.

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6 – Replacement of Spare Parts, Repair

2 If installed: remove belt tensioning screw (5-05).

3 Fix – but do not tighten yet – the belt take-up fixing screws (5-06) which should be

positioned more likely in the left part of the slotted hole.

5-03

5-04

5-06

5-08

5-03

5-11

Figure 6-8 X-belt LiHa

4 Lead the X-belt (5-03) over the pulleys

5-03 X-belt LiHa

5-04 Belt take-up LiHa

5-06 Fixing screw for belt take-up

5-08 Fixing screw for X-belt

5-11 Driver LiHa

5 Loosen the fixing screws of the driver (5-11).

6 Screw the belt tensioning screw (5-05)

6.5 mm

5-04

5-05

as shown in Figure 6-7 and fasten it (fixing screw 5-08) in the driver (5-11).

Make sure the belt is placed correctly over the pulleys (Figure 6-8).

with washer and pressure spring into the belt take-up (5-04) until the distance between inner face of the washer and the frame of the instrument is 6.5 mm (this corresponds to a tension of 9 N).

5-04 Belt take-up LiHa

5-05 Belt tensioning screw

5-06 Fixing screw for belt take-up

7 Check the position of the belt take-up

fixing screws (5-06) in the slotted hole; it should be in the left third of the slot.

5-06

1/3 2/3

Figure 6-9 Tensioning the X-belt LiHa

Otherwise you need to shorten the Xbelt.

8 Tighten the belt take-up fixing screws (5-06) and glue them with Tree Bond 1342.

9 Reinstall LiHa (see Section 6.5.2, ‘Complete LiHa 1 Assembly’ or Section 6.6.2,

‘Complete LiHa 2 Assembly’) and ensure operating readiness as described in Section 6.5.10, ‘Ensure Operating Readiness’ (for LiHa 1) or Section 6.6.11, ‘Ensure Operating Readiness’ (for LiHa 2).

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For RoMa X-Belt

6 – Replacement of Spare Parts, Repair

5-15

5-16

5-14

5-17

5-24

5-23

5-18

2x M4x10

5-19

Figure 6-10 Installing X-belt RoMa

5-14 X-belt RoMa 5-18 Fixing screw/washer for belt take-up

5-15 Fixing screw for X-belt RoMa 5-19 X-slide RoMa

5-16 Belt take-up RoMa 5-23 Belt lock RoMa

5-17 Belt tensioner (belt tensioning screw/ 5-24 Driver RoMa

washer/pressure spring)

M4x60

1 Cut the new belt to required size according to the replaced one.

2 If installed: remove belt tensioning screw (5-17).

3 Fix – but do not tighten yet – the belt take-up fixing screws (5-18) which should be

positioned more likely in the left part of the slotted hole.

4 Fix one end of the X-belt (5-14) in the belt lock (5-23), then lead it over the pulleys

as shown in Figure 6-10. Insert the other belt end in the belt take-up (5-16) and fasten the fixing screws (5-15).

Make sure the belt is placed correctly over the pulleys as shown in the upper illustration of Figure 6-8.

5 Loosen the fixing screws of the driver (5-24).

6 Screw the belt tensioning screw (5-17) with washer and pressure spring into the belt

take-up (5-16) until the distance between inner face of the washer and the frame of the instrument is 6.5 mm (this corresponds to a tension of 9 N). (See Figure 6-11,

‘Tensioning the X-belt RoMa’.)

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6 – Replacement of Spare Parts, Repair

6.5 mm

5-16

5-17

5-16 Belt take-up RoMa

5-17 Belt tensioning screw

5-18 Fixing screw for belt take-up

7 Check the position of the belt take-up

fixing screws (5-18) in the slotted hole;

5-18

1/3 2/3

Figure 6-11 Tensioning the X-belt RoMa

it should be in the left third of the slot. Otherwise you need to shorten the Xbelt.

8 Tighten the belt take-up fixing screws (5-18) and glue them with Tree Bond 1342.

9 For RMP instruments only:

• Install the steel plate supporting the Supervisor/Uniport board (41, 37).

• Install system liquid container.

