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Thermo Scientific Excelsior AS Service Manual A82310101 Issue 3

Company Information © Copyright 2013. Thermo Fisher Scientific Inc. All rights reserved. Thermo Fisher Scientific Inc. (Thermo Fisher Scientific) is the world leader in serving science, offering a unique combination of innovative technologies. Thermo Scientific is a brand name of Thermo Fisher Scientific. All other trademarks are the property of Thermo Fisher Scientific and its subsidiaries. Thermo Fisher Scientific makes every attempt to ensure that the information contained in this supporting document is correct and clearly stated, but does not accept responsibility for any errors or omissions. The development of Thermo Scientific products and services is an ongoing process. Please ensure that any published information you use as a reference is up to date and relates to the condition of the product. If necessary, check with your local Thermo Fisher Scientific representative. This document may not, in whole or in part, be copied, photocopied, reproduced, translated, or converted to any electronic or other form without prior written consent of Thermo Fisher Scientific. All information contained in this manual is proprietary and confidential, and the exclusive property of Thermo Fisher Scientific and is protected by copyright.

Contact Addresses: Thermo Shandon Limited (Trading as Thermo Fisher Scientific), Tudor Road, Manor Park, Runcorn, WA7 1TA, UK Tel: +44 (0) 1928 534 000; Fax: +44 (0) 1928 534 001; Web: www.thermoscientific.com/pathology

USA Distributor: Richard-Allan Scientific Co. Subsidiary of Thermo Fisher Scientific 4481 Campus Drive, Kalamazoo, MI 49008 USA Tel: 1-800-522-7270; Fax: +1 269-372-2674; Web: www.thermoscientific.com/pathology This instrument conforms to the essential requirements of: In Vitro Diagnostic Directive 98/79/EC Machinery Directive 2006/42/EC

iii

EMC Statement This IVD equipment complies with the emissions and immunity requirements of IEC 61326-2-6:2006. This equipment has been designed and tested to CISPR 11 Class A. It is intended for use in a laboratory environment by a trained and qualified professional. In a domestic environment it may cause radio interference, in which case it may be necessary to take measures to mitigate the interference.

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Symbols The following symbols and conventions may be used throughout this document and on the instrument: This symbol is used on the instrument, or in a document, to indicate that instructions must be followed for safe and correct operation. If this symbol appears on the instrument, always refer to the operator guide. This symbol is used on the instrument, or in a document, to indicate that there are potential biological risks associated with the instrument and / or instrument use. Always use Good Laboratory Practice. This symbol is used on the instrument, or in a document, to indicate that irritants or potentially harmful chemicals are present. Refer to the Material Safety Data Sheets for the products, and always use Good Laboratory Practice. This symbol indicates that a surface is hot. If this symbol appears on the instrument, always refer to the operator guide.

Manufacturer.

This symbol is used on the equipment, or in a document, to indicate that ESD precautions must be followed when handling ESD sensitive devices or when carrying out the procedures indicated.

This symbol is used on the instrument, or in the document, to indicate that instructions for use must be consulted.

Contents Company Information ............................................................................................................. iii EMC Statement ........................................................................................................................ v Symbols ................................................................................................................................... vi Safety Information ................................................................................................................. 1-1 General Safety ............................................................................................................................................... 1-1 Disposal of Sealed Lead Acid Batteries ........................................................................................................... 1-2 Chemical Safety ............................................................................................................................................. 1-2 Environment ................................................................................................................................................. 1-3 Warranty Statement ...................................................................................................................................... 1-3

Technical Description ............................................................................................................ 2-1 General Description ...................................................................................................................................... 2-1 Parts Identification .................................................................................................................................... 2-1 System Specifications ..................................................................................................................................... 2-2 Mechanical Specification ........................................................................................................................... 2-2 Electrical Specification ............................................................................................................................... 2-2 Interface Connections................................................................................................................................ 2-2 Fuses ......................................................................................................................................................... 2-2 Environmental Specification ...................................................................................................................... 2-3 For indoor use only. .................................................................................................................................. 2-3 Basic Structure .............................................................................................................................................. 2-4 Reaction Chamber..................................................................................................................................... 2-4 Reagent Storage Area ................................................................................................................................. 2-4 Electronics Assembly ..................................................................................................................................... 2-5 Safety Cut-out Circuit ............................................................................................................................... 2-5 Battery Backup .......................................................................................................................................... 2-5 SMPSU/Battery Detection ........................................................................................................................ 2-5 Battery Charger Circuit ............................................................................................................................. 2-5 Chamber and Wax Bath Temperature Monitoring .................................................................................... 2-6 Chamber and Wax Bath Over-Temperature (Heater Mat) Monitoring ..................................................... 2-7 Reagent (Storage) Heater Temperature Monitoring ................................................................................... 2-8 Power Supplies .......................................................................................................................................... 2-8 Wax and Chamber Heater Control............................................................................................................ 2-9 Remote Alarm Relays .............................................................................................................................. 2-10 External Connectors ................................................................................................................................ 2-10 1

Access Codes ............................................................................................................................................... 2-10

Production Services ................................................................................................................ 3-1 Introduction .................................................................................................................................................. 3-1 Production Services Screen ............................................................................................................................ 3-1 Voltages ......................................................................................................................................................... 3-2 Software, Logging and Options ..................................................................................................................... 3-3 Heater Currents............................................................................................................................................. 3-4 Temperature Settings..................................................................................................................................... 3-5 Temperature Readings ................................................................................................................................... 3-6 Pneumatics .................................................................................................................................................... 3-7 Switches, Level Sensors, PCBA Links............................................................................................................. 3-8 Fans............................................................................................................................................................... 3-9 Valve – Motor, Speed & Position ................................................................................................................ 3-10 Take Control ............................................................................................................................................... 3-11 Battery......................................................................................................................................................... 3-12 Specific Gravity ........................................................................................................................................... 3-13 Miscellaneous .............................................................................................................................................. 3-14

Functional Tests .................................................................................................................... 4-1 Earth Continuity and Insulation Resistance Tests .......................................................................................... 4-1 Production Services Automated Tests ............................................................................................................ 4-1 Test 8: Service: RC Valve Stiffness............................................................................................................. 4-1 Test 9: Service: SG Cal (Dry Cal) .............................................................................................................. 4-2 Test 10: Service: Known Fluid SG Cal (Wet Cal) ...................................................................................... 4-2 Test 11: Service: RC Leak Test .................................................................................................................. 4-3 Test 12: Service: RC Heater, Reduced Port Widths ................................................................................... 4-3 Test 18: Service: Control Motor ................................................................................................................ 4-4 Manual Tests ................................................................................................................................................. 4-6 Manual Specific Gravity Test .................................................................................................................... 4-6 Pneumatic System Tests ............................................................................................................................ 4-7 Reaction Chamber Level Sensor Testing .................................................................................................... 4-8 Production Services Voltage Tolerances ......................................................................................................... 4-9 Specific Gravity Meter Boundaries ............................................................................................................ 4-9 Parts Replacement Tests .............................................................................................................................. 4-10 Back Panel Removed Test ....................................................................................................................... 4-11 Deck Removed Test ................................................................................................................................ 4-11 Display Complete Removed Test ............................................................................................................ 4-11 2

Reaction Chamber Removed Test ........................................................................................................... 4-12 Wax Bath Removed Test ......................................................................................................................... 4-12 PSU Removed Test ................................................................................................................................. 4-13 Downdraft Fan Removed Test ................................................................................................................ 4-13 Deck Filter Switch Removed Test............................................................................................................ 4-13 Extract Fan Removed Test....................................................................................................................... 4-13 Extract Filter Microswitch Removed Test ................................................................................................ 4-13 Storage Door Sensor Removed Test......................................................................................................... 4-13 SG Assembly Components Removed Test ............................................................................................... 4-13 Reagent Heater Mat Removed Test ......................................................................................................... 4-14 Reagent Heater Thermistor Removed Test .............................................................................................. 4-14 Reaction Chamber Temperature Sensor Removed Test ........................................................................... 4-14 Hidden Bottle / Liquid Pipe Removed Test ............................................................................................. 4-14 Reaction Chamber Level Sensor Removed Test ....................................................................................... 4-14 Reaction Chamber Lid Switch Removed Test .......................................................................................... 4-14 Reaction Chamber Lid Removed Test ..................................................................................................... 4-15 Reaction Chamber Lid Seal Removed Test .............................................................................................. 4-15 Reaction Chamber Valve Motor Assembly Removed Test ....................................................................... 4-15 Reaction Chamber Rotor Removed Test ................................................................................................. 4-15 Reaction Chamber Brush Block Removed Test ....................................................................................... 4-15 Reaction Chamber Valve Seals Removed Test ......................................................................................... 4-15 Pump, Solenoid, Pressure Transducer and/or Pneumatics Removed Test ................................................ 4-16 Batteries Removed Test ........................................................................................................................... 4-16 Liquid Pipe Removed Test ...................................................................................................................... 4-16 Distribution PCB Replaced Test ............................................................................................................. 4-16 Microprocessor Replaced Test ................................................................................................................. 4-17 Digital I/O Replaced Test ....................................................................................................................... 4-17 Passive PCBA Replaced Test ................................................................................................................... 4-17 Battery Isolation Switch Replaced Test .................................................................................................... 4-17 Safety Cutout Switch Replaced Test ........................................................................................................ 4-17 DSP Display PCBA Replaced Test .......................................................................................................... 4-18 Inverter PCBA Replaced Test .................................................................................................................. 4-18

Troubleshooting .................................................................................................................... 5-1 Frequently Asked Questions .......................................................................................................................... 5-1 Action Guidance - Chamber Problems ........................................................................................................ 5-10 Valve Jammed ......................................................................................................................................... 5-10 3

Valve Turns Continuously (On Initialisation) ......................................................................................... 5-10 Valve Turns, Stops and Turns Again ....................................................................................................... 5-10 Valve Does Not Turn (Not Jammed) ...................................................................................................... 5-10 Rotary Valve Errors Engineers Log .......................................................................................................... 5-11 Air Leaks ................................................................................................................................................. 5-11 Fluid Leaks .............................................................................................................................................. 5-12 Acetone Usage ......................................................................................................................................... 5-12 Level Sensor Faults .................................................................................................................................. 5-12 Chamber Mat Heater Failure................................................................................................................... 5-12

Troubleshooting Flowcharts ................................................................................................... 6-1 Introduction .................................................................................................................................................. 6-1 Fan Errors ..................................................................................................................................................... 6-2 Downdraft Fans ........................................................................................................................................ 6-2 Extraction Fan ........................................................................................................................................... 6-3 Power Supply Errors ...................................................................................................................................... 6-4 Mains Fail ................................................................................................................................................. 6-4 Battery Isolator .......................................................................................................................................... 6-5 Process Left on Hold ..................................................................................................................................... 6-6 Lid Open Alarm ........................................................................................................................................ 6-7 Heater Faults ................................................................................................................................................. 6-8 Reaction Chamber Heat ............................................................................................................................ 6-8 Wax Heaters ................................................................................................................................................ 6-10 Wax Bath 1 Heater Fault ......................................................................................................................... 6-11 Wax Bath 2 Heater Fault ......................................................................................................................... 6-12 Wax Bath 3 Heater Fault ......................................................................................................................... 6-13 Reagent Heater ........................................................................................................................................ 6-14 Wax Under Temperature......................................................................................................................... 6-15 Underfill / Level Sensor Error .................................................................................................................. 6-16 Rotary Valve ............................................................................................................................................ 6-17 Specific Gravity ....................................................................................................................................... 6-18 Air Leak................................................................................................................................................... 6-19 Reaction Chamber................................................................................................................................... 6-23 Pipes........................................................................................................................................................ 6-26 Display Blank .......................................................................................................................................... 6-27

Exploded Drawings ................................................................................................................ 7-1 Introduction .................................................................................................................................................. 7-1 4

Top Level Parts ............................................................................................................................................. 7-2 Structure ....................................................................................................................................................... 7-3 Back Panel ..................................................................................................................................................... 7-4 Reaction Chamber......................................................................................................................................... 7-5 Deck and Display .......................................................................................................................................... 7-6 Pipes.............................................................................................................................................................. 7-7 Electronics Box .............................................................................................................................................. 7-8 Wax Tank ..................................................................................................................................................... 7-9 Specific Gravity (SG) ................................................................................................................................... 7-10 Parts List ..................................................................................................................................................... 7-11 Top level ................................................................................................................................................. 7-11 Structure ................................................................................................................................................. 7-11 Back Panel ............................................................................................................................................... 7-11 Reaction Chamber................................................................................................................................... 7-12 Deck and Display .................................................................................................................................... 7-12 Electronics Box ........................................................................................................................................ 7-13 Wax Tank ............................................................................................................................................... 7-13 Specific Gravity ....................................................................................................................................... 7-13

Parts Replacement .................................................................................................................. 8-1 Contents ....................................................................................................................................................... 8-1

Software Update Procedure .................................................................................................... 9-1 Introduction .................................................................................................................................................. 9-1 Update ...................................................................................................................................................... 9-1 Post Update ............................................................................................................................................... 9-1

Service Schedule................................................................................................................... 10-1 Excelsior Routine Maintenance Check List .................................................................................................. 10-1 Annual Maintenance Visit ....................................................................................................................... 10-1 3 Year (36 Month) Maintenance Visit ..................................................................................................... 10-5

Technical Drawings ............................................................................................................. 11-1 Introduction ................................................................................................................................................ 11-1 Digital I/O PCB ...................................................................................................................................... 11-2 Specific Gravity PCB ............................................................................................................................. 11-11 Passive I/O PCB .................................................................................................................................... 11-12 Tank Board ........................................................................................................................................... 11-15 Detector PCB ........................................................................................................................................ 11-16 Emmiter PCB........................................................................................................................................ 11-17 5

Motor PCB ........................................................................................................................................... 11-18 Distribution Board Schematic ............................................................................................................... 11-19 Electrical Schematic (Service) ................................................................................................................ 11-26 Pneumatic Schematic ............................................................................................................................ 11-31

Spares Lists ........................................................................................................................... A-1 Structure and Deck ...................................................................................................................................... A-1 Wax Baths .................................................................................................................................................... A-2 Pneumatics ................................................................................................................................................... A-2 Bottles .......................................................................................................................................................... A-2 Reaction Chamber........................................................................................................................................ A-3 Electronics .................................................................................................................................................... A-4 General Instrument Servicing ....................................................................................................................... A-5 Pipes............................................................................................................................................................. A-6 Special Tools ................................................................................................................................................ A-7 Accessories .................................................................................................................................................... A-7

Service Fault Codes ............................................................................................................... B-1 Repacking Instructions .......................................................................................................... C-1 Approved Reagents ................................................................................................................ D-1 Cleaning and Maintenance .................................................................................................... E-1 Cleaning safety and tasks ....................................................................................................... E-2 Cleaning Safety.......................................................................................................................................... E-2 Clearing Spillages ...................................................................................................................................... E-3 Daily and Weekly Cleaning Tasks ............................................................................................................. E-3 Wax and Wax Baths ...................................................................................................................................... E-4 Discarding Used Wax ................................................................................................................................ E-4 Cleaning the Wax Bath ............................................................................................................................. E-4 Reagent and Flush Bottles ............................................................................................................................. E-5 Cleaning the Reagent Supply Bottle Dip Tubes ......................................................................................... E-5 Cleaning the Flush 3 Water Bottle............................................................................................................. E-5 General Cleaning and Maintenance ............................................................................................................... E-6 Cleaning the Touchscreen Display ............................................................................................................ E-6 Changing Filters ........................................................................................................................................ E-6 Regular Maintenance Checks .................................................................................................................... E-7

Engineers Log Evaluation and Netmon .................................................................................. F-1 Introduction .................................................................................................................................................. F-1 Installation Requirements .............................................................................................................................. F-3 6

Setting Up and Configuring Netmon at Customer Sites ................................................................................ F-4 Accessing the Excelsior AS Netmon Functions .............................................................................................. F-7 Basic Operation ............................................................................................................................................. F-8 Downloading Engineers Log onto USB Device ........................................................................................... F-12 Downloading Engineers Log Remotely via Netmon .................................................................................... F-13 To close a Netmon Session .......................................................................................................................... F-14 Expanding Log.823 or Log.txt into Additional Sub Logs ............................................................................. F-15 Event Log Evaluation .................................................................................................................................. F-16 Interpreting Log Files .................................................................................................................................. F-18 Notes for Interpretation of Excelsior AS Rotary Valve Errors ....................................................................... F-21

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Excelsior AS A82310101

Contents Issue Control Issue 3

Contents Issue Control Safety Information ................................................................................................. Issue 3 Production Services ................................................................................................ Issue 3 Production Services ................................................................................................ Issue 3 Functional Tests ..................................................................................................... Issue 3 Troubleshooting ..................................................................................................... Issue 3 Troubleshooting Flowcharts ................................................................................... Issue 3 Exploded Drawings ................................................................................................ Issue 3 Parts Replacement .................................................................................................. Issue 3 Software Update Procedure ..................................................................................... Issue 3 Service Schedule ..................................................................................................... Issue 3 Technical Drawings ................................................................................................ Issue 3 Spares Lists ............................................................................................................ Issue 3 Service Fault Codes ................................................................................................ Issue 3 Repacking Instructions ........................................................................................... Issue 3 Approved Reagents .................................................................................................. Issue 3 Cleaning and Maintenance ..................................................................................... Issue 3 Engineers Log Evaluation and Netmon ................................................................... Issue 3

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1

Safety Information This section contain important information for the safe setup, use and servicing of the Excelsior AS instrument.

Excelsior AS A82310101

Safety Information Issue 3

Safety Information Thermo Fisher Scientific instruments are designed for convenient and reliable service; however, improper use or handling by a user may damage the instrument, or cause a hazard to health. The instrument must not be used in a manner not specified by Thermo Fisher Scientific. Correct maintenance procedures are essential for consistent performance. It is recommended that users secure a maintenance contract with our service department. Any problems and queries should be referred to your Thermo Fisher Scientific service department. The following sections contain important information for the safe setup and use of the instrument, and should be read and understood by the user before using the instrument.

General Safety This instrument, as supplied, conforms to IEC 61010-1 and IEC 61010-2-101; however, the addition of chemicals introduces potential hazards. Good Laboratory Practice must be employed and consideration must be given to the potential for hazard when dealing with these chemicals. Do not use the instrument in close proximity to strong electromagnetic radiation, as these may interfere with the proper operation. The electromagnetic environment should be evaluated prior to operation of the device. Good Laboratory Practice must be used when handling tissue samples to prevent cross contamination and infection. The user should complete a risk assessment to determine any potential hazards related to tissue handling. •

Do not introduce any source of ignition into, or near, the instrument once it has been loaded with reagents.

•

Do not remove any panels or access covers, unless specifically instructed to do so. The instrument does not have any user serviceable parts. Potentially lethal voltages are present inside the instrument.

•

The instrument must be properly connected to a good earth (ground) via the Mains input supply and positioned such that it is possible to interrupt the Mains supply at the source by removing the plug from the socket.

•

Use only factory approved accessories or replacement parts within the instrument.

•

Only use reagents recommended in the operator guide.

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Safety Information Issue 3

Excelsior AS A82310101

Disposal of Sealed Lead Acid Batteries The sealed lead acid batteries within this instrument need to be replaced every three years. If the instrument has mainly been operated in very low temperatures, or has been exposed to frequent Mains failures, the batteries should be replaced every year. The battery manufacturers advise their customers to comply with the relevant regulations within their particular country regarding disposal of this type of battery. The battery used within this instrument is: •

12 V 12Ah, valve regulated, sealed, lead acid type, rechargeable battery.

This battery is classified as "Class 8 & Group III UN No 2800 Batteries, wet, non-spillable, electric storage, special provision A67", and meets all requirements of the International Air Transport Association (I.A.T.A) Dangerous Goods Regulations. Batteries cannot be accessed by the customer and must only be replaced by trained service personnel.

Chemical Safety The introduction of chemicals creates potential hazards. Thermo Fisher Scientific has adopted the following position with regard to the subject of volatile chemicals used in laboratories:

1-2

•

Customers using non-specified chemicals in the instrument, do so at their own risk.

•

All chemicals recommended by Thermo Fisher Scientific have auto-ignition temperatures considerably above any surface temperatures that can be reached during a single fault failure on the instrument.

•

The instrument contains no source of ignition in any areas of the instrument where chemicals are stored, or likely to leak into, in a single fault condition.

•

The operator is fully aware of the contents of the specification documents detailing the properties of the chemicals they are using.

•

The operator has carried out any legally required assessment of chemicals used and is using Good Laboratory Practice.

•

Some chemicals which may be used during operation are flammable - do not sue sources of ignition in the vicinity of the instrument when it is loaded with reagents.

•

Harmful chemical vapours such as Xylene or Toluene may be emitted during the normal operation of some instruments and the operator should be aware of suitable precautions and safety measures.

Excelsior AS A82310101

Safety Information Issue 3

Environment This instrument is required to comply with the European Union's Waste Electrical and Electronic Equipment (WEEE) Directive 2002/96/EC. It is marked with the following symbol:

Thermo Fisher Scientific has contracts with one or more recycling / disposal companies in each EU Member State, and this product and packaging should be disposed of or recycled through them. For further information contact your Thermo Fisher Scientific service representative.

Warranty Statement Thermo Fisher Scientific is proud of their quality, reliability and of our after-sales service. We continuously strive to improve our service to our customers. Please ask your distributor or Thermo Fisher Scientific representative about service contracts which can help maintain your instrument in an optimal operating condition. Warranty provisions necessarily vary to comply with differences in national and regional legislation. Specific details can be found in the delivery documentation or from your dealer or representative. Please note that your warranty may be invalidated if: •

This instrument is modified in any way, or not used as intended by Thermo Fisher Scientific.

•

Accessories and reagents which have not been approved by Thermo Fisher Scientific are used.

•

The instrument is not operated or maintained in accordance with instructions

1-3

Technical Description This section provides an overview of the Excelsior AS automated tissue processor.

Excelsior AS A82310101

Technical Description Issue 3

Technical Description General Description Parts Identification The different components of the Excelsior AS tissue processor are shown in the diagrams below: 1

Touch screen

2

Removable tray

3

Filter compartment

4

USB port

5

Flush reagent bottles

6

Exchange bottles

7

Fixative bottles

8

Wax baths and waste wax tray

9

Reaction Chamber

10

Downdraft filter compartment

11

Electrical connections panel

12

Concealed reagent bottles

Figure 1: Excelsior AS (front view, doors open)

Figure 2: Excelsior AS (rear view) 2-1

Technical Description Issue 3

Excelsior AS A82310101

System Specifications The specifications of the Excelsior AS instrument are shown in the following tables. Use safe lifting practices when moving the instrument. Excelsior AS weighs approximately 165 kg (363 lb) when empty and 250 kg (551 lb) when full. At least two people are required to safely move the instrument.

Mechanical Specification Width

710 mm (27.9 in)

Depth

580 mm (22.8 in)

Height to working area (with tray)

1080 mm (42.5 in)

Height to top of monitor

1370 mm (54 in)

Weight with no reagents

165 kg (363 lb)

Weight with typical reagents

250 kg (551 lb)

Electrical Specification 100 - 240 VAC (~) Power Supply Voltages

Note Maximum supply voltage fluctuations not to exceed ± 10% of nominal voltage.

Frequency

50 / 60 Hz

Power

1300 VA (maximum) 300 VA (typical)

Interface Connections 24Vdc 3A max, non-powered output Remote Alarm

Note The external remote alarm system must comply with IEC60950 or IEC61010-1.

LIMS

Serial RS232 Note LIMS serial cable to have ferrite AP17168 fitted to the electronics box.

Netmon

RJ45

Test

Serial RS232

VDU

VGA

Fuses Fuses must be replaced by technically competent personnel. Remote alarm fuses (x 2) 2-2

F 5A 250V

Excelsior AS A82310101

Technical Description Issue 3

Environmental Specification For indoor use only. Temperature (operating limits)

+5°C to +40°C (+41°F to +104°F) +15°C to +30°C (+59°F to +86°F)

Temperature (recommended operation)

Performance may deteriorate when operated outside this temperature range.

Temperature (transit/storage)

-25°C to +55°C (-13°F to 131°F), +70°C (158°F) for short exposure.

Humidity

Maximum 80% RH at 31°C (88°F) decreasing linearly to 50% RH at 40°C (104°F)

Altitude

Up to 2000 m (6500 feet)

Pollution Degree

2

Over Voltage Category

II

Typical Flow Rates (measured at exhaust duct) Main Extraction Fan (Low Speed)

18 m³/h

Main Extraction Fan (High Speed)

33 m³/h

Downdraft Fan Speed

30 m³/h

Special design features of the Excelsior AS include: •

A touch screen display which displays the status of a process and the instrument in real-time

•

Simple, flexible programming to create processing programs

•

Battery back-up for enhanced specimen security and automatic underfill recovery

•

Automatic monitoring of the specific gravity of the first alcohol bottle to provide accurate information for economical reagent management. Quality Control prompts when to rotate reagents or to perform maintenance or service procedures

•

A downdraft system to remove unpleasant fumes when the Reaction Chamber lid is opened

•

A sloping glass lid to allow visual inspection of the process without the need to open the lid

•

Automated reagent rotation management - spent reagents are returned to their original bottles during processing, for safe and efficient removal

•

Use of reagents directly from manufacturer's containers (5 litres or 1 US gallon) which are located in the accessible storage area at the bottom of the instrument. Rotation group bottles are concealed, and are not handled by the operator.

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Technical Description Issue 3

Excelsior AS A82310101

Basic Structure The Thermo Scientific Excelsior AS tissue processor consists of a formed and welded sheet metal carcass, onto which the other components are mounted.

Reaction Chamber The Reaction Chamber is fastened onto supports that are welded to the carcass. The moulded deck sits over the Reaction Chamber on top of the carcass and is fastened to the carcass along the front and rear edges. Specimens are loaded into the Reaction Chamber for processing. Reagents and wax are pumped into the Reaction Chamber according to the selected program. A downdraft system operates when the Reaction Chamber lid is opened to vent any unpleasant fumes away from the operator's face, and to expel them from the rear of the instrument. A rotary valve used to select the relevant reagents is located inside the base of the Reaction Chamber. The rotor is heated by a silicone mat heater element attached to its underside. A slip ring assembly provides power to this heater. Components of the pneumatics system, incorporating the pump, solenoids and pressure transducer, are attached to the carcass at various points around the Reaction Chamber.

Reagent Storage Area The Reagent Storage Area is situated at the bottom of the instrument. There are three main areas: •

The load and unload area, where new reagents are loaded and used reagents are unloaded, and where the fixative and flush reagents are stored.

•

The wax baths that contain infiltrant.

•

The concealed bottles (at the back of the instrument) that contain dehydrants and clearant reagents.

A moulded water flush bottle is located at the bottom of the Reagent Storage Area. Six supplier's bottles containing reagents are stored in the Reagent Storage Area. Nine fixed bottles used for dehydrants and clearant reagents are hidden and are located at the rear of the instrument. A specific gravity assembly is located above the first hidden dehydrant bottle. This comprises a parallelogram type load cell, sink, and tareing mechanism mounted onto a bracket, plus a PCB mounted onto the structure. During measurement, the sink is suspended from the load cell into the dehydrant reagent. At all other times, the tareing mechanism lifts the sink off the load cell and holds it. The tareing mechanism is driven by a linear stepper motor. The stainless steel wax bath assembly is mounted underneath the Reaction Chamber inside the Reagent Storage Area. The wax tank has a hinged integrated hopper to make the loading of the wax into the 3 compartments easier. Each compartment has a silicone mat heater assembly fixed to its base. Each heater has an NTC thermistor and thermal cut-out. A second dip probe thermistor is mounted on a bracket at the rear of the tank to detect the wax temperature. An additional dip probe thermistor per compartment is mounted on the same bracket to detect low wax level. A fan draws any contaminated air from the Reagent Storage Area first through a charcoal filter, and then through a potassium permanganate filter, before expelling it from the rear of the instrument. When the Reagent Storage Area doors are opened, the fan speed increases. The speed returns to normal when the doors are closed.

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Excelsior AS A82310101

Technical Description Issue 3

Electronics Assembly Safety Cut-out Circuit The safety cut-out circuit is designed to cause the Reaction Chamber cut-off switch to disconnect the FUSED_48V supply from the Reaction Chamber valve heater (and the chamber jacket heaters). The circuit trips the chamber-cut-off switch by driving current through the ‘trip’ coil in the cut-out switch. This is sourced from the Distribution Board however the signals to trigger it come from any one of a variety of sources: •

Watchdog circuit (on the Distribution Board) will cause a trip if the processor stops toggling the circuit.

•

From the Processor (signal GC_7) via the ‘Push to Test’ switch (a trip will occur when either the Processor sets the signal high or the PTT switch is activated and breaks the signal). Note: This goes via the Digital I/O Board through the chamber trip circuit.

•

When the temperature in the chamber (NTC thermistor) is above approximately 75°C or the thermistor is short circuit. This goes via the Digital I/O Board through the chamber trip circuit.

•

When the temperature in the chamber (NTC thermistor) is below approximately -9°C or the thermistor is open circuit (or disconnected). This goes via the Digital I/O Board through the chamber trip circuit.

Battery Backup The processor memory is backed up by a NiMH battery to maintain settings when the instrument is off. While the Excelsior AS is powered, this battery is trickle-charged. The instrument uses two 12V 12Ah sealed (gel type) lead acid batteries for main battery backup to maintain operation during a temporary mains power fail. During a power fail these are configured in series to give a nominal 24V supply.

SMPSU/Battery Detection The 48V is monitored to determine whether the SMPSU is operational. In addition there is a /MAINS_OK signal from the SMPSU •

If the SMPSU is OK, the signal /MAINS_OK is low.

•

If a power cut forces the SMPSU to fail, the /MAINS_OK signal becomes open circuit and is pulled high (Distribution Board).

Battery Charger Circuit The battery charger circuit is on the Digital I/O Board. The charger has four states (refer to simplified diagram, Figure 3 below): •

Trickle charge - In this state a small trickle charge current is applied to the batteries until both the battery voltages reach the trickle charge threshold voltage (approximately 10V). If a battery is short circuited, the charger will not leave this state.

•

Bulk charge - The batteries are charged with approximately a constant current (current limited to around 1.2A) until the battery voltages reaches the over-charge voltage. Note: it is not unusual to see different currents charging each of the batteries.

•

Over charge - The voltage is held at the over-charge voltage (approximately 15V) and the current being accepted by the batteries gradually drops towards zero.

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Technical Description Issue 3 •

Excelsior AS A82310101

Float charge - Once the batteries are fully charged (when one or both batteries are drawing less than 150mA), the voltage drops to the float charge voltage (approximately 13.6V) and is held at that level.

The /CHARGE_EN signal is used to turn the charging circuit on and off (from the Processor). The state level (ST_LEV) and over charge indicator (OC_IND) signals indicate the charge state.

Figure 3: Battery charger states

Chamber and Wax Bath Temperature Monitoring The wax baths (temperature and level) and Reaction Chamber temperatures are monitored using curve-matched (to within 0.2°C, 5k resistance at 25°C) thermistors. Each thermistor is connected as the bottom resistor in a potential divider, with the top resistor being a precision 5k62. The potential divider is powered by a precision voltage reference. The centre of the divider is passed via a buffer to an ADC. Figure 4 shows how the signal to the ADC responds to changes in temperature.

Figure 4: Chamber and wax thermistors

The overall accuracy for the temperature measurements is approximately ± 0.4°C.

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Excelsior AS A82310101

Technical Description Issue 3

Chamber and Wax Bath Over-Temperature (Heater Mat) Monitoring The over-temperature monitors are thermistors similar to the wax bath and Reaction Chamber temperature monitors, (but with an accuracy of ± 0.7°C and 10k resistance at 25°C). The set-up is a similar potential-divider and buffer system as described for Chamber and Wax Bath Temperature Monitoring. There are different range requirements for the wax and chamber over-temperature monitors. The temperature curve for each is shown below in Figure 5 and Figure 6. Note: The temperature sensors in the Reaction Chamber jacket heaters have the same response as the wax heater mat over-temperature sensors.

Figure 5: Over-temperature monitors WAX

Figure 6: Over temperature monitor valve heater

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Technical Description Issue 3

Excelsior AS A82310101

Reagent (Storage) Heater Temperature Monitoring The reagent storage temperatures (in the back bottles) are monitored using 5k resistance at 25°C thermistors. A similar circuit is used to the other thermistors. Figure 7 shows how the signal to the ADC responds to changes in temperature.

Figure 7: Reagent storage thermistors

Power Supplies The 48V supply from the SMPSU connects to the Distribution Board (PL3). The voltage sense and power fail signals also connect to the Distribution Board (PL4). Supplies reference to several grounds used on the Excelsior AS.

2-8

Ground

Description

GND_POW

Power ground, used by heavy current devices (throughout the electronics). Connects to GND_DISP_PUMP_SOL (for display, pump and solenoids) at the edge connector between the Passive I/O and the Distribution Boards.

GND

Digital ground, used by the Processor Board and all other digital circuits (throughout the electronics). Connected to GND_POW via a filter (in the 12V supply circuit) on the Distribution Board.

GND_MON

Analogue ground used by monitoring circuits on the Distribution Board only. Connected to GND_POW via a low value resistor on the Distribution Board.

GND_MON2

Analogue ground used by monitoring circuits on the Digital I/O Board. Connected to GND via a zero ohm resistor on the Digital I/O Board. Connects to external devices (via the Passive I/O Board) as: GND_MON2: Reagent heater (back bottles) temperature sensors and battery temperature sensor (thermistor on the Passive I/O Board). GND_OT: Wax thermistors. GND_PRESSURE: Pressure transducer.

GND_COM2

Use for the LIMS RS232 connection only.

Excelsior AS A82310101

Technical Description Issue 3

There are several supplies: Supply

Description

+48V

48V from SMPSU (or nominal 24V from batteries during power fail) on the Distribution Board. Fused in various places on the Distribution Board for use as heater supplies and for other voltage converters.

+24V

Converted from 48V (or nominal 24V from batteries during power fail) on the Distribution Board. Fused and used for battery charging circuit (on Digital I/O Board). Also fused +24V_DISP_PUMP_SOL for display, pump and solenoids.

+12V

Converted from 48V on the Distribution Board. Fused to produce: +12VA: Used for remote alarm and battery relays, 5V supply, etc. Connects (via Passive I/O Board) to the Processor Board and the Digital I/O Board (for valve motor drive, level sensors, monitoring circuits, downdraft fan, battery trickle charge, ‘quiet’ supply for analogue circuits, etc). +12VB: Connects (via Passive I/O Board) to the fans, pressure transducer and trip switch (I_TRIP_SUPPLY).

+5V

Converted from +12VA on the Distribution Board. General purpose 5V supply, Used throughout the electronics.

+5V_PROC

5V supply for the Processor Board. Derived from the +5V supply (on the Digital I/O Board) via a low value resistor.

-5V

Converted from +5V on the Digital I/O Board. Used for the valve motor current sense circuit only.

Wax and Chamber Heater Control Fault Conditions If the processor fails to strobe HEATER_WDT_PULSE (via the I2C bus on the Distribution Board), the \HEATER_WDT_OK signal goes high which turns off the chamber base (valve) heater, the three chamber wall (jacket) heaters and the three wax heaters. It also switched off the two solenoid valves, activates the chamber trip, causes the relays to disconnect the batteries and activates the remote alarm 2 relay. If the mains supply fails (and the battery backup takes over), the signal from the SMPSU is used to initially switch off the chamber base (valve) heater, the three chamber wall (jacket) heaters and the three wax heaters. Once the Processor acknowledges the power fail and sets the ECHO_\MAINS_OK signal (via I2C on the Distribution Board) to match the signal derived from the SMPSU the heaters are re-enabled. This allows the Processor to set different demands when on mains power and when on batteries. It also helps to reduce sudden current demands on the batteries immediately after the mains power fail.

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Technical Description Issue 3

Excelsior AS A82310101

Remote Alarm Relays The connections for the relays shown on the back panel of the instrument show the relays in their normal operating conditions—Relay 1 in its unpowered state; Relay 2 in its powered state. Relay 2 is used as a power fail alarm and is in the alarm condition when Excelsior AS is first switched on. Alarm Relay

Description

Remote Alarm 1

Relay 1 (3A, 24V max).

Remote Alarm 2

Relay 2 (3A, 24V max).

Fuse 1

Fuse for Relay 1 (F5A, 250V).

Fuse 2

Fuse for Relay 2 (F5A, 250V).

External Connectors There are several external connections available on the rear panel of the electronics box: Connector

Description

VDU

Connection for external monitor.

LIMS

Serial LIMS interface.

Test

Serial test interface.

Network

Network connection for Netmon interface.

Remote Alarm 1

See Remote Alarm Relays.

Remote Alarm 2

See Remote Alarm Relays.

Access Codes The Excelsior AS has three Access Codes used to access different functions on the instrument. These are as follows: Reset Options

12345678

Admin Access

15935746

Production Services

65656565

Reset Options The reset options code allows you to update the software or return the instrument to factory settings.

Admin Access The Admin Access code allows you to enter the system and reset any forgotten access codes.

Production Services The Production Services code allows you to access Production Services and analyse and test the instrument.

2-10

Production Services This section provides information on Production Services which can be used to analyse and test Excelsior AS.

Excelsior AS A82310101

Production Services Issue 3

Production Services Introduction Use Production Services to analyse and test the Excelsior AS. To enter Production Services: 1. From the Main Screen, press the ‘Options’ button to go to the options screen. 2. Press the ‘Customer Services’ button, to go to the customer service screen. 3. Press the ‘Production Services’ button. 4. Enter the pin code ‘65656565’. 5. Press the ‘Enter Job Ref’ button. 6. Enter your job reference number, and then press the ‘Exit’ button. To exit Production Services: •

Press Exit (if no tests are running).

Production Services Screen The Production Services screen is shown below. The annotations refer to the relevant sections in the text.

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Production Services Issue 3

Excelsior AS A82310101

Voltages

No

3-2

Description

Comments

1

Mains

SMPSU 48V power fail signal – OK or Fail.

2

48V

From Mains SMPSU (or batteries during mains fail).

3

12V

12V.

4

5V

Processor 5V

5

5V

General 5V (for logic)

6

24V

Regulated 24V when on mains, unregulated from batteries during main fail.

Excelsior AS A82310101

Production Services Issue 3

Software, Logging and Options

No

Description 1

2

Comments Development Use Only

Software version

Numbers from SVN Build

APP

Application

UTL

Utility

I2C

I2C Driver

IOD

I/O Driver

LOG

Not Used

3

Service info and dates

4

IP Address

5

Instrument serial number

6

Service job number

7

Options select

Should all be OFF

8

Disk Logging

On/Off – normally Off

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Production Services Issue 3

Excelsior AS A82310101

Heater Currents

No

3-4

Description

Comments

1

Heater Budgets and Shortfall

Development Use Only

2

Wax Pipe Currents

3

Reagent Heaters 1 & 2 On/Off Indicators

4

Reagent Heaters 1 & 2 Current

5

Chamber Wall Heaters

Bottom, Middle, Top

6

Valve (Reaction Chamber)

Heater current

7

Wax1, Wax2, Wax3 Heater Currents

8

Reaction Chamber Valve

9

Wax 1, Wax 2, Wax 3 Heaters

Back Bottles (1 = On, 0 = Off)

Excelsior AS A82310101

Production Services Issue 3

Temperature Settings

No

Description

Comments

1

Chamber Wall Heaters and Wax Pipe On/Off

Chamber wall heaters and pipe heaters can be turned on and off when the cursor highlights the temperature. Press ‘Override’ to turn wall heaters on.

2

Reagent Heater

Back Bottles

3

Chamber Set Point

Trip must be in

4

Wax Set Points

Need to press ‘Start’

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Production Services Issue 3

Excelsior AS A82310101

Temperature Readings

No

3-6

Description

Comments

1

Reaction Chamber

In chamber wall

2

Chamber Wall Heaters

Bottom, Middle, Top

3

Valve OT Sensor

4

Wax 1, Wax 2, Wax 3 OT Sensors

5

Reagent Heaters Sensors

Back Bottles. X1 : A2

6

Wax Level, Wax 1, Wax 2, Wax 3

Upper, Short Probes

7

Wax Temperature, Wax 1, Wax 2, Wax 3

Lower, Longer Probes

Excelsior AS A82310101

Production Services Issue 3

Pneumatics

No

Description

Comments

1

Valve 1, Valve 2

Can be set to On or Off

2

Pump

Can be set to Off, 25%, 50%, 75%, 100%

3

Pressure

4

Pump Speed Feedback

5

Vacuum Control

Not used

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Production Services Issue 3

Excelsior AS A82310101

Switches, Level Sensors, PCBA Links

No

Description

Comments

1

Front Door

2

Chamber Lid

3

Filter D/D

Deck

4

Filter - Fix

Top

5

Filter - Charcoal

Bottom

6

Chamber Level

1-4 0.00V Not Used 123456 Processor Board

7

PCBA Links

1234 Digital I/O Board 1234 Distribution Board 12 SG Board (link 3 not fitted)

3-8

Excelsior AS A82310101

Production Services Issue 3

Fans

No

Description

Comments

1

D/D Fans Drive

2

D/D Fan 1&2 Feedback

3

RH Fan On/Off Feedback

Back Bottles. On/Off control is here

4

Extract Fan Drive

Off/Low/High

5

Extract Fan Feedback

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Production Services Issue 3

Excelsior AS A82310101

Valve – Motor, Speed & Position

No

Description

Comments

1

Motor Current Indication

2

GC8 Index Pulse Strength

3

Valve Opto Disc Sensors, Valve Position and Motor Quads

Repeat from below

4

Motor

Demand and Sense

5

Motor Drive

% Power

6

Motor Direction

Cw/Ccw

7

Motor Brake

On/Off

8

Can ‘Take Control’ from here

Refer to ‘Take Control’ section

9

Valve Opto Disc Sensors

10

Valve Position

11

Agitation Rate

12

Motor Quads

3-10

Excelsior AS A82310101

Production Services Issue 3

Take Control

No

Description 1

Release Control

2

Open Valve

3

Blow

4

Draw

5

Leaktest

Comments

3-11

Production Services Issue 3

Excelsior AS A82310101

Battery

No

Description

Comments OC ST 0 = Bulk Charge

1

Charge State Indicator

ST 0 = Over-Charge OC ST 2 = Float Charge

2

Battery Isolation Switch

ISOL or On

3

Serial Battery Relay

Normally Off, On when running on batteries to put them in series

4

Battery Relay

On/Off - connect/disconnect

5

Charger

On/Off

6

Battery Voltages

Battery A and Battery B

7

Battery Charge Currents

Battery A and Battery B

Note: Items 6 and 7, Battery A values are on the left, Battery B values are on the right. Physically Battery A (red and black wires) is furthest into the instrument, Battery B (yellow and blue wires) is closest to rear of the instrument. Battery B always has –ve terminal at 0V. Battery A has –ve terminal at 0V when charging but has –ve terminal connected to Battery B +ve terminal during mains fail when running on batteries in series (Battery A +ve terminal will be approximately 24V above 0V). When running on batteries, the voltages on screen (item 6) will nominally be: Batt 24.0 12.0V.

3-12

Excelsior AS A82310101

Production Services Issue 3

Specific Gravity

No

Description

Comments [Steps moved] [Target] (‘+’ = up, ‘-‘ = down)

1

SG Motor

2

Weight

3

SG (%)

Not Used

4

Temp

Not Used

Stopped or Moving

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Production Services Issue 3

Excelsior AS A82310101

Miscellaneous

No

3-14

Description

Comments

1

Chamber Trip

OK/ISOL

2

Alarm Relays

To remote alarm connectors

3

Chamber Trip

Drive state, Off=OK, On = driven out due to S/W, temperature, watchdog or PTT switch

4

Software Watchdog

On = running, Off = stopped

Excelsior AS A82310101

Production Services Issue 3

3-15

Functional Tests This section provides details of tests to confirm the correct operation of Excelsior AS after service or repair.

Excelsior AS A82310101

Functional Tests Issue 3

Functional Tests Earth Continuity and Insulation Resistance Tests Check the following: •

The earth continuity measures less than 1 Ω

•

The insulation resistance measures greater than 999 MΩ

Production Services Automated Tests This section describes the automated tests which are available from within Production Services: •

Test 8: Service: RC Valve Stiffness

•

Test 9: Service: SG Cal (Dry Cal)

•

Test 10: Service: Known Fluid SG Cal (Wet Cal)

•

Test 11: Service: RC Leak Test

•

Test 12: Service: RC Heater, Reduced Port Widths

•

Test 18: Service: Control Motor

Test 8: Service: RC Valve Stiffness Test 8 checks the valve turning torque and the rotor heater thermistor slip ring track at all positions to confirm electrical continuity. It will fail if the rotor temperature is greater than 45°C or less than 5°C. It also confirms the function of the Reaction Chamber liquid thermistor and trip circuit. The test turns the rotary valve, and records the motor drive current at each port position (20 open and 20 closed), through two full revolutions, this equates to turning torque. The results screen shows the maximum, minimum and average readings for each of the 40 positions: x0

x1

x2

x3

x4

x5

x6

x7

x8

x9

c-F3

Fix1

c-Fix1

Fix2

c-Fix2

A1

c-A1

Ex1

c-Ex1

A2

x10

x11

x12

x13

x14

x15

x16

x17

x18

x19

c-A2

A3

c-A3

A4

c-A4

A5

c-A5

A6

c-A6

X1

x20

x21

x22

x23

x24

x25

x26

x27

x28

x29

c-X1

Ex2

c-Ex2

X2

c-X2

X3

c-X3

WW

c-WW

W1

x30

x31

x32

x33

x34

x35

x36

x37

x38

x39

c-W1

W2

c-W2

W3

c-W3

F1

c-F1

F2

c-F2

F3

The overall maximum, minimum and average reading is also given. The test shows a fail if: •

Any single reading is greater than 2000 mA (typical maximum is 1250 mA) or less than 150 mA.

•

The average reading is greater than 1000 mA or less than 400 mA.