10 Install the X-bay covers.

11 Reinstall RoMa (see Section 6.7.2, ‘Complete RoMa 1 Assembly’ or Section 6.8.2,

‘Complete RoMa 2 Assembly’) and ensure operating readiness as described in Section 6.7.13, ‘Ensuring Operating Readiness’ (for RoMa 1) or Section 6.8.15, ‘Ensuring Operating Readiness’ (for RoMa 2).

Removal of X-motor

For Instruments without RoMa

The item numbers mentioned refer to Figure 6-5, ‘X-drive assembly for LiHa’.

1 Release tension of the X-belt as described earlier in this section (see ‘Removal of X-

Belt’, step 1 to 4).

2 Remove tubing cove

3 which is located in the left service

compartment – to access the X-motor fixing screws 5-10 (see Figure 6-12).

4 Carefully disconnect the X-motor cable

from the CU board (see Figure 6-22,

‘CU board cable connections’).

5 Open fixing screws (5-09, 5-10),

remove X-motor (5-01).

Do not attempt to remove motor cable and bracket.

Figure 6-12 Tubing cover

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6 – Replacement of Spare Parts, Repair

For Instruments with RoMa

The item numbers mentioned refer to Figure 6-6, ‘X-drive assembly for RoMa’.

1 Release tension of both X-belts as described earlier in this section (see ‘Removal of

X-Belt’, step 1 to 4), irrespective of which X-motor has to be replaced.

2 Take the RoMa X-belt (5-14) out of the belt lock (5-23).

3 Remove tubing cover – which is located in the left service compartment – to

access the X-motor fixing screws (5-10) (see Figure 6-12, ‘Tubing cover’).

4 Carefully disconnect both X-motor cables from the CU board (see Figure 6-22, ‘CU

board cable connections’).

5 Open fixing screws (5-09, 5-10, 5-20), remove complete X-motor assembly.

6 Unscrew fixing screw (5-22) to separate the two X-motors (5-01 and 5-12).

Do not attempt to remove motor cable and bracket.

Installation of X-motor

For Instruments without RoMa

The replacement X-motor is delivered with cable and bracket.

5-01

5-25

5-03

Figure 6-13 Installing X-motor LiHa

5-01 X-motor LiHa 5-09 Fixing screw for X-motor LiHa

5-02 X-motor cable LiHa (J13) 5-10 Fixing screw for X-motor LiHa

5-03 X-belt LiHa 5-25 Motor bracket

5-02

5-10

2x M4x10

5-25

5-09

3x M4x8

1 Install the X-motor (5-01) into the X-bay and tighten the fixing screws (5-09, 5-10).

2 Lead the X-motor cable trough the slot in the X-bay (see arrow in Figure 6-13) and

connect it to the CU board (J13) (see Figure 6-22, ‘CU board cable connections’).

3 Install the X-belt (5-03) as described earlier in this section (see ‘Installation of X-

Belt’, ‘For LiHa X-Belt’).

4 Install the tubing cover in the left service compartment (see Figure 6-12, ‘Tubing

cover’).

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6 – Replacement of Spare Parts, Repair

5 Reinstall LiHa (see Section 6.5.2, ‘Complete LiHa 1 Assembly’ or Section 6.6.2,

For Instruments with RoMa

The replacement X-motor is delivered with cable and bracket.

5-01

5-25

5-03

5-14

5-12

5-03

5-13 5-12

5-02

5-01

5-22

5-10

2x M4x10

Figure 6-14 Installing the X-motors

5-01 X-motor LiHa 5-12 X-motor RoMa

5-02 X-motor cable LiHa (J13) 5-13 X-motor cable RoMa (J09)

5-03 X-belt LiHa 5-14 X-belt RoMa

5-09 Fixing screw for X-motor LiHa 5-20 Fixing screw for X-motor RoMa

5-10 Fixing screw for X-motor LiHa 5-22 Fixing screw for X-motor RoMa

5-09, 5-20

5x M4x8

1 Place the two X-motors (5-01) and (5-12) on a plane surface and tighten the fixing

screw (5-22).

2 Install the X-motor assembly into the X-bay; first tighten the fixing screws (5-09) and

(5-20), then the fixing screws (5-10).

3 Lead both X-motor cables trough the slot in the X-bay (see arrows in Figure 6-14)

and connect them to the CU board (J13 = LiHa, J09 = RoMa) (see Figure 6-22, ‘CU

board cable connections’).

4 Install the X-belts (5-03, 5-14) as described earlier in this section (see ‘Installation of

X-Belt’).