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Functional Tests Issue 3

Excelsior AS A82310101

Test 9: Service: SG Cal (Dry Cal) Test 9 checks and calibrates the specific gravity (SG) assembly using air only. The test will prompt you to load an empty container in the Fix 2 position. Once confirmed the machine will draw A1 into the chamber and drain it to Fix 2. The machine will then allow 600 seconds for the SG weight to dry. Note There is the option to “override” the drying time, but is not recommended unless the A1 bottle was empty to begin with. After the calibration is complete the machine will draw the contents of Fix 2 and return it to the A1 bottle. The test fails if: •

Vref is greater than 192

•

Vref is less than 80

•

Dry sensor is less than 2500

•

Volume is greater than 730

•

Volume is less than 702

•

Tare is less than 10

Test 10: Service: Known Fluid SG Cal (Wet Cal) Test 10 checks and calibrates the specific gravity (SG) assembly using air, water, and alcohol of known or measured SG. The test will prompt you to load the following reagent bottle configuration: •

Fix 1 – Water

•

EX 1 – 100% Alcohol (Please note, you will need to know the SG value of the reagent you are using)

•

Fix 2 – Empty Bottle

Once the bottle assignments are confirmed, the machine will store A1 in the Fix 2 bottle, calibration with air is then performed. Water from Fix 1 is drawn into the chamber and drained into A1, calibration with water is then performed. The water in A1 is then drawn into the chamber and drained into Fix 1. EX 1 is then drawn into the chamber and drained into A1, calibration with alcohol is then performed. The machine will then draw the contents of A1 and return it to EX1, then draw the original contents of A1 from the Fix2 and drain it back into A1. The machine will then prompt you to enter the SG value of the alcohol that A1 was calibrated with. Typically 790 for 100%. A list of SG values for the different grades of alcohol will be displayed. The test fails if:

4-2

•

Vref is greater than 192

•

Vref is less than 80

•

Dry sensor is less than 2500

•

Volume is greater than 730

•

Volume is less than 702

•

Tare is less than 10

Excelsior AS A82310101

Functional Tests Issue 3

Test 11: Service: RC Leak Test Test 11 is the leak test, accelerated for field service. Make sure the Reaction Chamber is empty and dry, as solvent in the Reaction Chamber may affect the leak rate readings. If in doubt, draw and blow water, and wipe the Reaction Chamber dry before starting the test. The test checks the closed port leak performance in all 20 positions. The test reports the time, in seconds, it takes to draw to the test vacuum (600 mbar), and reports the pressure lost (in mbar) over 30 seconds. A typical leak test value is less than 10 mbar. The first position tested (F3) uses 25% pump speed to reach test vacuum to confirm the normal operation of the pump. All other positions use 100% pump speed—this reduces the test time. The following limits apply: •

Time to evacuate chamber F3 = 60 sec ± 5 sec

•

Time to evacuate all other chamber ports = 20 sec ± 5 sec

•

Leak test fail limit = 15 mbar

•

Leak test typical value = 10 mbar

If the test fails this could be due to leaks around the lid, chamber or port spigot seals. To check the lid seal first inspect the seal and top surface for wax or debris: •

Repeat the leak test while pressing down on the lid.

•

If the test now passes, the problem is due to the lid seal flattening.

•

Measure and note down the height of the sealing lip of the seal referenced from the underside of the clamp plate (a good seal will measure approximately 4.5 mm, a bad seal typically 2-3 mm).

To check the chamber and port spigot seals: •

Ensure the valve is in a closed position.

•

Put a small amount of water in the chamber, just enough to cover the rotor.

•

Using production services draw a vacuum in the chamber and inspect for air bubbles in the water.

•

Replace the leaking seal and re-test.

Test 12: Service: RC Heater, Reduced Port Widths Test 12 has three parts: heater power and the heater thermistors, and port widths.

Heater Thermistors The check fails if the heater over-temperature thermistor and the fluid thermistor are more than 10°C different from the W2 over-temperature thermistor. Note When the instrument is in service, this part of Test 12 is likely to fail, because the Reaction Chamber will be empty and cold, and the wax baths will be at 60°C. To override the fail and proceed, press Override.

Heater Power The test checks that the Reaction Chamber heater can be powered at all 20 open and 20 closed positions, and ensures that the thermistors are functional.

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Functional Tests Issue 3

Excelsior AS A82310101

The heater is powered in all positions, and passes the test if the measured current is within the range 6.0A – 8.5A, in all cases. Otherwise, the check fails. The jacket heater test fails if: •

Top heater jacket does not reach 55°C within 7 minutes.

•

Middle heater jacket does not reach 60°C within 7 minutes.

•

Bottom heater jacket does not reach 65°C within 7 minutes.

Reduced Port Width Test 12 measures the width of the closed port at 7 front bottle positions: Never run this part of the test when the Reaction Chamber is connected to full bottles as some liquid will be drawn into the Reaction Chamber at each position and mixed. Ensure all front facing bottles are removed or empty. •

For a given closed port, a vacuum is drawn on the Reaction Chamber.

•

The valve is indexed until the vacuum starts to decay.

•

The distance the motor moves is recorded.

•

These steps are performed in both directions, for each closed port, to test whether the Opto encoder disk for the valve position is correctly adjusted.

The test fails if: •

CCW average, or CW average, is less than 190 pulses.

•

Asym is greater than 42 pulses.

Testing the Heaters on a Working Machine If you want to test the heaters on a fully working machine, you must start the test with the lid open. When the heater test has passed, press Cancel, followed by OK to exit from the test. The test completes by itself, but will take a long time and give null results.

Test 18: Service: Control Motor Use this test to run the valve motor continuously, in either direction, at a preset speed. This is useful when checking valve position data. You can also use this test to bed in a new PTFE seal, after fitting new valve seals. When a seal is first fitted, machining marks on the seal can allow very small leaks to occur. Initial rotation wears these marks away. Do not run this test with the Reaction Chamber full of reagents. •

CW – rotates clockwise.

•

CCW – rotates counter clockwise.

•

Brake – applies brake.

With the brake on, you can change the speed by typing a number from 0 to 99. Press Cancel with the brake applied to exit.

4-4

Excelsior AS A82310101

Functional Tests Issue 3

Manual Tests This section describes the manual tests which can be performed to assess the functionality of Excelsior AS: •

Manual Specific Gravity Test

•

Pneumatic System Tests

•

Reaction Chamber Level Sensor Testing

•

Production Services Voltage Tolerances

Manual Specific Gravity Test Run this test instead of the automatic wet calibration test (Test 10: Service: Known Fluid SG Cal (wet cal)), if you do not know the specific gravity of the test alcohol, and no measuring device is available. •

Enter Production Services, and move the cursor to Tare.

•

Press Up and wait until the Moving message changes to 'Transit'. 

•

In this position, the Wgt value should be 0 g ± 2 g.

Press Down and wait until the Moving message changes to 'Off'. 

In this position, the Wgt value should be 38–48 g depending on the quality of the alcohol in the A1 bottle.

Exit Production Services. •

Use the Inspect Reagents option (from the Quality Control menu) to inspect and discard A1 into an empty bottle in the Ex1 position.

Enter Production Services, and move back to Tare. •

Press Up and wait until the Moving message changes to 'Transit'. 

•

Press Down and wait until the Moving message changes to 'Off'. 

•

In this position, the Wgt value should be 105 g ± 2 g (now measuring in air).

Exit Production Services. •

Place a bottle full of water in the Ex1 position. Use the Inspect Reagents option to load water into the A1 bottle.

•

Enter Production Services, and move back to Tare.

•

Press Up and wait until the Moving message changes to 'Transit'. 

•

In this position, the Wgt value should be 0 g ± 2 g.

Press Down and wait until the Moving message changes to 'Off'. 

•

In this position, the Wgt value should be 0 g ± 2 g.

In this position, the Wgt value should be 33 g ± 2 g (now measuring in water).

Exit Production Services. •

Use the Inspect Reagents option to inspect and discard the water in A1 into the empty bottle in the Ex1 position.

•

Replace the water in Ex1 with the bottle of alcohol originally discarded. 4-5

Functional Tests Issue 3 • •

Use the Inspect Reagents option to load alcohol back into the A1 bottle.

Enter Production Services, and move the cursor to Tare. •

Press Up and wait until the Moving message changes to 'Transit'. 

•

•

In this position, the Wgt value should be 0 g ± 2 g.

Press Down and wait until the Moving message changes to 'Off'. 

•

Excelsior AS A82310101

In this position, the Wgt value should be 38–48 g depending on the quality of the alcohol in the A1 bottle, and should be similar to the measurement originally taken.

Press Up and wait until the Moving message changes to 'Transit'.

Exit Production Services.

Pneumatic System Tests Use this set of tests to confirm the function of the pneumatic system after you have replaced components. The tests supplement the fault analysis flow charts.

Pressure Transducer Test •

With the Reaction Chamber lid open, check that the displayed pressure is 1000 mbar ± 12 mbar.

•

If it is not, remove the pneumatic connection to the pressure transducer and recheck.

•

If the reading is then correct, check the pneumatic pipe work for blockages.

•

If it remains outside the range, change the transducer.

Test A Enter Production Services. •

Set Solenoid Valve 2 ‘On’, Solenoid Valve 1 ‘Off’, Pump ‘25%’.

The pump frequency should be approximately 600Hz. •

Switch off the pump.

Note For an empty dry chamber the typical normal evacuation performance is as follows: Vacuum below atmospheric (600 mbar) Time to evacuate (60 seconds)

Test B Enter Production Services. •

Set Solenoid Valve 2 ‘On’, Solenoid Valve 1 ‘Off’, Pump ‘100%’.

The pump frequency should be approximately 2000 Hz. •

Switch off the pump.

Note For an empty dry chamber the typical normal evacuation performance is as follows: Vacuum below atmospheric (600 mbar) 4-6

Excelsior AS A82310101

Functional Tests Issue 3

Tim to evacuate (20 seconds)

Test C Open the lid and cover the air inlet with your thumb. •

Valve 1 ‘Off’, Valve 2 ‘On’, Pump ‘25%’, pull down to below 500 mBar in 2 seconds and below 200 mbar in 5 seconds.

•

Close the lid and set Valve 1 ‘Off’, Valve 2 ‘On’, Pump 100%, pull down to below 600 mbar.

•

Valve 1 ‘Off’, Valve 2 ‘Off’, Pump ‘Off’ – pressure should decay by less than 30 mbar in 1 minute (typically less than 10 mbar).

•

Valve 1 ‘On’, Valve 2 ‘Off’, Pump ‘Off’ – pressure should decay by less than 30 mbar in 1 minute (typically less than 10 mbar).

•

Valve 1 ‘On’, Valve 2 ‘On’, Pump ‘Off’ – pressure should decay back to atmospheric in less than 6 seconds.

Test D If lid seal is failing: •

Press down on the lid and start Test A.

•

If the test now passes, the problem is due to the lid seal flattening.

•

Measure and note down the height of the sealing lip of the seal referenced from the underside of the clamp plate (a good seal will measure approximately 4.5 mm, a bad seal typically 2-3 mm).

If the lid seal is passing: •

Press down on the front catch only and run Test A.

•

If the test now fails, the problem is associated with the lid seal.

•

Measure and note down the height of the seal above.

Chamber Leak Test The test measures how long it takes to draw vacuum in the tank to 600 mbar (60 seconds ± 5 seconds), then measures the pressure loss in one minute (15 mbar maximum, 10 mbar typical). Enter Production Services. •

Move the cursor to Reaction Tank, Take Control, refer to Take Control section in Production Services.

•

Ensure the valve is closed, and press Leaktest. 

•

The results of the test are displayed on the screen.

Press Release Control to exit.

Reaction Chamber Level Sensor Testing Be sure to clean the sensor with the level sensor cleaning kit before testing the suspected sensor.

Supply Voltage •

Check the voltage reading is 12Vdc between the Black and Red wires. The allowable range 11Vdc to 13Vdc. 4-7

Functional Tests Issue 3

Excelsior AS A82310101

Dry Sensor •

Check the dry sensor reading (in air) is 5Vdc, via the white wire and test point 10 on the tank pcb (gc ground). The allowable range 4.5V to 5.5V.

Wet Sensor •

Check the wet sensor reading (in fluid) is less then 50mVdc, via the white wire and test point 10 on the tank pcb (gc ground).

Production Services Voltage Tolerances In Production Services, the operating voltages are displayed. The following tolerances apply: •

48V: (mains) 43.9 – 52.3 V.

•

12V: 11.1 – 12.9 V.

•

5V (general): 4.6 – 5.4 V.

•

5V (processor): 4.6 – 5.4 V.

•

24V: 21.6 – 26.4 V.

•

Wax Pipe Heater Current 0.75A Nominal.

•

Reagent (storage) Heater 1 & 2 Current 0.8A Nominal.

•

RC Wall Heater 1 (bottom) Current 2.08A Nominal (displayed as 20).

•

RC Wall Heater 2 (middle) Current 1.46A Nominal (displayed as 14).

•

RC Wall Heater 3 (top) Current 1.04A Nominal (displayed as 10).

•

RC (Valve) Heater Current 7.3A Nominal.

•

Wax Tank 1, 2 & 3 Heater Currents 3.1A Nominal.

Specific Gravity Meter Boundaries •

4-8

SG Meter Boundaries 860 – 920 (Using default settings).

Excelsior AS A82310101

Functional Tests Issue 3

Parts Replacement Tests This section describes the tests to confirm the correct function of the Excelsior AS after parts replacement. Some tests specifically confirm the new part; some confirm the function of parts displaced during servicing. •

Back Panel Removed Test

•

Deck Removed Test

•

Display Complete Removed Test

•

Reaction Chamber Removed Test

•

Wax Bath Removed Test

•

PSU Removed Test

•

Downdraft Fan Removed Test

•

Deck Filter Switch Removed Test

•

Extract Fan Removed Test

•

Extract Filter Microswitch Removed Test

•

Storage Door Sensor Removed Test

•

SG Assembly Components Removed Test

•

Reagent Heater Mat Removed Test

•

Reagent Heater Thermistor Removed Test

•

Reaction Chamber Temperature Sensor Removed Test

•

Hidden Bottle / Liquid Pipe Removed Test

•

Reaction Chamber Level Sensor Removed Test

•

Reaction Chamber Lid Switch Removed Test

•

Reaction Chamber Lid Removed Test

•

Reaction Chamber Lid Seal Removed Test

•

Reaction Chamber Valve Motor Assembly Test

•

Reaction Chamber Rotor Removed Test

•

Reaction Chamber Brush Block Removed Test

•

Reaction Chamber Valve Seals Removed Test

•

Tank Flex-Rigid PCB / Opto Disk Removed Test

•

Pump, Solenoid, Pressure Transducer and/or Pneumatics Removed Test

•

Batteries Removed Test

•

Liquid Pipe Removed Test

•

Distribution PCB Removed Test

•

Microprocessor Replaced Test

•

Digital I/O Replaced Test 4-9

Functional Tests Issue 3 •

Passive PCBA Test

•

Battery Isolation Switch Replaced Test

•

Safety Cutout Switch Replaced Test

•

DSP Display PCBA Replaced Test

•

Inverter PCBA Replaced Test

Excelsior AS A82310101

Back Panel Removed Test •

Set the reagent storage temperature to 30°C (Options > Instrument Setup > Reagent Storage Temperature).

•

In Production Services, check that RH Fan is above 80%.

If RH Fan is not above 80%: •

Check that the supply voltage on pins 1 and 3 is 12 VDC ± 0.5V.

•

Check that the concealed reagent temperature control is set to 30°C.

•

Check the fan for physical obstructions, and clean if necessary.

•

If the fan is not spinning, or the feedback signal is still less than 80%, change the fan.

Deck Removed Test After the deck is removed: •

Check the downdraft fans – left and right.

•

Open the lid.

Note Ensure that the filter is fitted in order to for the fans to operate. •

In Production Services, check operation: ON with the lid open, OFF with the lid closed (there is a delay turning the fans off when you close the lid).

•

Check the filter switch.

•

Fit the filter.

•

In Production Services, confirm the IN message.

•

Remove the filter.

•

In Production Services, confirm the OUT message.

•

Check the Display and Touchscreen function - Display Complete Removed Test.

Display Complete Removed Test Confirm function of the display: •

Turn on the instrument and wait for the main screen to be displayed.

•

Confirm the colours are displaying correctly.

•

Press Options > Customer Services > Calibrate Touchscreen.

•

Carefully press on the centre of the target (cross). Repeat as the target moves around the screen.

4-10

Excelsior AS A82310101 •

Functional Tests Issue 3

At end of test tap screen to exit back to application.

Reaction Chamber Removed Test •

Check the lid switch by opening and closing the lid and checking the screen graphics.

•

Splash the level sensors with water and check the function in Production Services.

Check the temperature sensor: •

Press the chamber trip and ensure it stays in.

•

Draw in water to above level 1.

•

Measure the temperature of the water in the chamber and make sure the screen indication is within ± 1°C. If it is not, check that the ribbon cable between the tank board and the temperature sensor connector is correctly fitted.

•

Blow the water back to the bottle.

•

Check valve motion and positioning by running the valve stiffness test (Test 8: Service: RC Valve Stiffness Test).

Check the heater and associated sensor: •

In Production Services, set the RC heater to 60°C.

•

Check that the correct heater current is displayed (7.3A, ± 1A, nominally for the rotor)

•

If no current shows, check that the 2-pin trident connector for the heater wires are installed correctly.

•

Check the valve OT temperature. It should read ambient initially, and climb, then settle at, 68°C. If the temperature reading is incorrect, check that the ribbon cable is correctly fitted to the tank board.

•

Check the Reaction Chamber wall heaters – cursor to the 3 temperature positions and press ‘Override’. Check the currents are correct (1.04A for RC heater 3, 1.46A for RC heater 2 and 2.08A for RC heater 1 Nominally). The Reaction Chamber gets hot - take care.

•

Check bottle transfers. Because all the pipes for liquid have been removed from the base of the reaction vessel, you must check they have been replaced correctly.

•

Run a short test program (one minute each step, 10 minutes for the first wax), and check the log for an acceptable transfer performance.

Wax Bath Removed Test Wax baths are identified Wax3, Wax2 and Wax1 from left to right. The wax baths get hot - take care. Check the wax bath heaters and over-temperature sensors: •

In Production Services, switch each heater on in turn to 60°C, and ensure the correct current is produced - Production Services Voltage Tolerances.

•

Feel the heater plate to confirm that the correct heater is getting warm.

•

Check that the over-temperature sensor for each heater displays ambient temperature before it is switched on, then rises to stabilise at 68°C. 4-11

Functional Tests Issue 3

Excelsior AS A82310101

Check the tank liquid thermistors and liquid level thermistors: •

Check that each thermistor displays ambient temperature. 

Hold each sensor in turn, and confirm in Production Services that the correct temperature rises. If wax bath electrical components are incorrectly wired to the plug, instrument damage may occur.

PSU Removed Test Note Ensure that the cable is correctly pushed onto the Distribution PCB, if the connection is not made fully the instrument will assume PSU failure and run at reduced power. In Production Services ensure that the SMPU 48V is ‘OK’. •

Check the 48 V reading in Production Services.

•

Ensure that the speaker sounds when the keys on the screen are pressed.

Downdraft Fan Removed Test •

Check as described for Deck Removed Test.

Deck Filter Switch Removed Test •

Check as described for Parts Deck Removed Test.

Extract Fan Removed Test In Production Services, check the extract fan operation: •

High with the main doors open.

•

Low with the main doors closed and latched.

Extract Filter Microswitch Removed Test •

Fit and remove the filters.

•

In Production Services, confirm the In and Out messages.

Storage Door Sensor Removed Test In Production Services, check the storage door sensor operation is correct: •

Displays open when unlatched.

•

Displays closed when correctly latched.

SG Assembly Components Removed Test •

Run Test 10: Service: Known Fluid SG Cal (Wet Cal). - or -

•

Run Test 9: Service: SG Cal (Dry Cal) - or -

•

4-12

Run the Manual Specific Gravity Test.

Excelsior AS A82310101

Functional Tests Issue 3

Reagent Heater Mat Removed Test •

Set the reagent storage temperature to 30°C (Options > Instrument Setup > Reagent Storage Temperature).

•

In Production Services, check RHtr1 and RHtr2. When heating, '1' displays in front of the current (typically 0.8 A).

Note The two bottles containing the temperature sensors (A2 and X1) must contain liquid (as shown on the graphical display). The Reagent Heater Fan must be connected.

Reagent Heater Thermistor Removed Test •

Measure the temperature of the liquid in the bottle before refitting the sensor.

•

In Production Services, check the temperature displayed once the sensor is refitted (A2 is displayed on the left, X1 on the right).

Reaction Chamber Temperature Sensor Removed Test •

Draw water into the Reaction Chamber above level 1 and heat to 60°C.

•

Check the temperature is the same as the display, ± 1°C.

•

When the sensor is covered with water, draw vacuum to ensure there are no air bubbles.

Hidden Bottle / Liquid Pipe Removed Test For each disturbed bottle position: •

Draw and blow liquid from the relevant position.

•

Check for very high or very low pressures, extended transfer times, bubbles in the flow of liquid into the Reaction Chamber, or leaks as liquid drains from the Reaction Chamber.

Reaction Chamber Level Sensor Removed Test •

Splash the sensor with water, and check the function in Production Services.

•

Run the Pneumatic System Tests to ensure no leaks (draw liquid in above any of the first three levels and draw vacuum to check for bubbles).

Reaction Chamber Lid Switch Removed Test •

Open and close the Reaction Chamber lid, and check the screen graphics. 

When the bottom of the lid moulding is 5 mm or more above the front lip of the Reaction Chamber, the lid shows as OPEN.



When the top of the lid moulding is 5 mm or less from the front lip of the Reaction Chamber moulding, the lid shows as CLOSED.

4-13

Functional Tests Issue 3

Excelsior AS A82310101

Reaction Chamber Lid Removed Test Open and close the Reaction Chamber lid, and check the screen graphics: •

When the bottom of the lid moulding is 5 mm or more above the front lip of the Reaction Chamber, the lid shows as OPEN.

•

When the top of the lid moulding is 5 mm or less from the front lip of the Reaction Chamber moulding, the lid shows as CLOSED.

•

Run the Pneumatic System Tests.

Reaction Chamber Lid Seal Removed Test •

Run the Pneumatic System Tests.

•

Open and close the Reaction Chamber lid and check the screen graphics.

Reaction Chamber Valve Motor Assembly Removed Test •

Run automatic Test 8: Service: RC Valve Stiffness Test.

Reaction Chamber Rotor Removed Test •

Run automatic Test 8: Service: RC Valve Stiffness Test.

•

Run automatic Test 11: Service: RC Leak Test.

•

Run automatic Test 12: Service: RC Heater, Reduced Port Widths. You must have the lid closed when you run this test. The drive hub will be removed with the rotor and will require the optics to be calibrated and the port width portion of test 12 will need to be carried out. The process is covered in the parts replacement section.

Reaction Chamber Brush Block Removed Test •

Test as per Reaction Chamber Rotor Removed Test.

Reaction Chamber Valve Seals Removed Test Test as per Reaction Chamber Rotor Removed Test.

4-14

Excelsior AS A82310101

Functional Tests Issue 3

Tank Flex-Rigid PCB / Opto Disk Removed Test (Including Disk Calibration) The Reaction Chamber must be removed to replace these parts, or to re-calibrate the Opto disk. Complete the testing before fully fitting the Reaction Chamber (electrical connections are required, but test before you refit the liquid pipes). •

Run automatic Test 8: Service: RC Valve Stiffness Test.

•

Run automatic Test 12: Service: RC Heater, Reduced Port Widths. The full test is required. You must have the lid closed when you run this test. Ensure that all the seven front bottles are removed from the instrument or empty.

Pump, Solenoid, Pressure Transducer and/or Pneumatics Removed Test •

Run the Pneumatic System Tests.

Batteries Removed Test •

Turn off the battery switch and ensure the Battery Isolation Switch icon appears.

•

Remake the switch.

•

In Production Services, select Reaction Tank, Take Control.

•

Switch off the mains supply and check the Battery Isolation Switch icon appears. 

The value displayed should be above 80% for a correctly charged battery. If it is not, the batteries are not fully charged, or are faulty.



Draw and blow of an appropriate reagent – after this process the value should still be above 80%.

Liquid Pipe Removed Test •

Draw and blow liquid from the relevant position.

•

Check for very high or very low pressures, extended transfer times, bubbles in the flow of liquid into the chamber or leaks as liquid drains from Reaction Chamber. Always ensure that pipes are fully pushed into place before undertaking any maintenance or testing.

Distribution PCB Replaced Test Note Ensure that the cable is correctly pushed onto the Distribution PCB, if the connection is not made fully the instrument will assume PSU failure and run at reduced power. In Production Services ensure that the SMPU 48V is ‘OK’. •

In Production Services, check all voltages.

•

Press the red Push-to-Test button and ensure the tank trip operates.

•

Remake the trip.

•

In Production Services, set the Reaction Chamber and wax heaters to 60°C and confirm the seven currents are OK, Production Services Voltage Tolerances. 4-15

Functional Tests Issue 3

Excelsior AS A82310101

Microprocessor Replaced Test •

Test the function of the touchscreen – Display Complete Removed Test.

•

Press the red Push-to-Test button and ensure the tank trip operates.

•

Remake the trip.

•

Using the options on the File Operations menu, load customer programs and setup (If available) to confirm the correct operation of the USB port.

•

Set time and date.

•

Switch Off and On to confirm.

Digital I/O Replaced Test •

Ensure valve initialisation completes on power up.

•

Ensure the pressure reading is 1000 ± 12 mbar with the Reaction Chamber lid open.

•

Press the red Push-to-Test button and ensure the tank trip operates.

•

Remake the trip.

•

Run automatic Test 8: Service: RC Valve Stiffness Test.

•

Open and close the lid and check the screen graphics for operation.

•

In Production Services, check the extract fan operation:

•

High with the storage door open.

•

Low with the storage door closed and latched.

Passive PCBA Replaced Test If Passive PCBA replaced, make sure you carry out the following test: •

Distribution PCB Replaced Test.

•

Microprocessor Replaced Test.

•

Digital I/O Replaced Test.

Battery Isolation Switch Replaced Test If the battery isolation switch is replaced, carry out the following test: •

Batteries Removed Test.

Safety Cutout Switch Replaced Test If the Safety Cutout switch is replaced: •

Press the red Push-to-Test button and ensure that power is cut to the RC Heaters.

•

Remake the trip.

4-16

Excelsior AS A82310101

Functional Tests Issue 3

DSP Display PCBA Replaced Test If the DSP Display PCBA is replaced, carry out the following test: •

Display Complete Removed Test.

Inverter PCBA Replaced Test If the Inverter PCBA is replaced, carry out the following test: •

Display Complete Removed Test.

4-17

Troubleshooting This section provides the solutions to common Excelsior AS faults and problems.

Excelsior AS A82310101

Troubleshooting Issue 3

Troubleshooting Frequently Asked Questions The following frequently asked questions are answered in this section: •

How do I run a process with only one fixative step? – page 5-2

•

What is the recommended way to open the lid during a process run? – page 5-2

•

Why is the minimum time in the first wax 10 minutes? – page 5-2

•

How can a step be deleted in a program? – page 5-3

•

How do I change the alcohol quality rotation setting? – page 5-3

•

How can I abort a processing run? – page 5-3

•

How do I power off Excelsior AS correctly? – page 5-3

•

How do I check an underfill? – page 5-4

•

What level is 3.8l in the Reaction Chamber? – page 5-4

•

How can I start a processing run on a step other than step 1? – page 5-4

•

How can I discard a concealed reagent or wax? – page 5-5

•

How can I load new reagent into one of the back (concealed) reagent positions? – page 5-5

•

How can I manually rotate the concealed reagents and wax baths? – page 5-6

•

Does Excelsior AS automatically update for Daylight Savings Time (DST)? – page 5-6

•

What is an alcohol hydrometer and how do I use it to check alcohol percentages? – page 5-7

•

Can I use the flush cycle to clean my embedding base moulds? – page 5-7

•

Why is my quality control usage limit count red instead of green? – page 5-8

•

Why can I not enter values other than zero on my filters in the QC screen? – page 5-8

•

How can I determine when my last reagent rotation occurred? – page 5-9

•

How can I verify that all reagent / wax positions were used during the last processing run? – page 5-9

•

How do I retrieve my tissues if an instrument malfunction occurs while the instrument is under vacuum? – page 5-9.

5-1

Troubleshooting Issue 3

Excelsior AS A82310101

How do I run a process with only one fixative step? •

From the Main menu, press Options > Edit Program. The Select a Program screen appears.

•

Press the button of the required program. The Options – Edit Program screen appears.

•

Disable the Fixative 2 step by removing the checkmark (tick) from its box. For details, see Editing a Program Flush in the Excelsior AS Operator Guide.

How do I drain the Reaction Chamber one level at a time at the completion of a processing run? •

When processing is complete, press the Drain Next Level button. For details, see Draining the Reaction Chamber in the Excelsior AS Operator Guide.

What is the recommended way to open the lid during a process run? •

Press the Lid Release button.

•

Wait until the status message says ‘Lid released’ and then open the lid. For details, see Stopping a Process in the Excelsior AS Operator Guide.

Note Opening the lid without first pressing Lid Release will result in a Lid Open Alarm fault.

Why is the minimum time in the first wax 10 minutes? This is to allow sufficient time to heat the surface of the level sensors. If the surface of the level sensors are not allowed to heat up sufficiently, a covering of wax can be left on them when the Reaction Chamber is drained. This will cause the instrument to register the presence of wax up to the affected level and continue to attempt to drain an already empty chamber. It takes ten minutes to ensure that the level sensors are all up to temperature.

5-2

Excelsior AS A82310101

Troubleshooting Issue 3

How can a step be deleted in a program? Other than for the fixatives, individual steps cannot be removed from a program. To remove an entire group of reagents (for example, Dehydrant, Clearant or Infiltration): •

Remove the checkmark (tick) from the applicable box. For details, see Editing a Program Flush in the Excelsior AS Operator Guide.

Note Entering a zero time (00:00) for a step will NOT delete the step. The appropriate reagent will still be drawn into the chamber and then immediately drained.

How do I change the alcohol quality rotation setting? •

From the Main screen, press Options > Instrument Setup > Rotation Management. The Instrument Setup – Rotation Management screen appears. Use the A1 Quality Threshold arrow keys to adjust the rotation threshold up or down in 1.25% intervals. For details, see Reagent Rotation in the Excelsior AS Operator Guide.

How can I abort a processing run? •

From the Process Monitoring screen, press Stop > Abort. The Status line will say ‘Aborting Process’ while the Reaction Chamber drains. Once the chamber is empty, the baskets can be removed and another process started, if required.

Note It is not recommended to abort a rotation run beyond the fixative step(s). All reagents and waxes should be used in a program when rotations are to take place – otherwise, a scheduled discard or replenishment might not occur.

How do I power off Excelsior AS correctly? •

Ensure that the instrument is not running a process (if it is, wait until the process has completed).

•

Switch off the main power switch, located at the back of the unit, and wait while the instrument powers down.

•

When the screen goes blank, wait approximately 10 seconds or until a ‘click’ sound is heard. It is now safe to turn off the battery switch located in the front cabinet.

5-3

Troubleshooting Issue 3

Excelsior AS A82310101

How do I check an underfill? •

From the Main screen, press Quality Control > Inspect Reagents. The Quality Control – Inspect Reagents screen appears.

•

Select the bottle that you want to inspect from the display on the left of the screen and press Inspect Reagent. The reagent is drawn into the Reaction Chamber. Once this is complete, the reagent can be topped-up by pouring additional reagent directly into the chamber.

•

When finished, close the chamber lid and press Return Reagent.

•

For the precautions that need to be observed before attempting this procedure, see Inspecting Reagents and Waxes in the Excelsior AS Operator Guide. The chamber should be empty when inspecting a reagent. Ensure that the alcohol positions are topped-up with an appropriate percentage (i.e. a percentage that is close to that recorded during inspection). The use of an alcohol hydrometer is recommended for accuracy when attempting to determine percentages. The use of an inappropriate alcohol percentage has the potential to adversely affect processing results.

What level is 3.8l in the Reaction Chamber? The level is mid-way between level sensors 2 and 3. Note: The majority of under-fill problems on Excelsior AS can be eliminated by using 5 litre reagents.

How can I start a processing run on a step other than step 1? •

From the Reaction Chamber Available screen, press the Start Step button until the desired step is reached and then press Immediate Start. The selected reagent will be drawn into the Reaction Chamber and the remainder of the process will run as programmed.

Note A delayed start function is not available when ‘step-starting’ a process run.

5-4

Excelsior AS A82310101

Troubleshooting Issue 3

How can I discard a concealed reagent or wax? •

From the Main screen, press Quality Control > Inspect Reagents. The Quality Control – Inspect Reagents screen appears.

•

Select the bottle or wax bath that you want to discard from the display on the left of the screen and press Inspect Reagent. The reagent or wax is drawn into the Reaction Chamber.

•

Once the reagent or wax has been drawn into the Reaction Chamber, press Discard to discard it.

Note If you are inspecting wax, it needs to remain in the chamber for a minimum of 10 minutes prior to pressing Discard so that the chamber has sufficient time to heat. •

Check that an empty reagent bottle or waste wax tray is in place and press Confirm Loaded. The contents of the chamber drain into the appropriate container. For details, see Inspecting Reagents and Waxes and Discarding a Reagent After Inspection in the Excelsior AS Operator Guide.

How can I load new reagent into one of the back (concealed) reagent positions? •

From the Main screen, press Quality Control > Inspect Reagents. The Quality Control – Inspect Reagents screen appears.

•

Select the empty bottle that you want to load from the display on the left of the screen and press Load Reagent.

Note The Load Reagent button is only available if the selected bottle is empty. If the selected bottle is full, its contents will need to be inspected and discarded before loading with new reagent. •

Place the new reagent into the appropriate Exchange position (Ex1 or Ex2) and press Confirm Loaded. The contents of the Exchange bottle will be drawn into the Reaction Chamber and then automatically drained into the applicable concealed reagent position.

5-5

Troubleshooting Issue 3

Excelsior AS A82310101

How can I manually rotate the concealed reagents and wax baths? •

From the Main screen, press Quality Control > Inspect Reagents. The Quality Control – Inspect Reagents screen appears.

•

Select the reagent or wax container that you want to discard from the display on the left of the screen and press Inspect Reagent. The reagent or wax is drawn into the Reaction Chamber.

•

Once the reagent or wax has been drawn into the Reaction Chamber, press Discard to discard it.

Note If you are inspecting wax, it needs to remain in the chamber for a minimum of 10 minutes prior to pressing Discard so that the chamber has sufficient time to heat. •

Check that an empty reagent bottle or waste wax tray is in place and press Confirm Loaded. The contents of the chamber drain into the appropriate container. For details, see Inspecting Reagents and Waxes and Discarding a Reagent After Inspection in the Excelsior AS Operator Guide.

•

To rotate the next reagent or wax in the sequence down to the empty position, select that reagent’s image from the display on the left of the screen and press Inspect Reagent. The reagent is drawn into the Reaction Chamber.

•

Once the reagent or wax has been drawn into the Reaction Chamber, press Rotate Reagent. The contents of the chamber will drain one position down the reagent or wax line instead of being returned to its original container.

•

Continue this process until all reagents or waxes have been rotated appropriately.

Does Excelsior AS automatically update for Daylight Savings Time (DST)? No, it does not. If located in an area where DST is observed, the time needs to be manually changed. To change the time: •

From the Main Screen press Options > Set Time. The Options – Set Time screen appears.

•

To change the hour, press Hour. The Hour button becomes highlighted in yellow.

•

Use the single arrow keys (up or down) to change the time in one-hour increments

•

Press OK to save the changes.

5-6

Excelsior AS A82310101

Troubleshooting Issue 3

What is an alcohol hydrometer and how do I use it to check alcohol percentages? A hydrometer is used to measure the specific gravity of liquids. An alcohol hydrometer measures the specific gravity of alcohol and correlates it to a scale marked on the hydrometer that measures percentage or proof, or both. To check the alcohol percentage of a concealed dehydrant position: •

From the Main screen, press Quality Control > Inspect Reagents. The Quality Control – Inspect Reagents screen appears.

•

Select the bottle that you want to inspect from the display on the left of the screen and press Inspect Reagent. The reagent is drawn into the Reaction Chamber. Once the reagent has been drawn into the Reaction Chamber, a sample can be removed for testing purposes. For details, see Inspecting Reagents and Waxes in the Excelsior AS Operator Guide.

•

Pour the sample into a tall (preferably clear) container such as a graduated cylinder.

•

Gently lower the hydrometer into the cylinder – allowing it to come to rest.

Note It is important that the hydrometer floats freely in the sample and does not touch the bottom or sides of the container. Choose a container of suitable size and fill it with an appropriate amount of sample reagent so that the hydrometer floats within it. •

To read the value of the sample, look for the point at which the top of the sample touches the hydrometer and the corresponding point on the hydrometer’s percentage / proof scale.

Note: The majority of under-fill problems on Excelsior AS can be eliminated by using 5 litre reagents.

Can I use the flush cycle to clean my embedding base moulds? No. It is recommended that the flush cycle be used solely to clean the Reaction Chamber and basket(s). Cleaning base moulds during a flush cycle increases the amount of paraffin in the flush reagents.

Flush reagents can only be used a maximum of five times.

5-7

Troubleshooting Issue 3

Excelsior AS A82310101

Why is my quality control usage limit count red instead of green? Red usage limit count:

This indicates that the quality control limit has been reached (or exceeded) for that particular reagent or filter. A yellow QC triangle will also be shown in this scenario.

Yellow usage limit count:

This indicates that there is one use remaining (or in the case of a filter, one week remaining) until the limit has been reached.

Green usage limit count:

This indicates that the count is within the defined use limit period.

To view or edit use limit settings: •

From the Main screen, press Options > Instrument Setup > Reagent Use Limits. The Instrument Setup – Reagent Use Limits screen appears. From here you can view and define the use limits for fixatives, filters and flush reagents.

Why can I not enter values other than zero on my filters in the QC screen? Counts can only be cleared on filters and flush reagents within the Quality Control screen. To view or edit use limit settings: •

From the Main screen, press Options > Instrument Setup > Reagent Use Limits. The Instrument Setup – Reagent Use Limits screen appears.

Note For the flush reagents, use limit settings cannot be increased beyond the default value of five. If required, fixative counts can be adjusted. For example, if a process run was started and aborted in the first fixative step, you may wish to adjust the Fix1 count in order to more accurately reflect actual usage. To adjust a fixative count: •

From the Main screen, press Quality Control > Detailed Information. The Quality Control – Detailed Information screen appears.

•

Select the required fixative from the display on the left of the screen. An Adjust Count button appears within the Detailed Information screen.

•

Press Adjust Count. The Adjust Count – Fixative Use Count screen appears.

•

5-8

Enter the required fixative count value and press OK to save.

Excelsior AS A82310101

Troubleshooting Issue 3

How can I determine when my last reagent rotation occurred? •

From the Main screen, press Quality Control > Detailed Information. The Quality Control – Detailed Information screen appears. This screen lists all of the concealed reagents and wax baths and for each one shows the loading date, the last rotation date and the number of times that it has been used.

How can I verify that all reagent / wax positions were used during the last processing run? •

From the Main screen, press Quality Control > Reports > Concise Event Log – View. An on-screen report appears that shows a listing of the reagent / wax positions used during a particular processing run, their order of use and the times that each one was drawn into the Reaction Chamber.

Note Reports can be viewed for the last run, the last 24 hours, or the last 7 days.

Why are my processing results very poor immediately following a reagent rotation? Check the quality of your new A6 reagent to ensure that the previously discarded A1 waste has not been accidently reloaded into the instrument: •

From the Main screen, press Quality Control > Inspect Reagents.

•

Select the A6 bottle by pressing on its image and then press Inspect Reagent. Once the reagent has been drawn into the Reaction Chamber, it can be visually inspected. For more details, refer to Inspecting Reagents and Waxes in the Excelsior AS Operator Guide.

Note If waste has been accidentally reloaded, it should be readily apparent once the reagent is visually inspected. If in doubt, a hydrometer can be used to determine the alcohol percentage. The A6 position should always contain 100% alcohol. •

If it is determined that former A1 waste has been accidentally reloaded, each position from A6 through W3 should be discarded and loaded with fresh reagent / wax. For more details, refer to Discarding a Reagent After Inspection and Loading a Reagent or Wax After Discard in the Excelsior AS Operator Guide.

•

In the event of a xylene rotation only (that is, alcohol did not rotate along with xylene), start by inspecting X3. If it is determined that former X1 waste has been accidentally reloaded, each position from X3 through W3 should be discarded and loaded with fresh reagent / wax.

How do I retrieve my tissues if an instrument malfunction occurs while the instrument is under vacuum? •

Press the Lid Release or Stop / Abort options, if available. If these options are not available, open the right door, remove the metal baffle plate and pull the red emergency vacuum release. For details, see Fitting the Filters in the Excelsior AS Operator Guide.

•

Remove all specimens from the Reaction Chamber.

5-9

Troubleshooting Issue 3

Excelsior AS A82310101

Action Guidance - Chamber Problems Valve Jammed A Reaction Chamber and digital I/O board should be sent out for this type of call when the technician is dispatched as a precautionary measure. All attempts should be made to repair the installed Reaction Chamber prior to replacing. 1. If there is evidence of leaking from the Reaction Chamber (leaking through middle of valve), replace the rotor valve assembly and also the motor if there is evidence of reagent ingress into the motor, replace motor and investigate the digital I/O board for damage. 2. If there is no evidence of leaking, replace the motor and investigate the digital I/O board for damage. 3. If the fault persists after 1 and 2 above, escalate the call to the Service Manager or Runcorn Engineering.

Valve Turns Continuously (On Initialisation) 1. Check the optos and opto disk for foreign material or signs of fluid leak. If evidence of leaking, see Fluid Leak for details. 2. Check the operation of the green LED, and the other LEDs on the encoder board, the function detail can be seen in Production Services menu. If not operating properly, use the TANK FLEXI PCB KIT Note If wax has leaked on to the encoder disk it can cause the valve to turn continuously but is likely to be specific to one or more valve positions.

Valve Turns, Stops and Turns Again 1. If there is evidence of fluid on the opto disk or motor, (leaking through middle of valve), replace the rotor valve assembly and clean the disc. 2. If the problem persists, replace the Reaction Chamber and investigate the digital I/O board for damage.

Valve Does Not Turn (Not Jammed) If there is evidence of fluid on the opto disk or motor, (leaking through middle of valve), replace the rotor valve assembly and also the motor if there is evidence of reagent ingress into the motor, investigate the digital I/O board for damage and clean the encoder disk. If there is no evidence of leaking: •

Check the connection between the motor and Tank Flexi PCB Kit for bad connections.

•

Investigate the digital I/O PCB.

•

Replace the motor.

5-10

Excelsior AS A82310101

Troubleshooting Issue 3

Rotary Valve Errors Engineers Log 1. If the valve has single stall and recovery event; take no immediate action. 2. If the valve has had up to two stall and recovery events at either the start of a program, the start of the flush cycle or drain, or any time when the valve has been stationary, then take no action other than to monitor the situation. 3. If there are no signs of fluid on the opto disk or motor and the valve has more than a single stall and recovery event in the middle of a program, or more than two stall and recovery events at the start of a program, then replace the motor and investigate the digital I/O board for damage. Note The valve will be at its stiffest after it has been stationary or after wax has been in the Reaction Chamber and allowed to solidify (dirty flush). Once the valve has started to move it should become less stiff.

Air Leaks In Production Services, draw in clean F3. Pull a vacuum manually to 600 mbar. (Valve 1 off and valve 2 on with pump at 25% will pull vacuum). Check

How to check

If Yes:

Is the vacuum line connected and able to pull vacuum?

Put your finger over the air inlet while pulling vacuum, you should feel your finger being pulled against the port.

Is the large chamber seal leaking?

Look for large bubbles around the outer perimeter of the valve plate.

Replace seal.

Is the port seal leaking?

Look for large bubbles around the port seal while port is in a closed position

Replace port seal.

Is the level sensor leaking?

Look for large bubbles around sensors.

Check seal on level sensor, replace level sensor if necessary.

Is the temp sensor leaking?

Look for large bubbles around sensor.

Check tension on temperature sensor, look for cracks. Replace temperature sensor if necessary.

Is the lid seal leaking?

Look for distortions in lid seal, listen for leaking air.

Replace lid seal.

Is the chamber top surface distorted and not sealing against the lid seal?

Apply a thin layer of dc4 (Dow Corning #4 Electrical Grease) around the lid seal and close lid. Open lid and see if any dc4 has not transferred to the chamber.

Replace the Reaction Chamber.

Is the chamber cracked anywhere?

Visually inspect the chamber.

Replace the Reaction Chamber.

5-11

Troubleshooting Issue 3

Excelsior AS A82310101

Fluid Leaks Check

If Yes

Is the leak at one of the 20 port fittings?

Fix leak or replace port fitting or tubing.

If evidence of fluid on opto disk or motor (leaking through middle of valve).

Replace rotor valve assembly, motor and investigate the digital I/O board for damage.

Is the leak at one of the sensors?

Replace the sensor.

Is the chamber cracked and leaking?

Replace the Reaction Chamber.

Acetone Usage If acetone has been used, always replace the Reaction Chamber. The Reaction Chamber should be scrapped and not rebuilt.

Level Sensor Faults Use the troubleshooting flow chart. Never replace the Reaction Chamber.

Chamber Mat Heater Failure The valve plate assembly can be replaced. The Reaction Chamber should not be replaced to repair this fault. Note To check the chamber mat heater: Prior to disassembly, be certain the mat heater or the mat heater sensors have actually failed. Check the resistance for the mat heater which should be approximately 6.5 ohms. The mat heater is made up of two heater elements in parallel, each reading approximately 12 ohms. Each element has a cut out in series. A resistance reading of 12 ohms indicates a cut out or heater element has opened. The resistance can be checked at the connector located to the left of the chamber as viewed from the rear of the unit. The wires are white. Disconnect the connector from the unit for a true reading. The temperature sensor reads 11.65K ohms at room temperature and decreases in resistance as the temperature increases. The resistance can be checked from the connector on the tank flexi PCB kit. The wires are red. Disconnect the connector from the unit for a true reading. Proceed with the replacement procedure once it has been confirmed the assembly requires replacement.

5-12

Excelsior AS A82310101

Troubleshooting Issue 3

5-13

Troubleshooting Flowcharts This section provides flowcharts which can be used to troubleshoot common Excelsior AS faults and problems.

Excelsior AS A82310101

Troubleshooting Flowcharts Issue 3

Troubleshooting Flowcharts Introduction This section provides flowcharts that can be used to troubleshoot the following faults and problems: •

Fan Errors

6-2

•

Power Supply Errors

6-4

•

Lid Open Alarm

6-7

•

Heater Faults

6-8

•

Underfill / Level Sensor Error

6-16

•

Rotary Valve

6-17

•

Specific Gravity

6-18

•

Air Leak

6-19

•

Reaction Chamber

6-23

•

Pipes

6-26

•

Display Blank

6-27

6-1

Troubleshooting Flowcharts Issue 3

Excelsior AS A82310101

Fan Errors Downdraft Fans The downdraft fans are used to pull air that may be contaminated with reagent vapour away from the Reaction Chamber when the lid is open. The fans should turn on when the lid is opened. When running a program, press the Lid Release button to release any vacuum and start the fans. The air is drawn through two axial fans and pushed through a filter at the back of the unit, or into the house ventilation system. Note The downdraft system only operates when either the downdraft filter or the downdraft vent adaptor is fitted.