5 Install the tubing cover in the left service compartment (see Figure 6-12, ‘Tubing

cover’).

6 Reinstall LiHa (see Section 6.5.2, ‘Complete LiHa 1 Assembly’ or Section 6.6.2,

‘Complete LiHa 2 Assembly’).

7 Reinstall RoMa (see Section 6.7.2, ‘Complete RoMa 1 Assembly’ or Section 6.8.2,

‘Complete RoMa 2 Assembly’.

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6 – Replacement of Spare Parts, Repair

8 Ensure operating readiness as described in

• Section 6.5.10, ‘Ensure Operating Readiness’ (for LiHa 1) or

• Section 6.6.11, ‘Ensure Operating Readiness’ (for LiHa 2) and

• Section 6.7.13, ‘Ensuring Operating Readiness’ (for RoMa 1) or

• Section 6.8.15, ‘Ensuring Operating Readiness’ (for RoMa 2).

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6 – Replacement of Spare Parts, Repair

6.3.4 Power Modules

Note

• The old generation of power modules for Genesis RSP and RWS are replaced by the power modules PM 1, PM 2 and PM 4 as of September 2001.

• For supply ratings and allocation to the different Genesis instruments refer to

Section 3.1.2, ‘Supply Ratings’.

• For more information about wiring of the power module see the appropriate wiring diagram in Section 9.2.1, ‘Power Modules’.

• Check power rating printed on the type plate of the instrument for correct identification.

Spare Parts Power Modules

For spare parts list with part numbers refer to Section 7.1.4, ‘Spare Parts Power

Modules’.

Following item can be replaced as spare parts:

• Power module

The power module as a whole part is a spare part. For safety reasons no replacement of items is allowed. Do not attempt to perform repairs within this part. Faulty wiring will seriously endanger user and instrument.

Following descriptions are valid for the old and the new types of power modules.

Switch off the mains power and disconnect the mains power connection of the instrument before performing any work!

Removal The item numbers mentioned refer to Figure 6-15.

1 Make sure the instrument is not connected to the mains and the power switch is off.

2 Move arm(s) to the middle of the instrument, open top cover (2) and right access

door (6).

3 Unscrew possibly present panel (33-04) between diluter compartment and power

module (33).

4 Remove the fixing screws (33-03), the fixing screws and sealing washers (33-01).

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6 – Replacement of Spare Parts, Repair

5x M4x10

33-01

33-03

4x M4x10

Figure 6-15 Power module (old generation) on Genesis RSP instrument

3333-04 33-02

2 Top cover

6 Right access door

33 Power module (old generation)

33-01 Fixing screws with sealing washers

33-02 Power switch

33-03 Fixing screws

33-04 Panel

5For RMP:

• Unscrew the connector sheet (see

Figure 6-16).

• Unscrew the earth cable (33-05) from instrument frame and disconnect the mains power cable from the power switch (see Figure 6-18, ‘Power switch

for RMP’).

Figure 6-16 Connector shield on RMP instrument

new

old

J11

red

black

Figure 6-17 Connection to Optibo

• Disconnect the control lamp cable from the control lamp (access from the right access door).

6 Disconnect the red and black power

cables from the Optibo/Optibo Power (see Figure 6-17, ‘Connection to

Optibo’).

7 For old generation of power modules:

disconnect the power fail cable from the Optibo/Optibo Power.

Note: for the new power modules the jumper J11 must be set on Optibo/ Optibo Power.

8 Remove the power module by carefully

pulling forward.

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6 – Replacement of Spare Parts, Repair

Installation

Switch off the mains power and disconnect the mains power connection of the instrument before performing any work!

1 Install in reverse order.

In doing so, observe the directions given hereafter:

• For RMP: when installing the power switch, note the installation diagram

33-07

(33-06) and the correct orientation of the switch according to Figure 6-18.

33-02

correct

Figure 6-18 Power switch for RMP

P2P1

view A

33-06

33-05

33-02 Power switch

33-05 Earth cable

33-06 Installation diagram

33-07 Mains power cable

• When fixing the power module to its place: tighten the fixing screws (33-03) first, hereafter the fixing screws (33-01).

Do not forget the sealing washers on all top screws (33-01).

(The item numbers mentioned refer to Figure 6-15).