Alarm Codes •

AL_DOWNDRAFT_FAN_LEFT

2

•

AL_DOWNDRAFT_FAN_RIGHT

3

Flowchart

6-2

Excelsior AS A82310101

Troubleshooting Flowcharts Issue 3

Extraction Fan The extraction fan is used to extract fumes from within the Reagent Storage Area at the front of the unit. The extraction fan should turn on when the front door is opened. The fan pulls air through two filters, normally potassium permanganate and activated carbon, to extract the vaporised reagent from the air prior to re-circulating the air back to the laboratory.

Error Code •

AL_EXTRACT_FAN

4

Flowchart

6-3

Troubleshooting Flowcharts Issue 3

Excelsior AS A82310101

Power Supply Errors Mains Fail Voltage is supplied to the unit via a power cord, power entry module and a switch mode power supply. Input power should be 100 – 240V, 50/60 Hz. The mains fail alarm indicates that there has been an interruption to the power. If the unit is on and the display is powered, this may be a normal power interruption. If the power is not on to the unit, use the following chart.

Error Code •

AL_MAINS_FAIL

Flowchart

6-4

7

Excelsior AS A82310101

Troubleshooting Flowcharts Issue 3

Battery Isolator The Battery Isolation switch is used to disconnect the battery from the electrical circuit during shipping. It is located inside the front reagent storage cabinet on the top right-hand side. A Battery Isolation switch icon appears at the bottom of the display when the isolator is tripped.

Error Code •

AL_BATTERY_ISOLATOR

8

Flowchart

6-5

Troubleshooting Flowcharts Issue 3

Excelsior AS A82310101

Process Left on Hold If you press the Stop button, the process is put on hold. If you do not restart the program within a predefined interval, an alarm sounds.

Error Code •

AL_PROCESS_LEFT_ON_HOLD

Flowchart

6-6

12

Excelsior AS A82310101

Troubleshooting Flowcharts Issue 3

Lid Open Alarm The status of the lid is determined by a magnet within the lid and a proximity sensor mounted under the front edge of the Reaction Chamber. When the lid is closed, the magnet holds the switch closed. When the lid is open and the magnet is far enough from the switch, the contacts open, alerting the processor PCB that the lid is open.

Error Code •

AL_LID_OPEN_ALARM

13

Flowchart

6-7

Troubleshooting Flowcharts Issue 3

Excelsior AS A82310101

Heater Faults Reaction Chamber Heat Error Codes •

AL_CHAMBER_HEAT_CUTOUT

16

•

AL_CHAMBER_HEAT_MAT

17

Flowchart

6-8

Excelsior AS A82310101

Troubleshooting Flowcharts Issue 3

6-9

Troubleshooting Flowcharts Issue 3

Excelsior AS A82310101

Wax Heaters The wax baths are set to one operating temperature. Each wax bath has a heater plate in the bottom of the bath and a temperature sensor attached to the plate. The temperature of each heater plate is displayed in Production Services with the temperature readout. A second temperature sensor hangs into the wax, and is used to control the wax temperature and to display the actual temperature. If the wax is not high enough to reach the sensor, the base sensor keeps the wax molten, although it is less precise. During the melt cycle, the base temperature can reach 90°C. During normal control cycles, the base should never go below the set point and can go as high as 8°C above the set point. If a melt cycle is initiated before the paraffin pellets are added, the melt cycle ends and the normal control cycle starts. This can significantly lengthen the melt time. The temperature of the heater plate is displayed in Production Services as Wax1OT, with the temperature readout.

6-10

Excelsior AS A82310101

Troubleshooting Flowcharts Issue 3

Wax Bath 1 Heater Fault Error Code •

AL_WAX1_HEATER_MAT

18

Flowchart

6-11

Troubleshooting Flowcharts Issue 3

Excelsior AS A82310101

Wax Bath 2 Heater Fault The temperature of the heater plate for Wax Bath 2 is displayed in Production Services as Wax2OT, with the temperature readout.

Error Code •

AL_WAX2_HEATER_MAT

Flowchart

6-12

19

Excelsior AS A82310101

Troubleshooting Flowcharts Issue 3

Wax Bath 3 Heater Fault The temperature of the heater plate for Wax Bath 3 is displayed in Production Services as Wax3OT, with the temperature readout.

Error Code •

AL_WAX3_HEATER_MAT

20

Flowchart

6-13

Troubleshooting Flowcharts Issue 3

Excelsior AS A82310101

Reagent Heater Error Code •

AL_REAGENT_HEATER_MAT

Flowchart

6-14

21

Excelsior AS A82310101

Troubleshooting Flowcharts Issue 3

Wax Under Temperature Error Code •

AL_WAX_UNDER_TEMP

22

Flowchart

6-15

Troubleshooting Flowcharts Issue 3

Excelsior AS A82310101

Underfill / Level Sensor Error Error Code •

AL_LEVEL_SENSOR

Flowchart

6-16

23

Excelsior AS A82310101

Troubleshooting Flowcharts Issue 3

Rotary Valve The rotary valve is a fluid select valve that has 20 open position ports, and one closed port between each open port. If the valve cannot find the correct open or closed position, a rotary valve alarm is displayed.

Error Code •

AL_ROTARY_VALVE

25

Flowchart

6-17

Troubleshooting Flowcharts Issue 3

Excelsior AS A82310101

Specific Gravity The A1 bottle, normally used for the first alcohol, has a specific gravity (SG) measuring device attached to the top of the bottle. Each time the A1 solution drains into the A1 bottle, a measurement is taken and updated on the display (the measurement is not taken if A1 is the final, or only, step of the process cycle). The SG device consists of a sensor that weighs a weight that hangs inside the A1 bottle. The weight is converted to an SG value. Between measurements, a motor raises the weight off the scale to prevent damage to the scale. During preparation to take a reading the motor drives the assembly upward, often making a vibrating noise. The setup values for the SG are stored on the specific gravity PCB.

Error Code •

AL_SPECIFIC_GRAVITY

Flowchart

6-18

26

Excelsior AS A82310101

Troubleshooting Flowcharts Issue 3

Air Leak Error Code •

AL_AIR_LEAK

28

Flowcharts Step 1

6-19

Troubleshooting Flowcharts Issue 3

Step 2

6-20

Excelsior AS A82310101

Excelsior AS A82310101

Troubleshooting Flowcharts Issue 3

Step 3

6-21

Troubleshooting Flowcharts Issue 3

Step 4

6-22

Excelsior AS A82310101

Excelsior AS A82310101

Troubleshooting Flowcharts Issue 3

Reaction Chamber Error Code •

AL_CHAMBER_BOT

29

•

AL_CHAMBER_MID

30

•

AL_CHAMBER_TOP

31

Flowchart

6-23

Troubleshooting Flowcharts Issue 3

6-24

Excelsior AS A82310101

Excelsior AS A82310101

Troubleshooting Flowcharts Issue 3

6-25

Troubleshooting Flowcharts Issue 3

Excelsior AS A82310101

Pipes Error Code •

AL_PIPE

Flowchart

6-26

32

Excelsior AS A82310101

Troubleshooting Flowcharts Issue 3

Display Blank Flowchart

6-27

Exploded Drawings This section provides exploded drawings for Excelsior AS.

Excelsior AS A82310101

Exploded Drawings Issue 3

Exploded Drawings Introduction This section provides exploded drawings of the main component areas of the Excelsior AS tissue processor. Parts are labelled and cross referenced to a parts list at the end of this section. Drawings and parts lists of the following component areas are provided: •

Top Level Parts

•

Structure

•

Back Panel

•

Reaction Chamber

•

Deck and Display

•

Pipes

•

Electronics Box

•

Wax Tank

•

Specific Gravity (SG)

7-1

Exploded Drawings Issue 3

Top Level Parts

7-2

Excelsior AS A82310101

Excelsior AS A82310101

Exploded Drawings Issue 3

Structure

7-3

Exploded Drawings Issue 3

Back Panel

7-4

Excelsior AS A82310101

Excelsior AS A82310101

Exploded Drawings Issue 3

Reaction Chamber

7-5

Exploded Drawings Issue 3

Deck and Display

7-6

Excelsior AS A82310101

Excelsior AS A82310101

Exploded Drawings Issue 3

Pipes

7-7

Exploded Drawings Issue 3

Electronics Box

7-8

Excelsior AS A82310101

Excelsior AS A82310101

Exploded Drawings Issue 3

Wax Tank

7-9

Exploded Drawings Issue 3

Specific Gravity (SG)

7-10

Excelsior AS A82310101

Excelsior AS A82310101

Exploded Drawings Issue 3

Parts List Top level Label

Name

TL1

Deck Assembly

TL2

Reaction Chamber

TL3

Wax Tank Assembly

TL4

Structure

TL5

SG Assembly

TL6

Back Panel Assembly

TL7

Electronics Assembly

Structure Label

Name S1

Ball Transfer Unit

S2

Side Insulation

S3

Plinth Insulation

S4

Fan Spacer

S5

Fan Gasket

S6

Extraction Fan

S7

Main Door Sensor (opto interrupter)

S8

Reagent Bottle Heater Mat

S9

Reagent Bottle Heater Thermistor

S10

Pump Plate Assembly

S11

Pressure Transducer

S12

Solenoid

S13

Fixed Reagent Bottle

S14

Water Flush Bottle

S15

Battery

S16

Battery On/Off Switch

S17

Reaction Chamber Heater Cut-out - 80V DC, 30A

S18

Vacuum Release Plug

S19

A1 Bottle Support Foam

S20

Container 5Litre

DD2

Filter Sensor

Back Panel Label

Name

BP1

Bottle Heating Fan

BP2

Instrument Moving Handle

7-11

Exploded Drawings Issue 3

Reaction Chamber Label

Name

RC1

Upper Agitate Coupling

RC2

Agitate Bearing

RC3

Brush Block

RC4

Encoder Disk

RC5

Level Sensor

RC6

Lid Switch

RC7

Motor Assembly

RC8

Reaction Chamber Lid Assembly

RC9

Reaction Chamber Lid Seal

RC10

Reaction Chamber Thermistor

RC11

Reaction Chamber Wall Heater

RC12

Heater Insulation

RC13

Insulation Tape (200 mm)

RC14

Tie wrap

RC15

Valve Port Seal

RC16

Valve Port Insert Static Seal

RC17

Rotor Outer Seal

RC18

Brush Block Insulation Disc

RC19

Valve Rotor Assembly

RC20

Tank PCB kit

RC21

Screw, Cap, M4

RC22

Insulation Tape (700 mm)

RC23

Heat Dispersion Plate

RC24

Chamber Lid Handle

Deck and Display Label

7-12

Name

DD1

Downdraft Fan Assembly

DD2

Filter Sensor

DD3

Display Complete

DD4

Pivoting Filter Lid

DD5

Filter Microswitch Bracket Assembly

DD6

Display Driver PCB

DD7

Display Inverter PCB

DD8

Display Rear Moulding

DD9

Top Deck Assembly

Excelsior AS A82310101

Excelsior AS A82310101

Exploded Drawings Issue 3

Electronics Box Label

Name

EB1

Processor PCB

EB2

Digital IO PCB

EB3

Distribution PCB

EB4

Passive PCB

EB5

Switch

EB6

Power Supply Unit

EB7

Speaker

Wax Tank Label

Name

WT1

Wax Temperature Sensor

WT2

Wax Heater

WT3

Wire Retaining Foam

Specific Gravity Label

Name

SG1

Specific Gravity Weight Assembly

SG2

Lift arm Specific Gravity Unit

SG3

Specific Gravity Suspension Bar

SG4

Specific Gravity Linear Actuator

SG5

Specific Gravity Sensor with Bracket

SG6

Anti-Evaporation Tube and Gasket

SG7

Cable tie

SG8

Specific Gravity Bottle Assembly

SG9

Specific Gravity PCB

7-13

Parts Replacement This section describes the parts replacement procedures for Excelsior AS. In this Section: Access Panels Parts Replacement Procedures Structure & Deck Parts Replacement Procedures Reaction Chamber Parts Replacement Procedures Concealed Bottles Parts Replacement Procedures Wax Baths Parts Replacement Procedures Pneumatics Parts Replacement Procedures Electronics Parts Replacement Procedures

Excelsior AS A82310101

Parts Replacement Issue 3

Parts Replacement Contents Parts Replacement .............................................................................................................. 8-1 Contents ................................................................................................................................................... 8-1

Access Panels Procedures ............................................................................................... 8.1.1-1 Removing the Back Panel .................................................................................................................... 8.1.1-1 Removing the Service Panel Assembly ................................................................................................. 8.1.2-1

Structure Deck Procedures ............................................................................................ 8.2.1-1 Removing the Deck ............................................................................................................................. 8.2.1-1 Replacing the Downdraft Fans ............................................................................................................ 8.2.2-1 Replacing the Filter Sensor .................................................................................................................. 8.2.3-1 Replacing the Pivoting Filter Lid ......................................................................................................... 8.2.4-1 Replacing the Display Complete.......................................................................................................... 8.2.5-1

Reaction Chamber Procedures ....................................................................................... 8.3.1-1 Removing the Reaction Chamber ........................................................................................................ 8.3.1-1 Replacing the Reaction Chamber Thermistor ...................................................................................... 8.3.2-1 Replacing the Level Sensors or Lid Switch ........................................................................................... 8.3.3-1 Removing the Motor ........................................................................................................................... 8.3.4-1 Removing the Motor In Situ ............................................................................................................... 8.3.5-1 Replacing the Disk and Calibrating the Optics .................................................................................... 8.3.6-1 Removing the Flexi-Rigid PCB............................................................................................................ 8.3.7-1 Removing the Lid ................................................................................................................................ 8.3.8-1 Changing the Lid Seal ......................................................................................................................... 8.3.9-1 Removing the Brush Block PCB ........................................................................................................ 8.3.10-1 Removing the Chamber Wall Heater ................................................................................................. 8.3.11-1 Removing the PTFE Seal................................................................................................................... 8.3.13-1 Removing the Brush Block Insulation ............................................................................................... 8.3.14-1 Removing the Lid Handle ................................................................................................................. 8.3.15-1 Removing the Valve Rotor Assembly Complete ................................................................................. 8.3.16-1 Removing the Port Seal ..................................................................................................................... 8.3.17-1 Removing the Upper Coupling and Agitate Bearing .......................................................................... 8.3.18-1

Concealed Bottles Procedures ........................................................................................ 8.4.1-1 Removing the Bottles .......................................................................................................................... 8.4.1-1 Removing the Specific Gravity Unit .................................................................................................... 8.4.2-1 8-1

Parts Replacement Issue 3

Excelsior AS A82310101

Disassembling the Specific Gravity Unit .............................................................................................. 8.4.3-1 Removing and Replacing the Reagent Heaters ..................................................................................... 8.4.6-1 Replacing the Bottle Heating Fan ........................................................................................................ 8.4.7-1 Replacing the Bottle Heating Thermistors ........................................................................................... 8.4.8-1

Wax Baths Procedures ................................................................................................... 8.5.1-1 Replacing the Heater ........................................................................................................................... 8.5.1-1 Special Tools and Materials ................................................................................................................. 8.5.1-1 Procedure ............................................................................................................................................ 8.5.1-1 Removing the Temperature and Level Sensors ..................................................................................... 8.5.2-1 Removing the Wax Baths .................................................................................................................... 8.5.3-1

Pneumatics Procedures.................................................................................................. 8.6.1-1 Removing the Solenoid Assembly and Pressure Transducer ................................................................. 8.6.1-1 Special Tools and Materials ................................................................................................................. 8.6.1-1 Procedure ............................................................................................................................................ 8.6.1-1 Removing the Solenoids from the Plate ............................................................................................... 8.6.2-1 Removing the Pump Assembly ............................................................................................................ 8.6.3-1

Electronics Procedures .................................................................................................. 8.7.1-1 Removing the Front Panel and PCBs .................................................................................................. 8.7.1-1 Replacing Remote Alarm Fuses............................................................................................................ 8.7.2-1 Removing the Passive PCBA ............................................................................................................... 8.7.3-1 Removing the Speaker ......................................................................................................................... 8.7.4-1 Removing the Power Supply Unit ....................................................................................................... 8.7.6-1 Removing the Electronics Assembly..................................................................................................... 8.7.7-1 Replacing the Battery Isolation Switch................................................................................................. 8.7.8-1 Replacing the Safety Cut-out Switch ................................................................................................... 8.7.9-1 Replacing the Extraction Fan ............................................................................................................. 8.7.10-1 Replacing the Door Sensor ................................................................................................................ 8.7.11-1 Removing the Filter Switches ............................................................................................................ 8.7.12-1 Replacing the Batteries ...................................................................................................................... 8.7.13-1 Replacing the DSP Display Fused PCBA ........................................................................................... 8.7.14-1 Replacing the Inverter PCBA............................................................................................................. 8.7.15-1

8-2

Excelsior AS A82310101

Parts Replacement Issue 3

8-3

Parts Replacement Issue 3

8-4

Excelsior AS A82310101

Access Panels: Parts Replacement Procedures In this Section: Removing the Back Panel ..................................................................................................................... (Issue 3) Removing the Service Panel Assembly .................................................................................................. (Issue 3)

Access Panels Issue 1

ii

Excelsior AS A82310101

Excelsior AS A82310101

Removing the Back Panel Issue 3

Access Panels Procedures Removing the Back Panel Special Tools and Materials None required.

Procedure

1. Turn the quarter-turn fasteners anti-clockwise and release the back panel.

2. Angle the back panel slightly to gain access to the fan connector and the earth lead on the rear of the panel.

3. Disconnect the fan connector and earth lead.

8.1.1-1

Removing the Back Panel Issue 3

Excelsior AS A82310101

4. Remove the back panel. To refit the Back Panel, carry out the following: 5. Position the Back Panel in place on the instrument. 6. Connect the Fan Connector and Earth Lead to the Back Panel. 7. Push the Back Panel into place and turn the fasteners a quarter turn clockwise to lock the panel in place. 8. Complete the Back Panel Removed Test.

– End of Procedure – 8.1.1-2

Excelsior AS A82310101

Removing the Service Panel Assembly Issue 3

Removing the Service Panel Assembly Special Tools and Materials None required.

Procedure 1. Open the two front doors fully

2. Remove the six securing screws from the Service Panel Assembly.

Note When you remove the service panel assembly, ensure that you lift the bottom of the panel out first to disengage the locking clip located on the upper left hand corner of the panel.

3. Carefully remove the Service Panel Assembly from the instrument.

To refit the Service Panel Assembly, carry out the following: Note When you fit the new service panel assembly, ensure that you fit the upper left hand corner first to engage the locking clip in place. 4. Fit the Service Panel Assembly onto the instrument. 5. Fit the six securing screws in place on the Service Panel Assembly. 6. Tighten the screws. 7. Close the two front doors.

8.1.2-1

Removing the Service Panel Assembly Issue 3

Excelsior AS A82310101

– End of Procedure – 8.1.2-2

Structure and Deck: Parts Replacement Procedures In this Section: Removing the Deck .............................................................................................................................. (Issue 3) Replacing the Downdraft Fans ............................................................................................................. (Issue 3) Replacing the Filter Sensor ................................................................................................................... (Issue 3) Replacing the Pivoting Filter Lid .......................................................................................................... (Issue 3) Replacing the Display Complete ........................................................................................................... (Issue 3)

Excelsior AS A82310101

Removing the Deck Issue 3

Structure Deck Procedures Removing the Deck Special Tools and Materials None required.

Procedure

1. Remove the Service Panel Assembly from the instrument, refer to section 8.1.2 Removing the Service Panel Assembly

2. Remove the Back Panel from the instrument, refer to section 8.1.1 Removing the Back Panel.

3. Disconnect the touchscreen connector from the PCB behind the front panel.

4. Disconnect the two Down Draft Fan Assembly connectors from the Reaction Tank PCB.

5. Disconnect the Down Draft Filter Switch connector from the Reaction Tank PCB.

8.2.1-1

Removing the Deck Issue 3

Excelsior AS A82310101

6. Disconnect the Deck Earth Lead from the instrument.

7. Remove the six screws that secure the deck to the instrument.

8. Lift off the deck. To refit the Deck onto the instrument, carry out the following: Note When you refit the Deck, ensure that you feed the Touchscreen connector through the hole in the top of the instrument. 9. Position the deck in place on the instrument. 10. Install the six screws that secure the deck to the instrument. 11. Reconnect the Deck Earth Lead to the instrument. 12. Reconnect the two Down Draft Fan Assembly connectors to the Reaction Tank PCB. 13. Reconnect the Down Draft Filter Switch connector to the Reaction Tank PCB. 14. Reconnect the touchscreen connector to the PCB behind the front panel. 15. Refit the Service Panel Assembly to the instrument, refer to section 8.1.2 Removing the Service Panel Assembly. 16. Refit the Back Panel to the instrument, refer to section 8.1.1 Removing the Back Panel. 17. Complete the Deck Removed Test. – End of Procedure – 8.2.1-2

Excelsior AS A82310101

Replacing the Downdraft Fans Issue 3

Replacing the Downdraft Fans Special Tools and Materials None required.

Procedure 1. Remove the Deck from the instrument, refer to section 8.2.1 Removing the Deck.

2. Remove the two retaining screws that secure the Fan Cover to the instrument.

3. Remove the Fan Cover from the instrument. 4. Remove the Fan Cover Seal from the instrument.

5. Lower the Down Draft Fan Assembly out of the instrument.

Note When you fit the new Down Draft Fan Assembly into the instrument, ensure that the Fan is in the correct orientation with the arrow pointing towards the filter. 6. Fit the Down Draft Fan Assembly into the instrument. Note When you fit the fan cover seal, ensure that you route the cable form from the Fan Assembly through the groove in the housing to ensure that no damage to the cableform occurs. 7. Fit the fan cover seal onto the instrument. 8. Fit the Fan Cover in place on the instrument. 9. Refit the two retaining screws and secure the fan cover in place. 10. Refit the Deck to the instrument, refer to section 8.2.1 Removing the Deck. 11. Complete the Downdraft Fan Removed Test. 8.2.2-1

Replacing the Downdraft Fans Issue 3

Excelsior AS A82310101

– End of Procedure – 8.2.2-2

Excelsior AS A82310101

Replacing the Filter Sensor Issue 3

Replacing the Filter Sensor Special Tools and Materials None required.

Procedure Note If possible carry out this task without removing the deck. 1. Open the Pivoting Filter Lid and remove the filter, if fitted.

2. Remove the two retaining screws that secure the Filter Microswitch to the instrument.

3. Remove the Filter Microswitch from the instrument.

4. Put the new Filter Microswitch in place on the deck. 5. Fit the 2 retaining screws and secure the Microswitch in place. 6. Refit the filter and close the Pivoting Filter Lid. Note If you remove the Deck in order to carry out this procedure then carry out the following: 7. Refit the Deck to the instrument, refer to section 8.2.1 Removing the Deck. 8. Complete the Deck Filter Switch Removed Test.

8.2.3-1

Replacing the Filter Sensor Issue 3

Excelsior AS A82310101

– End of Procedure – 8.2.3-2

Excelsior AS A82310101

Replacing the Pivoting Lid Issue 3

Replacing the Pivoting Filter Lid Special Tools and Materials None required.

Procedure

1. Open the Pivoting Filter Lid.

2. Slide the two dowels out of each side of the Pivoting Filter Lid to release the Filter lid from the instrument.

3. Remove the Pivoting Filter Lid from the instrument.

4. Position the Pivoting Filter Lid on the instrument. 5. Slide the two dowels in each side of the Pivoting Filter Lid. 6. Close the Pivoting Filter Lid. 7. Complete the Deck Filter Switch Removed Test.