• Tip for leading the power cables easily through the cable channel: fix the cables together with a strip of adhesive tape. Refer to Figure 6-17, ‘Connection to Optibo’ for correct cable connection.

• Before connecting the instrument to the mains, make sure the power switch is switched off.

2 Ensure operating readiness: control and carry out following settings:

(For detailed information refer to the Genesis Instrument Software Manual.)

Step Test or Setup

1 Random move

Attention: never perform a random move test with a Genesis RMP!

2 Liquid detection

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6.3.5 Electronic Boards

ATTENTION

Observe precautions for handling electrostatic discharge sensitive devices. Wear a wrist strap.

6 – Replacement of Spare Parts, Repair

Spare Parts Covered in This Section

For spare parts list with part numbers refer to Section 7.1.5, ‘Spare Parts Electronic

Boards’.

Following items can be replaced as spare parts:

• Optibo

• Optibo Power

• Fuses

• CU board

• X-DC-Servo board

• Supervisor board

• Uniport board

• CANDI board

• SMIO/SAFY

The PosID 1 CU board and the PosID 2 CU board are described in Section 6.9.3,

‘Electronic Boards for PosID 1’ and Section 6.10.3, ‘Electronic Boards for PosID 2’.

Optibo, Optibo Power

Optibo: for all RSP, all RMP and for RWS 100 Optibo Power: for RWS 150/200

The Optibo is located in the left service compartment. On its rear side it holds the CU board and, plugged into latter, the X-

DC-Servo board which controls the Xmotor(s) for LiHa and RoMa.

39 Optibo/Optibo Power

Figure 6-19 Optibo or Optibo Power location

Removal

1 Make sure the instrument is switched off and the mains power connection is

disconnected.

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6 – Replacement of Spare Parts, Repair

2 Disconnect all cables from Optibo/Optibo Power.

Do not forget to disconnect the Diluter cable on the solder side of the PCB.

3 Disconnect all cables from the CU board.

4 Remove Optibo/Optibo Power fixing screws, take care not to damage the PCBs

connected to the Optibo/Optibo Power rear side.

5 Disconnect CU board from Optibo/Optibo Power as described later in this section.

Installation

1 Make sure the instrument is switched off and the mains power connection is

disconnected.

2 Make sure the CU board and X-DC-Servo board (address switch must be set to #5)

are connected to the Optibo/Optibo Power rear side.

3 Control if the jumpers J12 and J13 on Optibo/Optibo Power have been set correctly

according to the configuration of the instrument (see Section 6.2.2, ‘Jumper and

Address Settings Overview’).

4 Install in reverse order.

For correct cable connection see Figure 6-20, ‘Optibo cable connections’ and

Figure 6-22, ‘CU board cable connections’.

Power fail cable (if present)

Power cable (red)

Power cable (black)

RoMa flex cable

LiHa flex cable

CAN-bus cable for options or CANDI, Uniport

Figure 6-20 Optibo cable connections

J12 J13

PC cable (RS 232)

CAN-bus cables for options

40-01

Diluter cable

39 Optibo

40 CU board

40-01 X-DC-Servo board (LiHa/RoMa)

5 Ensure operating readiness: control and carry out following tests:

(For detailed information refer to the Genesis Instrument Software Manual.)

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6 – Replacement of Spare Parts, Repair

Step Test or Setup

1 CAN-bus resistance (see Section 6.2.3)

2RoMa test

3 FWO pump test

4 PosID test

5 Incubator test

6 Random move

Attention: never perform a random move test with a Genesis RMP!

Fuses The fuses are located on the Optibo or Optibo Power.

See Figure 6-21, ‘Fuses on Optibo and Optibo Power’ for correct allocation.

39-01

Option 1Option 1

39-02

Option 5

Figure 6-21 Fuses on Optibo and Optibo Power

39-01 Fuse 6.3 AT

39-02 Fuse 8 AT, sand filled

Option 2

Option 3

Option 4

CU board

Option 1 to 4

Diluter

LiHa

RoMa

CANDI and Uniport

or Option 5

39-01

Option 1

Option 2

39-02

Option 3

Option 4

Option 5

1 Check if all the green LEDs near the fuses are on; otherwise the corresponding fuse

is blown.