8.2.4-1

Replacing the Pivoting Lid Issue 3

Excelsior AS A82310101

– End of Procedure – 8.2.4-2

Excelsior AS A82310101

Replacing the Display Complete Issue 3

Replacing the Display Complete Special Tools and Materials None required.

Procedure 1. Remove the four retaining screws that secure the Display Assembly to the instrument.

Note When you disconnect the display cableform, ensure that you support the weight of the Display Assembly.

2. Disconnect the display cableform from the rear of the Display Assembly.

3. Remove the Display Assembly from the instrument.

4. Position the Display Assembly on the instrument. Note When you reconnect the display cableform onto the Display Assembly, ensure that you support the weight of the Display Assembly. 5. Reconnect the display cableform onto the rear of the Display Assembly. 6. Refit the four retaining screws that secure the Display Assembly to the instrument. 7. Complete the Display Complete Removed Test. 8.2.5-1

Replacing the Display Complete Issue 3

Excelsior AS A82310101

– End of Procedure – 8.2.5-2

Reaction Chamber: Parts Replacement Procedures In this Section: Removing the Reaction Chamber ......................................................................................................... (Issue 3) Replacing the Reaction Chamber Thermistor ....................................................................................... (Issue 3) Replacing the Level Sensors or Lid Switch ............................................................................................ (Issue 3) Removing the Motor ............................................................................................................................ (Issue 3) Removing the Motor In Situ ................................................................................................................ (Issue 3) Replacing the Disk and Calibrating the Optics ..................................................................................... (Issue 3) Removing the Flexi-Rigid PCB ............................................................................................................. (Issue 3) Removing the Lid ................................................................................................................................. (Issue 3) Changing the Lid Seal .......................................................................................................................... (Issue 3) Removing the Brush Block PCB ........................................................................................................... (Issue 3) Removing the Chamber Wall Heater .................................................................................................... (Issue 3) Removing the PTFE Seal ...................................................................................................................... (Issue 3) Removing the Brush Block Insulation .................................................................................................. (Issue 3) Removing the Lid Handle .................................................................................................................... (Issue 3) Removing the Valve Rotor Assembly Complete .................................................................................... (Issue 3) Removing the Port Seal ........................................................................................................................ (Issue 3) Removing the Upper Coupling and Agitate Bearing ............................................................................. (Issue 3) Wear gloves when servicing the Reaction Chamber or cleaning up leaks. Solvent and possible tissue bio hazards may be present.

Reaction Chamber Issue 1

ii

Excelsior AS A82310101

Excelsior AS A82310101

Removing the Reaction Chamber Issue 3

Reaction Chamber Procedures Removing the Reaction Chamber Special Tools and Materials None required.

Procedure 1. Open the left hand and right hand door. 2. Remove the Service Panel Assembly from the instrument, refer to section 8.1.2 Removing the Service Panel Assembly. 3. Remove the Deck from the instrument, refer to section 8.2.1 Removing the Deck.

4. Undo and remove the screw that secures the front of the Reaction Chamber.

5. Disconnect the ribbon cable, heater wires and earth lead.

8.3.1-1

Removing the Reaction Chamber Issue 3

Excelsior AS A82310101

Note When you disconnect the liquid and pneumatic pipes, you must push the collar on the connector upwards whilst pulling the pipes downwards to disengage them from the reaction chamber. 6. Disconnect the liquid and pneumatic pipes. 7. Loosen the 4 screws (2 each side) that secure the Reaction Chamber to the brackets. 8. Slide the reaction chamber forward slightly until the retaining screws are lined up with the large holes in the bracket.

9. Pull the tank forward and lift it up to remove it.

In order to refit the Reaction Chamber, carry out the following: 10. Fit the Reaction Chamber in position on the instrument, ensure that the locking screws are seated correctly in the holes. 11. Push the Reaction Chamber back slightly so the retaining screws lock the Chamber in place. 12. Tighten the four screws (2 each side of the Reaction Chamber) to secure the Chamber in place. Note When you refit the pipes onto the Reaction Chamber, ensure that use the earth stud at the rear of the Chamber as a reference for where to start fitting the pipes. This will ensure that you do not fit a pipe to the wrong position on the Reaction Chamber. 13. Refit the liquid and pneumatic pipes on to the Reaction Chamber. 14. Refit the ribbon cable, heater wires and earth lead. 15. Refit and tighten the screw that secures the front of the Reaction Chamber. 16. Refit the Service Panel Assembly to the instrument, refer to section 8.1.2 Removing the Service Panel Assembly. 17. Refit the Deck to the instrument, refer to section 8.2.1 Removing the Deck. 18. Complete the Reaction Chamber Removed Test. 19. Complete the Carcass Insulation Removed Test.

– End of Procedure – 8.3.1-2

Excelsior AS A82310101

Replacing the Reaction Chamber Thermistor Issue 3

Replacing the Reaction Chamber Thermistor Special Tools and Materials Socket T61450

Procedure 1. Remove the back panel from the instrument, refer to section 8.1.1 Removing the Back Panel. 2. Remove the 700 mm Armaflex Tape from around the Reaction Chamber.

3. Disconnect the Chamber Thermistor connector from the Tank Board PCB.

4. Remove the lower cable tie from around the circumference of the chamber. Note When you feed the electrical connector under the chamber insulation, ensure that you only loosen the insulation enough to free the connector. 5. Feed the electrical connector underneath the chamber insulation.

6. Unscrew the Chamber Thermistor and remove it from the instrument including the 40mm self adhesive tape.

8.3.2-1

Replacing the Reaction Chamber Thermistor Issue 3

Excelsior AS A82310101

To fit a new Chamber Thermistor, carry out the following: Note When you fit a new chamber thermistor, use the special socket (T61450). 7. Fit a new Chamber Thermistor and tighten to relevant torque setting. 8. Lift the chamber insulation, form loops in the cable and tape them to the chamber wall. Use 40mm long self adhesive tape. Re-position the chamber insulation over the cable. 9. Fit a new cable tie in place around the Chamber. 10. Reconnect the thermistor electrical connector to the Tank Board PCBA. 11. Fit 700 mm of Armaflex Tape around the Chamber to cover the thermistor. 12. Refit the back panel to the instrument, refer to section 8.1.1 Removing the Back Panel. 13. Complete the Reaction Chamber Temperature Sensor Removed Test.

– End of Procedure – 8.3.2-2

Excelsior AS A82310101

Replacing the Level Sensors or Lid Switch Issue 3

Replacing the Level Sensors or Lid Switch Special Tools and Materials 26mm Modified Socket. 10mm Modified Socket.

Procedure 1. Remove the Back Panel from the instrument, refer to section 8.1.1 Removing the Back Panel. 2. Remove the Service Panel Assembly, refer to section 8.1.2 Removing the Service Panel Assembly. 3. Disconnect the connectors from each of the level sensors and lid switch on the Tank Board PCB. Note When you remove the level sensors and the lid switch, ensure you use the special tools provided.

4. Unscrew and remove the level sensors from the Reaction Chamber.

5. Cut the 5 cable ties and unscrew and remove the lid switch from the Reaction Chamber.

8.3.3-1

Replacing the Level Sensors or Lid Switch Issue 3

Excelsior AS A82310101

Note When you install the level sensors, ensure that you torque them to 1.8 Nm and ensure that the O-ring is fully compressed. 6. Install new level sensors and connect the electrical connectors in the correct positions on the Tank Board PCB. Note When you fit the new lid switch, ensure that you torque it to 1 Nm. 7. Fit the new lid switch and connect the electrical connector on the Tank Board PCB. Route the cables (blue) with the Chamber heater cables (red wires) and secure in place with 5 cable ties. 8. Refit the Service Panel Assembly, refer to section 8.1.2 Removing the Service Panel Assembly. 9. Refit the Back Panel from the instrument, refer to section 8.1.1 Removing the Back Panel. 10. Complete the Reaction Chamber Level Sensor Removed Test.

– End of Procedure – 8.3.3-2

Excelsior AS A82310101

Removing the Motor Issue 3

Removing the Motor Special Tools and Materials None required.

Procedure 1. Remove the Reaction Chamber from the instrument, refer to section 8.3.1 Removing the Reaction Chamber.

2. Cut the cable tie.

Note When you remove the flexi cable, take care not to cause damage to the cable as it is fragile. 3. Disconnect the motor flexi cable from the Encoder PCB ZIF socket, by lifting the ears on the ZIF socket and removing the motor connection.

4. Remove the Encoder PCB from the motor assembly.

8.3.4-1

Removing the Motor Issue 3

Excelsior AS A82310101

5. Remove the three screws and washers.

6. Remove the motor assembly from the reaction chamber.

7. Fit the new motor assembly to the Reaction Chamber. Note When you refit the motor assembly, ensure you use Loctite 242 on the three motor plate screws. 8. Install the three screws and washers that secure the motor assembly to the Reaction Chamber. 9. Refit the Encoder PCB to the motor assembly. Note When you fit the flexi cable, take care not to cause damage to the cable as it is fragile. 10. Reconnect the motor flexi cable to the Encoder PCB ZIF socket, by pushing the flexi cable into the socket on the Encoder. 11. Fit a new cable tie to secure the Encoder PCB to the motor assembly 12. Refit the Reaction Chamber to the instrument, refer to section 8.3.1 Removing the Reaction Chamber. 13. Complete the Reaction Chamber Valve Motor Assembly Test.

– End of Procedure – 8.3.4-2

Excelsior AS A82310101

Removing the Motor In Situ Issue 3

Removing the Motor In Situ Special Tools and Materials None required.

Procedure 1. Remove the Back Panel from the instrument, refer to section 8.1.1 Removing the Back Panel. 2. Remove the Service Panel Assembly, refer to section 8.1.2 Removing the Service Panel Assembly. Note When you disconnect the pipes, do not remove them from the instrument just bend them out of the way to gain access to the motor assembly.

3. Disconnect pipes A2, A3, A4, A5 and EX1 from the couplings on the Reaction Chamber. Refer to the Exploded Drawings section.

Note When you disconnect the electrical connector from the Encoder PCB, take care not to damage the cable as it is fragile. 4. Disconnect the electrical cable from the Encoder PCB. 5. Remove the three screws and washers that secures the motor to the reaction Chamber. 6. Gently lower the Motor and the Encoder PCB until it is clear of the Reaction Chamber. Note If you cannot remove the motor due to lack of clearance, loosen the five bolts that secure the Reaction Chamber to the Deck. Do Not remove the bolts. Gently lift the Reaction Chamber until the motor is clear enough to be removed.

8.3.5-1

Removing the Motor In Situ Issue 3

Excelsior AS A82310101

7. Remove the motor assembly from the reaction chamber.

8. Remove the Encoder PCB and bracket from the old motor and fit it to the new motor assembly. 9. Fit the Motor assembly and Encoder PCB to the Reaction Chamber. Note When you refit the motor assembly, ensure that you use Loctite 242 on the three motor plate screws. 10. Install the three screws and washers that secure the motor assembly to the Reaction Chamber. 11. Reconnect the electrical cable from the Encoder PCB. Note 12. When you reconnect the electrical connector to the Encoder PCB, take care not to damage the cable as it is fragile. 13. Reconnect pipes A2, A3, A4, A5 and EX1 to the couplings on the Reaction Chamber. 14. Refit the Service Panel Assembly, refer to section 8.1.2 Removing the Service Panel Assembly. 15. Refit the Back Panel to the instrument, refer to section 8.1.1 Removing the Back Panel. 16. Complete the Reaction Chamber Valve Motor Assembly Test.

– End of Procedure – 8.3.5-2

Excelsior AS A82310101

Replacing the Disk and Calibrating the Optics Issue 3

Replacing the Disk and Calibrating the Optics Special Tools and Materials T61401 – Valve Alignment Pin Multi-meter

Procedure 1. Remove the Reaction Chamber from the instrument, refer to section 8.3.1 Removing the Reaction Chamber. 2. Remove the Motor from the Reaction Chamber, refer to section 8.3.4 Removing the Motor. 3. Remove two retaining screws from the Emitter PCB. 4. Remove the Emitter PCB from the instrument. Note Before you remove the screws and the Disk, mark the disk to ensure correct alignment is maintained. 5. Remove the three screws that secure the Disk to the instrument. Note When you remove the Disk, ensure that you do not cause any damage to the Detector PCB.

6. Lift the Disk off the instrument.

To refit the Disk, carry out the following: 7. Position the Disk on the instrument. 8.3.6-1

Replacing the Disk and Calibrating the Optics Issue 3

Excelsior AS A82310101

8. Fit the three screws that secures the Disk to the instrument. 9. Fit the Emitter PCB to the instrument. 10. Fit the two retaining screws to the Emitter PCB. To Calibrate the Instrument, carry out the following: Note The new disk only fits one way. 11. Fit the new Disk onto the instrument. 12. Manually turn the square shaft to rotate the valve to the wax waste open port position.

13. Insert a valve alignment pin (T61401) into the port to ensure alignment.

8.3.6-2

Excelsior AS A82310101

Replacing the Disk and Calibrating the Optics Issue 3

14. Connect the Ribbon Cable the instrument to the Tank PCB. 15. Connect a multi meter to test points 1 & 10 on the Tank PCB.

16. Set the multi meter to VDC. 17. Rotate the encoder disk until the lowest possible voltage is achieved. 18. Tighten the three fixing screws on the disk. 19. Refit the Motor to the Reaction Chamber, refer to section 8.3.4 Removing the Motor. 20. Refit the Reaction Chamber to the instrument, refer to section 8.3.1 Removing the Reaction Chamber. 21. Complete the RC Heater, Reduced Port Widths. 22. Complete the Tank Flex-Rigid PCB / Opto Disk Removed Test.

– End of Procedure – 8.3.6-3

Excelsior AS A82310101

Removing the Flexi-Rigid PCB Issue 3

Removing the Flexi-Rigid PCB Special Tools and Materials None.

Procedure 1. Remove the Reaction Chamber from the instrument, refer to section 8.3.1 Removing the Reaction Chamber. 2. Remove the Motor from the Reaction Chamber, refer to section 8.3.4 Removing the Motor. 3. Disconnect the connectors from each of the level sensors and lid switch on the Tank Board PCB. 4. Disconnect the Chamber Thermistor connector from the Tank Board PCB. 5. Disconnect the Brush Block Connector from the Tank Board PCB.

6. Disconnect the Chamber Wall Heater Connector from the Tank Board PCB.

7. Remove the Emitter PCB from the Reaction Chamber. 8. Remove the Disk from the instrument, refer to section 8.3.6 Removing the Disk and Calibrating Optics. Note When you remove the Detector PCB, ensure that you do not disconnect the Detector Cableform. 9. Remove the Detector PCB from the instrument. Note When you remove the three securing screws, ensure that you support the weight of the Flexi-Rigid PCB. 10. Remove the three securing screws that secure the Tank Board PCB to the Reaction Chamber.

8.3.7-1

Removing the Flexi-Rigid PCB Issue 3

Excelsior AS A82310101

11. Remove the Flexi-Rigid PCB from the instrument.

In order to install a new Flexi-Rigid PCB, carry out the following procedure: Note When you fit the Flexi-Rigid PCB, ensure you support the weight of the PCB and all the components to avoid any damage to the instrument. 12. Position a new Flexi-Rigid PCB in place on the instrument and secure in place using the three retaining screws. 13. Fit the Detector PCB to the instrument. 14. Fit the Disk to the instrument, refer to section 8.3.6 Removing the Disk and Calibrating Optics. 15. Fit the Emitter PCB to the Reaction Chamber. 16. Connect the connectors from each of the level sensors and lid switch to the Tank Board PCB. 17. Connect the Chamber Thermistor connector to the Tank Board PCB. 18. Connect the Brush Block Connector to the Tank Board PCB. 19. Connect the Chamber Wall Heater Connector to the Tank Board PCB. 20. Refit the Motor to the Reaction Chamber, refer to section 8.3.4 Removing the Motor. 21. Calibrate the Optics, refer to section 8.3.6 Replacing the Disk and Calibrating Optics. 22. Refit the Reaction Chamber to the instrument, refer to section 8.3.1 Removing the Reaction Chamber. 23. Complete the Tank Flex-Rigid PCB / Opto Disk Removed Test.

– End of Procedure – 8.3.7-2

Excelsior AS A82310101

Removing the Lid Issue 3

Removing the Lid Special Tools and Materials None required.

Procedure 1. Remove the Deck from the instrument, refer to section 8.2.1 Removing the Deck. 2. Open the Reaction Chamber Lid. 3. Remove the two Hinge Pins that secure the Lid to the Reaction Chamber.

4. Lift the Reaction Chamber Lid off the instrument.

To replace the Reaction Chamber Lid, carry out the following: 5. Position the Lid in place on the Reaction Chamber. 6. Fit the two Hinge Pins in place to secure the Lid in place. 7. Close the Reaction Chamber Lid. 8. Fit the Deck to the instrument, refer to section 8.2.1 Removing the Deck. 9. Complete the Reaction Chamber Lid Removed Test.

8.3.8-1

Removing the Lid Issue 3

Excelsior AS A82310101

– End of Procedure – 8.3.8-2

Excelsior AS A82310101

Changing the Lid Seal Issue 3

Changing the Lid Seal Special Tools and Materials None required.

Procedure 1. Open the lid to the Reaction Chamber. 2. Remove the eight screws and washers from the underside of the lid. 3. Remove the Seal Clamp Plate. Note When you remove the lid seal and glass lid panel, ensure that you do not drop the glass lid panel out of the lid seal.

4. Carefully remove the Lid Seal and Glass Lid Panel from the Reaction Chamber.

5. Remove the lid seal from the around the glass lid panel. 6. Install a new lid seal around the glass lid panel and fit in place on the lid of the reaction chamber. Note When you install the eight retaining screws, they need to be torqued to 1.8 Nm. 7. Install the seal clamp plate over the lid seal and secure in place using the eight screws and washers. 8. Complete the Reaction Chamber Lid Seal Removed Test.

8.3.9-1

Changing the Lid Seal Issue 3

Excelsior AS A82310101

– End of Procedure – 8.3.9-2

Excelsior AS A82310101

Removing the Brush Block PCB Issue 3

Removing the Brush Block PCB Special Tools and Materials •

Tool P12580

Procedure 1. Remove the Reaction Chamber from the instrument, refer to section 8.3.1 Removing the Reaction Chamber. 2. Remove the Disk and Calibrating Optics, refer to section 8.3.6 Replacing the Disk and Calibrating Optics. 3. Remove the Valve Rotor Assembly, refer to section 8.3.16 Removing the Valve Rotor Assembly. 4. Remove the electrical connector from the brush block PCB. 5. Remove the three screws that secures the brush block to the reaction chamber.

6. Remove the brush block from the reaction chamber.

7. Fit the new brush block into the reaction chamber. 8. Fasten in place with the three fixing screws. 9. Feed the cableform through the hole in the base of the reaction chamber. 10. Reconnect the electrical connector to the cableform. 11. Refit the valve rotor assembly to the reaction chamber, refer to section 8.3.16 Removing the Valve Rotor Assembly. 12. Replace the Disk and Calibrating Optics, refer to section 8.3.6 Replacing the Disk and Calibrating Optics. 13. Refit the Reaction Chamber to the instrument, refer to section 8.3.1 Removing the Reaction Chamber 14. Complete the Reaction Chamber Brush Block Removed Test.

8.3.10-1

Removing the Brush Block PCB Issue 3

Excelsior AS A82310101

– End of Procedure – 8.3.10-2

Excelsior AS A82310101

Removing the Chamber Wall Heater Issue 3

Removing the Chamber Wall Heater Special Tools and Materials None required.

Procedure 1. Remove the reaction chamber from the instrument, refer to section 8.3.1 Removing the Reaction Chamber. 2. Disconnect the four level sensors from the PCBA Tank Board. 3. Remove the motor cableform from the PCBA Tank Board. 4. Disconnect the Detector Cableform from the PCBA Tank Board. Note When you disconnect the chamber wall heater electrical connector from the PCBA tank board, ensure you remove the six cable ties that secure the cable to the chamber. 5. Disconnect the Chamber Wall heater Mat Sensors connector from the PCBA Tank Board. 6. Disconnect the connector from the Brush Block.

7. Disconnect the electrical connector from the chamber thermistor assembly.

8.3.11-1

Removing the Chamber Wall Heater Issue 3

8. Remove the PCBA Tank Board from the Reaction Chamber.

Note Before you remove the three large cable ties, remove the five small cable ties holding the Lid Sensor and Heater Cables. 9. Remove the three large cable ties from around the Reaction Chamber.

10. Remove the two strips of Armaflex tape from the reaction chamber.

11. Remove the Chamber Insulation from around the Reaction Chamber.

8.3.11-2

Excelsior AS A82310101

Excelsior AS A82310101

Removing the Chamber Wall Heater Issue 3

Note Before you remove the wall heater mat, ensure that you mark the positions of the heater matt on the reaction chamber with a pencil to make it easier when fitting a new heater matt.

12. Remove the chamber wall heater mat from the reaction chamber.

When you remove the Heat Dispersion Plate, ensure you handle with care as the edges of the Heat Dispersion Plate are very sharp. 13. Remove the Heat Dispersion Plate from the Reaction Chamber. Fit the new Heat Dispersion Plate onto the Reaction Chamber, ensuring that you adhere to the following guidelines: Note When you fit a new Heat Dispersion Plate, ensure you line up the ‘V’ shaped slot in the heat dispersion plate with the mark you made on the Reaction Chamber when you removed the Wall Heater Mat. Note The Heat Dispersion Plate is self adhesive so ensure that you have it in the correct position before fitting to the Reaction Chamber. 8.3.11-3

Removing the Chamber Wall Heater Issue 3

Excelsior AS A82310101

14. Position the Heat Dispersion Plate in the correct place and orientation on the Reaction Chamber.

Note When you fit the new Wall Heater Mat, ensure that you position it in the correct place on the Reaction Chamber making sure that the ‘V’ shaped cut-outs on the Heat Dispersion Plate and the Wall Heater Matt line up exactly and are in the correct orientation to prevent incorrect fitting of the Wall Heater Mat. Note The Wall Heater Mat is self adhesive so ensure that you have it in the correct position before fitting to the Reaction Chamber.

15. Fit the new Wall Heater Matt to the Reaction Chamber, ensuring the ‘V’shaped cut-outs line up. 16. Position wires running vertical up towards the bottom of the tank. Fit flame retardant adhesive tape 170mm long over the red coloured heater wires and then loop the wire over the outside surface of the tape vertically down towards the lid.

Note When you fit the new chamber insulation ensure that you start at the rear of the Reaction Chamber. Fit the insulation over the ports for the level sensors then move around the Reaction Chamber making sure that the self adhesive insulation is sat in the correct orientation and covers the Wall Heater Mat completely. Note When you fit the insulation, make sure you feed the electrical connector (white wires) at the rear of the chamber towards the bottom of the chamber and the wiring to the Chamber Thermistor Assembly (red wires) underneath the insulation towards the top of the chamber.

8.3.11-4

Excelsior AS A82310101

Removing the Chamber Wall Heater Issue 3

17. Fit the new Chamber Insulation onto the Reaction Chamber. 18. Put a 200mm piece of Armaflex Tape down the join of the Chamber Insulation at the front of the Reaction Chamber. 19. Fit the three cable ties onto the Reaction Chamber, around the insulation at the top, middle and bottom of the chamber.