Use sand filled 8 AT type fuses only – except for the fuse for the CU board, which is

6.3 AT and not sand filled.

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6 – Replacement of Spare Parts, Repair

CU Board The CU board is located in the left service compartment. As it is connected to the solder

side of the Optibo or Optibo Power, it can only be accessed by removing the Optibo/ Optibo Power.

The X-DC-Servo board, which controls the X-motors of the LiHa and RoMa, is plugged into the CU board.

Special Tools

• IC release tool

Removal

1 Switch off instrument.

2 Remove Optibo/Optibo Power as described earlier in this section (see Optibo,

Optibo Power).

3 Unscrew the CU board fixing screws. With a pair of pliers press the barbs on the two

board clips, carefully remove the CU board from the Optibo/Optibo Power.

4 Remove X-DC-Servo board.

5 Use IC release tool to remove the EEPROM (IC6) if you want to install it on the new

board (see Figure 6-22, ‘CU board cable connections’).

Use of EEPROM from the replaced CU board ! an error might be carried forward.

Use of new EEPROM ! you loose all settings.

Installation

Spare CU boards may be delivered with an older firmware version. In this case, upgrading of the firmware is necessary.

LEDs

IC6

Door lock cable left

(RMP)

RS-485 cable

I/O cable

40-01

X-motor cable RoMa

X-motor cable LiHa

Door lock cable right

(RMP)

J22

Figure 6-22 CU board cable connections

40 CU board 40-01 X-DC-Servo board

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6 – Replacement of Spare Parts, Repair

1 Control if the jumpers J1 and J22 on the CU board have been set correctly

according to the configuration of the instrument (see Section 6.2.2, ‘Jumper and

Address Settings Overview’).

2 X-DC-Servo board: check if address switch is set to #5.

3 Install in reverse order.

Refer to Figure 6-22, ‘CU board cable connections’ for correct cable connections.

4 Ensure operating readiness: control and carry out following tests:

(For detailed information refer to the Genesis Instrument Software Manual.)

Step Test or Setup

1 CAN-bus resistance (see Section 6.2.3)

2 ‘Check Error States’ as described later in this section

3 Check reference positions

– LiHa – RoMa

4 Liquid detection test

5 Disposable tips (DiTi eject test)

6 Precision test

7RoMa

8 FWO pump test

9 LICOS test

10 PosID test

11 Door lock test (RMP only)

12 Random move

Attention: never perform a random move test with a Genesis RMP!

Check Error States

• Check the LEDs on the CU board according to the following table:

Green LED Red LED Error

blinking off Normal operation

stays on or off stays on or off Fatal hardware error

blinking on Flash not accessible

blinking blinking Power fail circuit failure

blinking fast blinking fast Firmware download required

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6 – Replacement of Spare Parts, Repair

X-DC-Servo Board The X-DC-Servo board – which controls the X-motors of the LiHa and RoMa – is

plugged into the CU board that in turn is connected to the solder side of the Optibo/ Optibo Power.

It is not necessary to remove the Optibo/Optibo Power to access the X-DC-Servo board.

Removal

• From inside of the instrument remove the X-DC-Servo board from the CU board.

Installation

1 Set address switch of the X-DC-Servo

board to #5.

2 From within the instrument, connect the

40-01

X-DC-Servo board to the CU board.

39 Optibo/Optibo Power

40 CU board

40-01 X-DC-Servo board

Figure 6-23 X-DC-Servo board, connected to the CU board

3 Ensure operating readiness: control and carry out following test:

(For detailed information refer to the Genesis Instrument Software Manual.)

Step Test or Setup

1 Random move

Attention: never perform a random move test with a Genesis RMP!

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6 – Replacement of Spare Parts, Repair

Supervisor Board, Uniport Board, CANDI Board

For RMP Instruments

41, 37, 38

Figure 6-24 PCB location for RMP instruments

For RSP/RWS Instruments

39, 37, 38

The Supervisor and the Uniport boards are located in the right service compartment of the add-on module. The CANDI board may be installed either in the left service compartment (directly connected to the Optibo/Optibo Power) or in the right service compartment (connected to the Uniport).

15 Add-on module

37 Uniport board

38 CANDI board

41 Supervisor board

There is no Supervisor board necessary. The Uniport and CANDI boards may be installed either in the left service compartment (directly connected to the Optibo/Optibo Power) or in the right service compartment (connected via cable to the Optibo/Optibo Power).

1 Left access door

37 Uniport board

Figure 6-25 PCB location for RSP/RWS instruments

38 CANDI board

39 Optibo/Optibo Power

Special Tools

• IC release tool

Removal of Supervisor, Uniport, CANDI Board

The Firmware version on the new Supervisor board must be identical with the version on the now installed Supervisor board. Therefore check the Firmware version prior to replacing this PCB.

Default Firmware version on all new Supervisor PCBs is V1.21. However, an EPROM with the Supervisor Firmware V1.11 is enclosed to the delivery of a new board.

1 For Supervisor board:

• If the Firmware version of the installed PCB is different to the one on the new PCB, remove EPROM (IC7) from the installed PCB using an IC release tool.

• Disconnect LICOS and waste tubing from Supervisor board.

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6 – Replacement of Spare Parts, Repair

2 Disconnect all cables from the PCB to be removed.

3 Remove appropriate board fixing screws.

4 Carefully disconnect the board from the other connected board and remove it.

Installation

RSP, RWS

Alarm device J25

2nd RT incubator J16, J17, J12

RT incubator

Reader

Washer

OEM

Balance

OEM

Washer

Reader

RMP

IC 7 EPROM

Waste (LICOS)

System (LICOS)

J5 Niveau

CAN-bus cable

Figure 6-26 Cable connections on Supervisor, Uniport and CANDI boards

37 Uniport board 39 Optibo/Optibo Power

38 CANDI board 41 Supervisor board

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6 – Replacement of Spare Parts, Repair

1 For Supervisor board:

• If necessary: install the EPROM (IC7) with the correct Firmware version on the PCB.

• Control if address switch of the Supervisor board is set to #1.

2 Install in reverse order.

For correct cable connection refer to the respective diagram in Section 9.2.2,

‘Electronic Boards’ or to Section Figure 6-26, ‘Cable connections on Supervisor, Uniport and CANDI boards’.

3 For Uniport:

• Ensure operating readiness: control and carry out following tests:

(For detailed information refer to the Genesis Instrument Software Manual.)

Step Test or Setup

1 CAN-bus resistance (see Section 6.2.3)

2 Washer test

3 Reader test

SMIO/SAFY

The SMIO/SAFY is located in the right service compartment (connected via cable to the Optibo/Optibo Power).

The SMIO/SAFY is part of the access option for RSP and RWS instruments. Please refer to Document Doc ID 392 330 for further information.

Figure 6-27 SMIO/SAFY

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6 – Replacement of Spare Parts, Repair

6.4 Liquid System – Disassembly and Assembly Procedures

6.4.1 Overview

Definition of Liquid System

Standard Liquid System for RSP and RWS

The term “liquid system” refers to all instrument modules and parts which contain or directly influence liquid. These main components are:

• LiHa 1 and LiHa 2 (see Section 6.5 and Section 6.6)

• Tips (refer to respective Instrument Operating Manual)

• Tubing system (see Section 6.4.2)

• Diluter/Dilback (see Section 6.4.3)

•MPO/FWO* (see Section 6.4.4)

• Low volume option* (see Section 6.4.5)

• 6-way valve option* (see Section 6.4.6)

Components marked with an asterisk (*) are optional and therefore not available on all instruments.

The following figure shows the main components of a standard liquid system for RSP or RWS instruments with 8 tips and optional FWO/MPO*.

30-03

30-01

Figure 6-28 Overview of standard liquid system for RSP/RWS with 8 tips and MPO/FWO

4 Diluter 30-03 Pipetting tubing

8 LiHa1, LiHa 2 30-04 Wash station

9 Tips 30-05 Waste tubing

30-01 Aspiration tubing 32 Dilback

30-02 Interconnecting tubing 35 MPO/FWO

30-02

4, 32

30-04

30-05

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6 – Replacement of Spare Parts, Repair

Standard Liquid System for RMP

The following figure shows the main components of a standard liquid system for RMP instruments with 8 tips and optional MPO/FWO*.

30-01

Figure 6-29 Overview of standard liquid system for RMP with 8 tips and MPO/FWO

30-02

4, 32

30-05

30-03

30-04

4 Diluter 30-03 Pipetting tubing

8 LiHa1, LiHa 2 30-04 Wash station

9 Tips 30-05 Waste tubing

30-01 Aspiration tubing 32 Dilback

30-02 Interconnecting tubing 35 MPO/FWO

6.4.2 Tubing System

This section describes the customary tubing system which is available in three material variants: standard, high resistant type A, high resistant type B.