20. Refit the PCBA Tank Board onto the Reaction Chamber.

21. Use six smaller cable ties to secure the chamber Heater Sensors (red wires), to the Reaction Chamber. Route together with the blue wires from the lid switch, refer to section8.3.3 Replacing the Level Sensors or Lid Switch. Note When you fit the Armaflex Tape around the Reaction Chamber, ensure you position the Chamber Thermistor and the cableform from the Chamber Thermistor underneath the tape. 22. Fit a 700mm long piece of Armaflex Tape around the Reaction Chamber just above the lower cable tie. 23. Engage the electrical connection from the wall heater matt on the PCBA Tank Board. 24. Connect the electrical connector from the Chamber Thermistor onto the PCBA Tank Board. 25. Connect the electrical connectors from the level sensors onto the PCBA Tank Board. 26. Refit the Lid Switch cableform onto the Reaction Chamber, refer to section 8.3.3 Replacing the Level Sensors or Lid Switch. 27. Reconnect the Detector Cableform on the PCBA Tank Board. 28. Reconnect the Motor Cableform onto the PCBA Tank Board. 8.3.11-5

Removing the Chamber Wall Heater Issue 3

Excelsior AS A82310101

29. Reconnect the Earth Lead onto the Reaction Chamber.

30. Refit the Reaction Chamber into the instrument, refer to section 8.3.1Removing the Reaction Chamber. 31. Complete the Wax Bath Removed Test.

– End of Procedure – 8.3.11-6

Excelsior AS A82310101

Removing the PTFE Seal Issue 3

Removing the PTFE Seal Special Tools and Materials •

None Required.

Procedure 1. Remove Valve Rotor Assembly from the instrument, refer to section 8.3.16 Removing the Valve Rotor Assembly.

2. Lift out the PTFE Seal from inside the Reaction Chamber.

To fit a new PTFE Seal, carry out the following procedure: 3. Apply a thin layer of silicon grease (DC4) to the outside sedge and bottom of the seal. Note When you fit the new seal into the reaction chamber, ensure you do not push it into place using your fingers as this will cause indentations in the seal. It should be set in place using the valve rotor assembly. 4. Fit a new PTFE Seal into the Reaction Chamber. 5. Refit the Valve Rotor Assembly to the instrument, refer to section 8.3.16 Removing the Valve Rotor Assembly. 6. Complete the Reaction Chamber Valve Seals Removed Test.

8.3.13-1

Removing the PTFE Seal Issue 3

Excelsior AS A82310101

– End of Procedure – 8.3.13-2

Excelsior AS A82310101

Removing the Brush Block Insulation Issue 3

Removing the Brush Block Insulation Special Tools and Materials •

Tool P12580

Procedure 1. Remove the Reaction Chamber from the instrument, refer to section 8.3.1 Removing the Reaction Chamber. 2. Remove the Valve Rotor Assembly complete from the instrument, refer to section 8.3.16 Removing the Valve Rotor Assembly Complete. 3. Remove the Brush Block PCB from the reaction chamber, refer to section 8.3.10 Removing the Brush Block PCB.

4. Carefully remove the Brush Block Insulation from the reaction chamber.

Note When you fit the new brush block insulation, ensure that it is located centrally over the retaining plate to prevent the brushes from contacting with retaining plate. 5. Fit a new Brush Block Insulation over the Retaining Plate. 6. Refit the Brush Block PCB into the reaction chamber, refer to section 8.3.10 Removing the Brush Block PCB. 7. Refit the valve rotor assembly complete to the instrument, refer to section 8.3.16 Removing the Valve Rotor Assembly Complete. 8. Refit the reaction chamber to the instrument, refer to section 8.3.1 Removing the Reaction Chamber. 9. Complete the Reaction Chamber Brush Block Removed Test.

8.3.14-1

Removing the Brush Block Insulation Issue 3

Excelsior AS A82310101

– End of Procedure – 8.3.14-2

Excelsior AS A82310101

Removing the Lid Handle Issue 3

Removing the Lid Handle Special Tools and Materials •

None Required.

Procedure 1. Open the Lid to the Reaction Chamber. 2. Remove the securing screw that secures the Lid Handle and the Striker to the Reaction Chamber Lid. Note When you lift the striker out of position, ensure that you do lose the small spring. 3. Lift the Striker out its position on the Chamber Lid.

4. Remove the Lid Handle from the instrument.

In order to fit the new Lid Handle, carry out the following: 5. Apply Loctite “N”- Primer type 7649 to securing screw and leave to dry for a few minutes. 6. Apply Loctite adhesive “234” in to the hole of the plastic lid handle. 7. Position a new Lid Handle in place on the Reaction Chamber Lid. 8. Position the Striker in place on the Chamber Lid. Ensure that the spring is in the correct position inside the striker. 9. Secure the Handle and the Striker in place using the securing screw. 10. Torque the securing screw to 1.2Nm. 8.3.15-1

Removing the Lid Handle Issue 3

Excelsior AS A82310101

– End of Procedure – 8.3.15-2

Excelsior AS A82310101

Removing the Valve Rotor Assembly Complete Issue 3

Removing the Valve Rotor Assembly Complete Special Tools and Materials •

Torque Wrench 55mm Socket.

Procedure 1. Remove the Reaction Chamber from the instrument, refer to section 8.3.1 Removing the Reaction Chamber. 2. Remove the Motor from the Reaction Chamber, refer to section 8.3.4 Removing the Motor. 3. Remove the Flexi-Rigid PCB from the Reaction Chamber, refer to section 8.3.7 Removing the Flexi-Rigid PCB. 4. Remove the Disk from the Reaction Chamber, refer to 8.3.6 Replacing the Disk and Calibrating Optics.

5. Remove the three grub screws from the Valve Nut. Remove the valve nut that secures the valve rotor assembly to the Reaction Chamber.

6. Lift the Valve Rotor Assembly out of the Reaction Chamber.

7. Remove the Main Seal from the reaction chamber, refer to section 8.3.13 Removing the PTFE Seal.

8.3.16-1

Removing the Valve Rotor Assembly Complete Issue 3

Excelsior AS A82310101

To replace the Valve Rotor Assembly, carry out the following procedure: 8. Fit a new Main Seal to the reaction chamber, refer to section 8.3.11 Removing the PTFE Seal. 9. Position the new Valve Rotor Assembly in place on the instrument. 10. Whilst holding the Valve Rotor Assembly in place, secure it in place using the valve nut. 11. Tighten the three grub screws so they are finger tighten only. 12. Torque the valve nut to 15 Nm and then loosen then re-torque the valve nut to 10 Nm. 13. Replace the Disk to the Reaction Chamber, refer to 8.3.6 Replacing the Disk and Calibrating Optics. 14. Replace the Flexi-Rigid PCB to the Reaction Chamber, refer to section 8.3.7 Removing the Flexi-Rigid PCB. 15. Replace the Motor to the Reaction Chamber, refer to section 8.3.4 Removing the Motor. 16. Refit the Reaction Chamber in the instrument, refer to section 8.3.1 Removing the Reaction Chamber. 17. Complete the Reaction Chamber Rotor Removed Test.

– End of Procedure – 8.3.16-2

Excelsior AS A82310101

Removing the Port Seal Issue 3

Removing the Port Seal Special Tools and Materials •

None.

Procedure

1. Open the Reaction Chamber Lid.

2. Remove the four screws that secure the valve port seal holder to the Reaction Chamber.

3. Remove the valve port seal holder, the port seal gasket and the port seal assembly from the reaction chamber.

8.3.17-1

Removing the Port Seal Issue 3

Excelsior AS A82310101

Note When you replace the port seal, ensure that you use the valve port seal kit and replace the port seal, port seal gasket and the four retaining screws with new items from the valve port seal kit. Apply a quantity of silicon grease (DC4) to the bottom of the port seal when you fit it to the reaction chamber. 4. Fit the new port seal, port seal gasket and the port seal holder in place in the reaction chamber. When you fit the four retaining screws, ensure you use Loctite 222. 5. Secure in place using the four retaining screws, torque the screws to 1.8Nm. 6. Close the reaction chamber lid. 7. Complete the Reaction Chamber Valve Seals Removed Test.

– End of Procedure – 8.3.17-2

Excelsior AS A82310101

Removing the Upper Coupling and Agitate Bearing Issue 3

Removing the Upper Coupling and Agitate Bearing Special Tools and Materials •

None.

Procedure

1. Open the Reaction Chamber Lid.

Note In order to remove the upper coupling, rotate the upper coupling through 45° to disengage the magnets that hold the coupling in place. 2. Remove the Upper Coupling from the reaction chamber.

3. Remove the Agitate Bearing from the reaction chamber.

8.3.18-1

Removing the Upper Coupling and Agitate Bearing Issue 3 4. After you remove the Agitate Bearing, ensure that you remove any debris. 5. Fit a new Agitate Bearing into the reaction chamber. 6. Fit a new Upper Coupling to the reaction chamber. 7. Close the lid of the reaction chamber.

– End of Procedure –

8.3.18-2

Excelsior AS A82310101

Concealed Reagent Bottles: Parts Replacement Procedures In this Section: Removing the Bottles ........................................................................................................................... (Issue 3) Removing the Specific Gravity Unit ..................................................................................................... (Issue 3) Disassembling the Specific Gravity Unit ............................................................................................... (Issue 3) Removing the Reagent Bottles and Reagent Heaters ............................................................................. (Issue 3) Replacing the Bottle Heating Fan ......................................................................................................... (Issue 3) Replacing the Bottle Heating Thermistors ............................................................................................ (Issue 3)

Concealed Reagent Bottles Issue 1

ii

Excelsior AS A82310101

Excelsior AS A82310101

Removing the Bottles Issue 3

Concealed Bottles Procedures Removing the Bottles Special Tools and Materials None required.

Procedure 1. Remove the back panel refer to section 8.1.1 Removing the Back Panel. 2. Disconnect the bottle thermistors. 3. Lift out the air pipes. 4. Remove the bottles by sliding off the liquid pipes.

Note: Refer to Concealed Reagent Bottles: Removing the Specific Gravity Unit for information on removing the specific gravity bottle. 5. Complete the Carcass Insulation Removed Test. 8.4.1-1

Removing the Bottles Issue 3

Excelsior AS A82310101

– End of Procedure – 8.4.1-2

Excelsior AS A82310101

Removing the Specific Gravity Unit Issue 3

Removing the Specific Gravity Unit Special Tools and Materials None required.

Procedure 1. Remove the rear panel, refer to section 8.1.1 Removing the Back Panel. 2. Remove the common air pipe.

3. Disconnect the connector from the sensor and motor to the specific gravity PCB.

4. Loosen the nuts that hold the SG unit mounting bracket to the vertical baffle plate:

8.4.2-1

Removing the Specific Gravity Unit Issue 3

Excelsior AS A82310101

5. Remove the foam insert from the instrument and then loosen the nearest screw holding the bottle support plate and slide it to the right.

6. Lift up the SG mounting bracket and bottle so that the bracket can be moved over the nut.

7. Carefully slide the bottle from the fluid pipe and move the bracket and bottle out of the instrument chassis.

Note The Specific Gravity may need to be calibrated after refitting. 8. Complete the SG Assembly Components Removed Test.

– End of Procedure – 8.4.2-2

Excelsior AS A82310101

Disassembling the Specific Gravity Unit Issue 3

Disassembling the Specific Gravity Unit Special Tools and Materials None required.

Procedure Note Use this procedure for all components in the SG Assembly as appropriate. Ensure that all ESD precautions are followed. 1. Remove the Specific Gravity Unit from the instrument, refer to section 8.4.2 Removing the SG Unit.

2. Remove the four screws that secure the PCB cover to the specific gravity electrical assembly.

3. Remove the PCB cover from the SG Unit.

4. Remove the four spacers from the top of the specific gravity electrical assembly.

5. Disconnect the sensor lead and the motor lead from the PCB.

8.4.3-1

Disassembling the Specific Gravity Unit Issue 3

6. Remove the specific gravity PCB assembly.

7. Remove the cable tie from the SG Unit.

8. Remove the SG Bottle from the SG Unit.

9. Remove the two screws that secure the SG Sensor and the suspension bracket from the assembly.

10. Remove the SG Sensor and the Bracket from the assembly.

11. Remove the suspension bar from the unit and remove the weight assembly from the suspension bracket.

8.4.3-2

Excelsior AS A82310101

Excelsior AS A82310101

Disassembling the Specific Gravity Unit Issue 3

12. Remove the SG Tube and Gasket and the weight from the assembly.

13. Remove the two screws that secure the bracket to the assembly.

14. Remove the bracket from the assembly.

15. Remove the four screws that secure the four pillar spacers to the assembly.

16. Remove the pillar spacers from the assembly.

17. Remove the nut and washer from the shaft of the motor. Remove the lift arm and spacer.

8.4.3-3

Disassembling the Specific Gravity Unit Issue 3

Excelsior AS A82310101

18. Remove the two securing screws and remove the motor from the assembly.

To rebuild the Specific Gravity Unit, carry out the procedure in the reverse order: 19. Position the SG Sensor and the Bracket in place on the assembly. 20. Fit the two screws to secure the bracket in place. 21. Position the motor in place on the assembly and secure in place using the two screws. 22. Fit the spacer and lift arm in place and secure using the nut and washer. 23. Refit the four pillar spacers using the four securing screws. 24. Fit the assembly to the bracket using the two securing screws. 25. Feed the weight assembly through the SG tube and gasket assembly. 26. Fit the complete weight and SG tube assembly onto the suspension bracket on the assembly using the weight suspension bar. Note When you fit the SG Bottle onto the assembly, ensure that you use Silicone Grease around the gasket to seal the unit. 27. Fit the SG bottle onto the assembly. 28. Fit a new cable tie around the bottle and the bracket to secure in place. 29. Fit a piece of armaflex tape over the join on the cable tie. 30. Reconnect the electrical connector from the motor to the PCB. 31. Reconnect the electrical connector from the sensor assembly to the PCB. 32. Refit the PCB cover using the four fixing screws. 33. Refit the Specific Gravity Assembly to the instrument, refer to section 8.4.2 Removing the SG Unit. 34. Complete the SG Assembly Components Removed Test.

– End of Procedure – 8.4.3-4

Excelsior AS A82310101

Removing and Replacing the Reagent Heaters Issue 3

Removing and Replacing the Reagent Heaters Special Tools and Materials None required.

Procedure 1. Remove the SG Unit from the instrument, refer to section 8.4.2 Removing the SG unit. 2. Remove the bottles and pipes to gain access to the Reagent Heaters, refer to section 8.4.1 Removing the Bottles.

3. Remove the two bottle support foam inserts and the two side insulation panels from the instrument.

4. Follow the cables from each of the two heater mats, up to the connectors on the vertical baffle plate and then disconnect them.

5. Unclip the heater cables from the vertical baffle plate.

8.4.6-1

Removing and Replacing the Reagent Heaters Issue 3

Excelsior AS A82310101

6. Remove the left hand and right hand heater mats by peeling them from the vertical baffle plate.

7. Clean the vertical baffle plate with isopropyl alcohol to remove any adhesive residue. 8. Fix the new heaters to the vertical baffle plate. Ensure that each of the heaters are fixed to the position indicated in the following diagrams:

Rear view left: Heater mat position

Rear view right: Heater mat position

9. Clip the heater cable to the vertical baffle plate, following the path of the original cable. 10. Connect the cable to the connector on the vertical baffle plate. 11. Refit the bottles and pipes, refer to section 8.4.1 Removing the Bottles. 12. Refit the SG Unit to the instrument, refer to section 8.4.2 Removing the SG unit. Complete the Reagent Heater Mat Removed Test.

– End of Procedure – 8.4.6-2

Excelsior AS A82310101

Replacing the Bottle Heating Fan Issue 3

Replacing the Bottle Heating Fan Special Tools and Materials P12580 Trident Pin Extractor.

Procedure 1. Remove the back access panel from the instrument, refer to section 8.1.1 Removing the back Panel. Note The wires have to be removed from the connector so that they can be fed through the hole in the back panel sealing angle.

1. Make a note of the position of each coloured wire in the connector and remove the wires from the electrical connector.

2. Remove the three screws that secure the fan to the rear panel.

3. Remove the fan from the panel.

To refit the bottle heating fan, carry out the following procedure: 4. Line up the fan with the duct. 5. Secure the new fan to the rear panel using the three retaining screws but do not fully tighten them. 6. Feed the electrical wire from the fan through the hole in the sealing angle on the panel. 7. Refit the wires, in the correct positions, into the electrical connector and position the connector on the bracket. 8. Tighten the three securing screws to a torque of 1.8 Nm. 9. Refit the back access panel to the instrument, refer to section 8.1.1 Removing the back Panel. 10. Complete the Back Panel Removed Test.

8.4.7-1

Replacing the Bottle Heating Fan Issue 3

Excelsior AS A82310101

– End of Procedure – 8.4.7-2

Excelsior AS A82310101

Replacing the Bottle Heating Thermistors Issue 3

Replacing the Bottle Heating Thermistors Special Tools and Materials None required.

Procedure 1. Remove the back panel from the instrument, refer to section 8.1.1 Removing the Back Panel.

2. Disconnect the electrical connectors to the bottle heating thermistors.

Note When you remove the bottle heating thermistors, slightly angle the piping and coupling outwards in order to get the thermistors out of the instrument.

3. Push the collar on the Tee Coupling in order to release the thermistor from the coupling.

4. Remove the thermistor from the instrument.

In order to fit the new thermistor, carry out the following: 5. Seat the new thermistor into the tee coupling and push it downwards until it clicks into place. 6. Connect the electrical connector to the connector on the baffle plate. 7. Refit the back panel to the instrument, refer to section 8.1.1 Removing the Back Panel. 8. Complete the Reagent Heater Thermistor Removed Test.

8.4.8-1

Replacing the Bottle Heating Thermistors Issue 3

Excelsior AS A82310101

– End of Procedure – 8.4.8-2

Wax Baths: Parts Replacement Procedures In this Section: Replacing the Heater ............................................................................................................................ (Issue 3) Removing the Temperature and Level Sensors ...................................................................................... (Issue 3) Removing the Wax Baths ..................................................................................................................... (Issue 3)

Excelsior AS A82310101

Replacing the Heater Issue 3

Wax Baths Procedures Replacing the Heater Special Tools and Materials Tool P12580

Procedure 1. Open the front doors of the instrument. 2. Remove the three bolts that secure the wax tank heat shield assembly and the harness protector shield to the instrument. 3. Remove the wax tank heat shield assembly and the harness protector shield from the instrument.

4. Remove the vertical and horizontal wire retainer foam pieces from the instrument. Note When you remove the pins from the electrical connector, ensure that make a note of the pin positions for when you install a new heater. 5. Locate the electrical connector and remove the relevant pins from the heater mat to be replaced. 6.

8.5.1-1

Replacing the Heater Issue 3

Excelsior AS A82310101

7. Mark a mark along one edge of the heater mat that is to be replaced to ensure you can position the new heater mat in the correct place. 8. Peel off the heater mat from the instrument. 9. Clean the area where the heater mat was to ensure that when you fit the new heater mat it has a smooth clean surface to stick to. Note When you fit the new heater mat ensure that you use the mark you made when removing the old heater to locate it in the correct position. 10. Position the new heater mat in place on the instrument. Note When you fit the new electrical cables into the connector, ensure that you get the correct cables in the correct positions on the connector. 11. Locate the electrical connector and fit the relevant pins from the heater mat in the correct positions. 12. Route the cables in the harness retainers on the wax tank assembly. 13. Fit the vertical and horizontal wire retainer foam pieces to the instrument to protect the cabling. 14. Refit the harness protector shield and the wax tank heat shield assembly to the instrument. 15. Refit the five nuts that secure the wax tank heat shield assembly and the harness protector shield to the instrument. 16. Close the front doors of the instrument. 17. Complete the Wax Bath Removed Test.

– End of Procedure – 8.5.1-2

Excelsior AS A82310101

Removing the Temperature and Level Sensors Issue 3

Removing the Temperature and Level Sensors Special Tools and Materials None required.

Procedure

1. Open the Left Hand Lower Front Door.

2. Open the two Wax Baths Front Flaps on the instrument.

Note When you remove the service covers to gain access to the temperature and level sensors, make sure that you do not remove the wax tank from the instrument. The image shown below is to highlight the procedure only and does not represent the wax tank being removed.

3. Remove the Service Covers from inside the Wax Tanks.

8.5.2-1

Removing the Temperature and Level Sensors Issue 3

Excelsior AS A82310101

4. Unscrew the Nut Lock from the each of the temperature sensors and level sensors to be changed.

Note When you remove the pins from the electrical connector, ensure that make a note of the pin positions for when you install a new sensor. 5. Unclip the relevant cableform from cable clips to release the temperature or level sensor. 6. Locate the electrical connector and remove the relevant pins from the temperature or level sensor to be replaced. 7. Remove the Temperature or Level Sensor from the instrument. To fit a new Temperature or Level Sensor do the reverse of the procedure given above. 8. Complete the Wax Bath Removed Test.

– End of Procedure – 8.5.2-2

Excelsior AS A82310101

Removing the Wax Baths Issue 3

Removing the Wax Baths Special Tools and Materials Tool P12580

Procedure 1. Open the front doors of the instrument. 2. Remove the five nuts that secure the wax tank heat shield assembly and the harness protector shield to the instrument.

3. Remove the wax tank heat shield assembly and the harness protector shield from the instrument.

4. Open the two Wax Baths Front Flaps on the instrument.

Note Image shown below is to highlight the procedure only and does not represent the wax tank already removed.

8.5.3-1

Removing the Wax Baths Issue 3

Excelsior AS A82310101

5. Remove the two Service Covers from inside of Wax Baths.

6. Remove the Service Panel Assembly, refer to section 8.1.2 Removing the Service Panel Assembly.

7. Disconnect the two electrical connectors.

Note When you remove the six nuts that secure the wax bath assembly in place, ensure that you hold the weight of the wax bath assembly to prevent any damage being caused to the instrument.

8. Locate the six nuts that secure the wax bath assembly to the instrument. Loosen and remove the six nuts.

9. Remove the wax bath assembly from the instrument. 10. Complete the Wax Bath Removed Test.

– End of Procedure – 8.5.3-2

Pneumatics: Parts Replacement Procedures In this Section: Removing the Solenoid Assembly and Pressure Transducer .................................................................. (Issue 3) Removing the Solenoids from the Plate ................................................................................................ (Issue 3) Removing the Pump Assembly ............................................................................................................. (Issue 3)

Excelsior AS A82310101

Removing the Solenoid Assembly and Pressure Transducer Issue 3

Pneumatics Procedures Removing the Solenoid Assembly and Pressure Transducer Special Tools and Materials None required.

Procedure 1. Remove the Back Panel, refer to section 8.1.1 Removing the Back Panel. 2. Remove the Service Panel Assembly from the front of the instrument, refer to section 8.1.2 Removing the Service Panel Assembly.

3. Remove the electrical connector from the top of the pressure transducer assembly.

4. Remove the two cable ties from the retaining clips and pull the pressure transducer away from the clips.

8.6.1-1

Removing the Solenoid Assembly and Pressure Transducer Issue 3

Excelsior AS A82310101

5. Disconnect the push to fit coupling and remove the pressure transducer from the pipe.

6. Disconnect the push to fit coupling on the pipe on the base of the solenoid plate.

7. Disconnect the push to fit coupling on the pump.

Note The Deck in the following image has been removed for illustration purposes only to show the connection on the top of the reaction chamber. Access to this connection is through the rear of the instrument.

8. Locate the pipe on the reaction chamber from the rear of the instrument and disconnect the push to fit coupling and remove the pipe from the connector.