For the MPO/FWO tubing system refer to Section 6.4.4. For the Low volume option tubing system refer to Section 6.4.5. For 6-way option tubing system refer to Section 6.4.6.

Spare Parts For spare parts list with part numbers refer to Section 7.2.1, ‘Spare Parts Tubing

Systems’.

Following items can be replaced as spare parts:

• Tubing and fittings for Standard Tubing

• Tubing and fittings for High Resistant Tubing Type A (FEP/PVDF)

• Tubing and fittings for High Resistant Tubing Type B (FEP/PP)

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6 – Replacement of Spare Parts, Repair

Standard Tubing

4 Tips

30-08

8 Tips

30-03

High Resistant Tubing Type A and Type B

30-02

30-01

30-06

Figure 6-30 Standard tubing

30-01 Aspiration tubing 30-05 Waste tubing

30-02 Interconnecting tubing 30-06 I-connector

30-03 Pipetting tubing 30-07 Y-connector

30-04 Wash station 30-08 Distributor 1 to 4

4 Tips

30-07

30-10

30-08

30-07

30-08

8 Tips

30-10

30-07

30-02

30-04

30-05

30-09

30-01

Figure 6-31 High resistant tubing type A and B

30-01 Aspiration tubing 30-08 Distributor 1 to 4

30-02 Interconnecting tubing 30-09 Screw plug

30-07 Distributor 1 to 2 30-10/11 Tubing to distributor 1 to 4

6 – 48 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 August 2002

30-02

30-11

30-01

30-08

30-02

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Replacement

6 – Replacement of Spare Parts, Repair

WARNING

The liquid system may contain compounds hazardous to your health. Make sure the complete liquid system has been properly decontaminated before you perform any service tasks.

1 Empty the liquid system.

2 Switch off the instrument.

3 Replace relevant tubing.

For detailed descriptions of the exchange routines please refer to the Genesis Maintenance and Service Logbook Doc ID 390 924.

• When replacing the pipetting

800 mm

#1 #8

tubing: diluter #1 (on the far left) is connected to tip #1 (the closest to the back of the instrument), diluter #2 to tip #2 etc.

• Adjust all pipetting tubing length to 800 mm.

Do not cut the remaining tubing, but pull it back and place it in the liquid pan of the instrument.

4 Ensure Operating Readiness:

Ensure Operating Readiness

• Tightness check

• FaWa pump test

• Precision test

… as described later in this section.

Figure 6-32 Installing the pipetting tubing

Step Test or Setup

1 – Tightness check: fill/flush system and check all tubing connections

– FaWa pump test

Necessary after replacement of

• Pipetting tubing

• Interconnecting tubing

• Aspiration tubing

2 – Precision test

Necessary after replacement of

• Pipetting tubing

• Interconnecting tubing

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6 – Replacement of Spare Parts, Repair

6.4.3 Diluter and Dilback

Spare Parts For spare parts list with part numbers refer to Section 7.2.2, ‘Spare Parts Diluter/

Dilback’.

Following items can be replaced as spare parts:

• Diluters

XP 3000 XP 3000 plus

• Diluter spare part

3-way valve Syringe with flat caps, Syringe with conical caps Syringe caps, flat, Syringe caps, conical

• Dilback-8

Diluter XP 3000, XP 3000 Plus

Diluter type XP 3000 is installed on RSP, RMP and RWS instruments up to serial number 4999. Diluter type XP 3000 plus is installed on RSP, RMP and RWS instruments with serial

numbers ≥ 5000.

Overview

30-03

30-02

4-01

4-02

4-03

4 Diluter XP 3000 or XP 3000 plus

4-01 3-way valve

4-02 Syringe cap

4-03 Syringe

30-02 Interconnecting tubing (in)

30-03 Pipetting tubing (out)

Figure 6-33 Diluter – principal components

Removal

1 Empty the liquid system.

2 Switch off the instrument.

3 Open the top cover (2) of the instrument.

6 – 50 Genesis RSP, RWS and RMP Service Manual – Doc ID 391895 V1.0 August 2002