8.6.1-2

Excelsior AS A82310101

Removing the Solenoid Assembly and Pressure Transducer Issue 3

Note The reaction Chamber has been removed for illustrations purposes only to show the location and the electrical connectors on the solenoids.

9. Loosen the locking screw on both of the electrical connectors attached to the solenoids and remove the connectors.

Note When you loosen the nuts securing the solenoid assembly, ensure that you only loosen them and do not remove them. 10. Loosen the four nuts that secure the solenoid assembly to the instrument. 11. Gently lift the solenoid mounting plate assembly upwards to disengage the nuts from the bracket.

12. Remove the solenoid mounting plate assembly from the instrument.

13. To fit a new solenoid assembly or pressure transducer, carry out the above procedure in the reverse order.

8.6.1-3

Removing the Solenoid Assembly and Pressure Transducer Issue 3

Excelsior AS A82310101

14. Refit the Service Panel Assembly to the front of the instrument, refer to section 8.1.2 Removing the Service Panel Assembly. 15. Refit the Back Panel, refer to section 8.1.1 Removing the Back Panel. 16. Complete the Pump, Solenoid, Pressure Transducer and / or Pneumatics Removed Test.

– End of Procedure – 8.6.1-4

Excelsior AS A82310101

Removing the Solenoids from the Plate Issue 3

Removing the Solenoids from the Plate Special Tools and Materials None required.

Procedure 1. Remove the solenoid assembly and pressure transducer, refer to section 8.6.1 Removing the Solenoid Assembly and Pressure Transducer. 2. Remove the four screws that secure the solenoids to the plate. 3. Remove the Solenoids from the Plate.

4. Complete the Pump, Solenoid, Pressure Transducer and / or Pneumatics Removed Test.

8.6.2-1

Removing the Solenoids from the Plate Issue 3

Excelsior AS A82310101

– End of Procedure – 8.6.2-2

Excelsior AS A82310101

Removing the Pump Assembly Issue 3

Removing the Pump Assembly Special Tools and Materials None required.

Procedure 1. Remove the back panel, refer to section 8.1.1 Removing the Back Panel.

2. Disconnect the electrical connector attached to the pump.

3. Disconnect the two pipes from the connectors on the top of the pump.

8.6.3-1

Removing the Pump Assembly Issue 3

Excelsior AS A82310101

4. Remove the four fixing screws from the pump and lift the pump out of the instrument.

5. To refit a new pump, carry out the procedure given above in the reverse order. 6. Refit the back panel, refer to section 8.1.1 Removing the Back Panel. 7. Complete the Pump, Solenoid, Pressure Transducer and / or Pneumatics Removed Test.

– End of Procedure – 8.6.3-2

Electronics: Parts Replacement Procedures In this Section: Removing the Front Panel and PCBs ................................................................................................... (Issue 3) Replacing Remote Alarm Fuses ............................................................................................................. (Issue 3) Removing the Passive PCBA ................................................................................................................ (Issue 3) Removing the Speaker .......................................................................................................................... (Issue 3) Removing the Power Supply Unit ........................................................................................................ (Issue 3) Removing the Electronics Assembly ...................................................................................................... (Issue 3) Replacing the Battery Isolation Switch .................................................................................................. (Issue 3) Replacing the Safety Cut-out Switch .................................................................................................... (Issue 3) Replacing the Extraction Fan ................................................................................................................ (Issue 3) Replacing the Door Sensor ................................................................................................................... (Issue 3) Removing the Filter Switches ............................................................................................................... (Issue 3) Replacing the Batteries ......................................................................................................................... (Issue 3) Replacing the DSP Display Fused PCBA .............................................................................................. (Issue 3) Replacing the Inverter PCBA ................................................................................................................ (Issue 3)

Electronics Issue 2

ii

Excelsior AS A82310101

Excelsior AS A82310101

Removing the Front Panel and PCB’s Issue 3

Electronics Procedures Removing the Front Panel and PCBs Special Tools and Materials None required.

Procedure Ensure that all ESD precautions are followed. 1. Remove the back panel, refer to section 8.1.1 Removing the Back Panel.

2. Disconnect the ribbon cable from the left hand side of the electronics assembly.

3. Disconnect the electrical cables from the right hand side of the electronics assembly.

8.7.1-1

Removing the Front Panel and PCB’s Issue 3

Excelsior AS A82310101

4. Remove the four fixing screws that secure the front panel to the electronics assembly. When you remove the front panel, ensure that you do not remove the earth cable. Leave it attached to the front panel and move the panel clear of the PCB’s.

5. Remove the front panel from the electronics assembly.

6. Using the PCB ejectors on the I/O PCB and the Distribution PCB, remove the two PCB’s from the electronics assembly.

7. Carefully slide the Processor PCB out of the Electronics assembly

To replace the PCB’s and refit the front panel, carry out the above procedure in the reverse order. 8. Refit the back panel, refer to section 8.1.1 Removing the Back Panel. 9. Complete the Distribution PCB Removed Test. 10. Complete the Microprocessor Replaced Test. 11. Complete the Digital I/O Replaced Test.

– End of Procedure – 8.7.1-2

Excelsior AS A82310101

Replacing Remote Alarm Fuses Issue 3

Replacing Remote Alarm Fuses Special Tools and Materials None required.

Procedure

1. Unscrew the caps and remove the remote alarm fuses from the distribution board.

2. Fit new remote alarm fuses to the distribution board and secure in place with the two caps.

8.7.2-1

Replacing Remote Alarm Fuses Issue 3

Excelsior AS A82310101

– End of Procedure – 8.7.2-2

Excelsior AS A82310101

Removing the Passive PCBA Issue 3

Removing the Passive PCBA Special Tools and Materials None required.

Procedure 1. Remove the back panel, refer to section 8.1.1 Removing the Back Panel. 2. Remove the electronics assembly from the instrument, refer to section 8.7.7 Removing the Electronics Assembly. 3. Remove the front panel and PCB’s from the electronics assembly, refer to section 8.7.1 Removing the Front Panel and PCB’s. 4. Remove the four fixing screws from the Passive PCBA. 5. Remove the Passive PCBA from the electronics assembly.

6. Fit a new Passive PCBA onto the electronics assembly. 7. Fit the four retaining screws to secure the PCBA into place. 8. Refit the three PCB’s and the front panel onto the electronics assembly, refer to section 8.7.1 Removing the Front Panel and PCB’s. 9. Refit the electronics assembly to the instrument, refer to section 8.7.7 Removing the Electronics Assembly. 10. Refit the back panel, refer to section 8.1.1 Removing the Back Panel. 8.7.3-1

Removing the Passive PCBA Issue 3

Excelsior AS A82310101

11. Complete the Passive PCBA Test.

– End of Procedure – 8.7.3-2

Excelsior AS A82310101

Removing the Speaker Issue 3

Removing the Speaker Special Tools and Materials None required.

Procedure 1. Remove the back panel, refer to section 8.1.1 Removing the Back Panel. Note The Deck and the Reaction Chamber have been removed for illustrations purposes only, to show the removal of the speaker. DO NOT remove the Deck or the Reaction Chamber when changing the speaker. 2. Disconnect the electrical connector from the Passive PCBA. 3. Remove the four fixing screws that secure the speaker to the body of the electronics assembly. 4. Remove the speaker from the instrument.

In order to replace the speaker, carry out the procedure given above in the reverse order. 5. Refit the back panel, refer to section 8.1.1 Removing the Back Panel.

8.7.4-1

Removing the Speaker Issue 3

Excelsior AS A82310101

– End of Procedure – 8.7.4-2

Excelsior AS A82310101

Removing the Power Supply Unit Issue 3

Removing the Power Supply Unit Special Tools and Materials None required.

Procedure 1. Remove the Rear Panel from the instrument, refer to section 8.1.1 Removing the Back Panel. 2. Remove the earth leads from the electronics assembly.

3. Disconnect the two electrical connectors from the side of the electronics assembly.

4. Remove the two fixing screws from the front of the power supply and remove the power supply from the instrument.

5. Fit a new power supply into the instrument. 6. Fit the two fixing screws and secure the power supply in place on the instrument. 7. Reconnect the two electrical connectors to the side of the electronics assembly. 8. Reconnect the two earth leads to the electronics assembly. 8.7.6-1

Removing the Power Supply Unit Issue 3

Excelsior AS A82310101

9. Refit the Rear Panel to the instrument, refer to section 8.1.1 Removing the Back Panel. 10. Complete the PSU Removed Test.

– End of Procedure –

8.7.6-2

Excelsior AS A82310101

Removing the Electronics Assembly Issue 3

Removing the Electronics Assembly Special Tools and Materials None required.

Procedure 1. Remove the Rear Panel from the instrument, refer to section 8.1.1 Removing the Back Panel. 2. Remove the Service Panel Assembly from the front of the instrument, refer to section 8.1.2 Removing the Service Panel Assembly. 3. Disconnect the Battery Cableform connector from the Power Supply Unit. 4. Disconnect the Secondary Cableform connector from the Power Supply Unit. 5. Disconnect the Pneumatics Cableform connector from the Power Supply Unit.

6. Disconnect the Passive to Display Cableform connector from the Power Supply Unit.

7. Disconnect the electrical cables from the right hand side of the electronics assembly.

8.7.7-1

Removing the Electronics Assembly Issue 3

8. Disconnect the ribbon cable from the left hand side of the electronics assembly.

9. Disconnect the six electrical connections from the Passive PCBA.

10. Remove the four fixing screws then remove the electronics assembly out of the instrument.

11. Fit a new electronics assembly into the instrument. 12. Fasten in place using the four fixing screws. 13. Reconnect the six electrical connectors onto the Passive PCBA. 14. Reconnect the ribbon cable to the left hand side of the electronics assembly. 15. Reconnect the electrical cables to the right hand side of the electronics assembly. 16. Reconnect the Passive to Display Cableform connector to the Power Supply Unit. 17. Reconnect the Pneumatics Cableform connector to the Power Supply Unit. 18. Reconnect the Secondary Cableform connector to the Power Supply Unit. 8.7.7-2

Excelsior AS A82310101

Excelsior AS A82310101

Removing the Electronics Assembly Issue 1

19. Reconnect the Battery Cableform connector to the Power Supply Unit. 20. Refit the Service Panel Assembly to the front of the instrument, refer to section 8.1.2 Removing the Service Panel Assembly. 21. Refit the Back Panel to the instrument, refer to section 8.1.1 Removing the Back Panel. 22. Complete the Distribution PCB Removed Test. 23. Complete the Microprocessor Replaced Test. 24. Complete the Digital I/O Replaced Test.

8.7.7-3

Removing the Electronics Assembly Issue 3

Excelsior AS A82310101

– End of Procedure – 8.7.7-4

Excelsior AS A82310101

Replacing the Battery Isolation Switch Issue 3

Replacing the Battery Isolation Switch Special Tools and Materials None required.

Procedure 1. Remove the back panel from the instrument, refer to section 8.1.1 Removing the Back Panel. 2. Remove the Batteries from the instrument, refer to section 8.7.13 Replacing the Batteries. 3. Remove the Battery Tray to gain access to the battery isolation switch.

4. Make a note of the wire connections and then disconnect the wires.

5. Unclip the switch and remove it from the instrument.

6. Position the new switch on the instrument and clip into place. 7. Reconnect the wires in the same order you disconnected them. 8.7.8-1

Replacing the Battery Isolation Switch Issue 3

Excelsior AS A82310101

8. Refit the Battery Tray to the instrument. 9. Refit the Batteries to the instrument, refer to section 8.7.13 Replacing the Batteries. 10. Refit the back panel to the instrument, refer to section 8.1.1 Removing the Back Panel. 11. Complete the Battery Isolation Switch Replaced Test.

– End of Procedure – 8.7.8-2

Excelsior AS A82310101

Replacing the Safety Cut-out Switch Issue 3

Replacing the Safety Cut-out Switch Special Tools and Materials None required.

Procedure 1. Remove the back panel from the instrument, refer to section 8.1.1 Removing the Back Panel. 2. Remove the Batteries from the instrument, refer to section 8.7.13 Replacing the Batteries. 3. Remove the Battery Tray to gain access to the safety cut out switch.

4. Open the right hand door and remove the nut and washer that secure the safety cut out switch in place.

5. Make a note of the wire connections and then disconnect the wires.

6. Remove the safety cut out switch assembly from the instrument.

8.7.9-1

Replacing the Safety Cut-out Switch Issue 3

Excelsior AS A82310101

7. Position the new switch on the instrument and secure in place with the washer and nut.

8. Reconnect the wires in the same position as you removed them.

9. Refit the Battery Tray into the instrument. 10. Refit the Batteries to the instrument, refer to section 8.7.13 Replacing the Batteries. 11. Refit the back panel to the instrument, refer to section 8.1.1 Removing the Back Panel. 12. Complete the Safety Cutout Switch Replaced Test.

– End of Procedure – 8.7.9-2

Excelsior AS A82310101

Replacing the Extraction Fan Issue 3

Replacing the Extraction Fan Special Tools and Materials None required.

Procedure 1. Remove the deck assembly to gain access to the extract fan, refer to section 8.2.1 Removing the Deck. 2. Disconnect the electrical connector from the Passive PCBA. 3. Remove the three fixing screws from the extractor fan.

4. Remove the extractor fan from the instrument.

5. Fit a new extraction fan in place and secure using three fixing screws. 6. Reconnect the electrical connector to the Passive PCBA. 7. Refit the deck assembly to the instrument, refer to section 8.2.1 Removing the Deck. 8. Complete the Extract Fan Removed Test

8.7.10-1

Replacing the Extraction Fan Issue 3

Excelsior AS A82310101

– End of Procedure – 8.7.10-2

Excelsior AS A82310101

Removing the Filter Switches Issue 3

Removing the Filter Switches Special Tools and Materials None required.

Procedure 1. Remove the back panel from the instrument, refer to section 8.1.1 Removing the Back Panel. 2. Remove the batteries from the instrument, refer to section 8.7.13 Replacing the Batteries. 3. Disconnect the electrical connections from each of the filter switches. 4. Remove the two screws from each of the two switches. Note The components that have been removed in the image below are for clarity only to show the filter switches. There is no requirement to remove other components other than those detailed above.

5. Remove the filter switches from the instrument.

6. Position the new filter switches in place on the instrument and secure in place with the screws. 7. Reconnect the electrical connectors to each of the filter switches. 8. Refit the batteries to the instrument, refer to section 8.7.13 Replacing the Batteries. 9. Refit the back panel to the instrument, refer to section 8.1.1 Removing the Back Panel. 10. Complete the Extract Filter Microswitch Removed Test.

8.7.12-1

Removing the Filter Switches Issue 3

Excelsior AS A82310101

– End of Procedure – 8.7.12-2

Excelsior AS A82310101

Replacing the Batteries Issue 3

Replacing the Batteries Special Tools and Materials None required.

Procedure 1. Remove the back panel, refer to section 8.1.1 Removing the Back Panel. 2. Release the Velcro straps, and the four link wires on the top of the batteries. 3. To reinstall the batteries, reverse this sequence, and ensure the terminal connections are correct. Note: Always replace both batteries at the same time.

4. Refit the back panel to the instrument, refer to section 8.1.1 Removing the Back Panel. 5. Complete the Batteries Removed Test.

8.7.13-1

Replacing the Batteries Issue 3

Excelsior AS A82310101

– End of Procedure – 8.7.13-2

Excelsior AS A82310101

Replacing the DSP Display Fused PCBA Issue 3

Replacing the DSP Display Fused PCBA Special Tools and Materials None required.

Procedure 1. Remove the touchscreen assembly, refer to section 8.2.5 Replacing the Display Complete. 2. Disconnect the three electrical connectors to the PCBA.

3. Remove the four fixing screws from the PCBA and remove the PCBA from the touchscreen assembly.

4. Position a new DSP Display Fused PCBA onto the touchscreen assembly. 5. Use the four fixing screws to fasten in place. 6. Reconnect the three electrical connectors to the PCBA. 7. Refit the touchscreen assembly to the instrument, refer to section 8.2.5 Replacing the Display Complete. 8. Complete the DSP Display PCBA Replaced Test.

8.7.14-1

Replacing the DSP Display Fused PCBA Issue 3

Excelsior AS A82310101

– End of Procedure – 8.7.14-2

Excelsior AS A82310101

Replacing the Inverter PCBA Issue 3

Replacing the Inverter PCBA Special Tools and Materials None required.

Procedure

1. Remove the touchscreen assembly from the instrument.

2. Remove the two fixing screws from that secure the Inverter PCB to the touchscreen assembly. Note When you remove the Inverter PCB, ensure that you retain the spacers for the installation of the new Inverter PCB.

3. Remove the Inverter PCB from the assembly.

Note Ensure that you fit the spacers behind the PCB when fitting. 4. Fit a new Inverter PCB in place on the touchscreen assembly. 5. Fasten the fixing screws to secure that PCB in place. 6. Refit the touchscreen assembly to the instrument. 7. Complete the Inverter PCBA Replaced Test.

8.7.15-1

Replacing the Inverter PCBA Issue 3

Excelsior AS A82310101

– End of Procedure – 8.7.15-2

Software Update Procedure This section provides details of the Excelsior AS software update process.

Excelsior AS A82310101

Software Update Procedure Issue 3

Software Update Procedure Introduction The Software update is done via the User Interface using a USB flash drive. This process works for updating: •

The main instrument software.

•

The display driver PCB firmware (Hex file), if ever required.

•

The production and service test limits file.

Software will be provided in electronic format within a zip file. To create the USB flash drive for software update: •

Unzip the A82320097_xx software file (maintain file structure).

•

Copy the ‘deploy’ folder to the root folder of the USB flash drive.

Update To update the software: •

Save customer set-up and programs.

•

Put USB flash drive into the instrument.

•

Navigate to ‘Options – Customer Services – Reset Options’ and then enter the code ‘12345678’.

•

Press the ‘Update Software’ button on the user interface.

Note When updating the software this could take up to 10 minutes to complete. •

Wait for the software to update.

•

When the application loads, navigate to ‘Options – Customer Services. Check the software version displayed on this screen matches the one loaded.

•

Press Reset Options’ and then enter the code ‘12345678’. Press ‘Reset 7’, then press ‘Fake Load’.

•

Switch Off the mains supply and switch back On. When the application loads, navigate to ‘Options – Customer Services. Check the software version displayed on this screen matches the one loaded. (This is to make sure there are no boot issues post software update).

•

Reload the customer set-up and programs.

Post Update After loading the software it is possible the instrument serial number and/or touchscreen calibration data may have been erased and need re-entry:

To re-calibrate touchscreen: •

Carefully press on the centre of the target (cross).

•

Repeat as the target moves around the screen.

•

When there are no more targets to press, tap the screen twice to return to the Customer Services screen. 9-1

Software Update Procedure Issue 3

To re-enter serial number:

•

Enter valid serial number

Note ‘OK’ will not be displayed until a valid serial number format has been entered.

•

9-2

Press ‘OK’.

Excelsior AS A82310101

Service Schedule This section provides details of the Excelsior AS service schedule.

Excelsior AS A82310101

Service Schedule Issue 3

Service Schedule Excelsior Routine Maintenance Check List Contract Number: Serial Number: Date: Note

For the Annual Service, order A82310043 Annual Service Kit before commencing the service visit. For the 3 year service, order A82310043 Annual Service Kit and A78410058 Set of Batteries.

Annual Maintenance Visit 1. Test the instrument for Earth Continuity and Insulation Resistance. •

Earth continuity measures less than 1Ω

•

Insulation resistance measures greater than 999MΩ at 500 V

Note If instrument fails, do not proceed with the service until the cause of the failure has been established and the fault corrected. Check the Engineer’s Log and look for errors. Investigate the cause of errors before continuing. 2. Fluid Transfer System ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ 3. Check the number of times that the Flush reagents are used (5 Max). Advise customer of possible problems caused by overuse of flush reagents. 4. Check Max Fluid / Base Temperatures, investigate any discrepancies. 5. Specific Gravity Meter (SG Boundaries 860-920) If ok ignore tests 34 & 35 ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________ 6. Errors ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________

10-1

Service Schedule Issue 3

Excelsior AS A82310101

Enter Production Services Screen 7. Check the touch screen calibration by moving cursor with arrow keys. Recalibrate if necessary. 8. Check Modification Strike status, update if required. 9. Check software version is correct. Update to latest software if required. 10. Check the Reaction Chamber Serial No. and Issue No. in Production Services and update if required. 11. Inspect Lid Seal for damage/debris. Clean if required. 12. Open and close lid and ensure operation is correct and down draft fans respond 13. Check level sensors for contamination and clean with the level sensor cleaning pad. Squirt each level sensor in turn with water and check response in Production Services. Note Leave the level sensor cleaning pad with the customer. i.

Level Sensor 1 OK

ii.

Level Sensor 2 OK

iii.

Level Sensor 3 OK

iv.

Level Sensor 4 OK

14. Change the Valve Port Spigot, Static Seal, Screws and Agitate Bearing. 15. Operate red push to test button and ensure trip operates - remake trip. 16. Operate battery switch and check Icon appears - remake switch 17. Pull vacuum in chamber and test emergency vacuum release. (Leave pump running) 18. Clean pump using the following method: •

Put some clean paper by the exhaust of the pump.

•

With a pipette squirt some xylene in the air inlet hole at the top of the chamber.

•

Go into production services and run the pump.

•

Repeat the 3 steps above a couple of times until the paper is clean.

•

Repeat the first 3 steps above using alcohol.

19. Check all heater currents and voltages in Production Services. •

48V (mains) 43.9 – 52.3V

•

12V 11.1 – 12.9V

•

5V 4.6 – 5.4V

•

22V 19.7 – 24.8V

RC Heater Current 7.3A +/- 1A Nominally Wax Tank Heater Current 3.1A Nominally Storage Heater Current 0.8A Nominally RC Heater 3 Current 1.04A Nominally RC Heater 2 Current 1.46A Nominally RC Heater 1 Current 2.08A Nominally 10-2

.

Excelsior AS A82310101

Service Schedule Issue 3

Wax Pipe Heater Current 0.75A Nominally.

Automatic Tests 20. Perform Test 8 RC Valve Stiffness Test. 21. Perform Auto Test 11 RC Leak Test. Note Remove Front Reagent Bottles before starting the next test. •

Time to evacuate the chamber F3

60 seconds +/- 5 seconds

•

Time to evacuate the chamber and other ports

20 seconds +/- 5 seconds

•

Leak test fail limit

15 mBar

•

Leak test typical value

10 mBar

22. Carry out Auto Test 12 RC Heater, Reduced Port Widths Test. Stop the test after the heaters pass. Refit Front Reagent Bottles when test complete. Note Perform the following steps while the test is running: 23. Clean Filter Baffle and change Charcoal and Permanganate Filters if necessary (consumables normally supplied by the customer). 24. Check Production Services Screen shows Filters in place. 25. Open storage door - ensure icon appears and extract fan speed increases In Production Services, check the extract fan operation: High speed when ‘High is pressed and Low Speed when ‘Low’ is pressed. 26. Check pipes in storage area for damage, leaks, kinks etc. 27. Check spill containment area and clean if required. 28. Inspect wax tanks for debris/water contamination. 29. Measure wax bath temperatures and ensure similar to screen.

Remove Rear Panel 30. Check machine for leaks - around rear bottles, under reaction vessel, at pipe fittings. 31. Check temperature of Liquid in A2 on screen (Analogues Section, below RH Set. Left number is X2, right number is A2). Remove thermistor from A2 and compare the liquid temperature using a calibrated probe. 32. Inspect all back bottles, check for obvious evaporation, if contaminated clean out. Change reagent bottles that are heavily contaminated. 33. Remove the anti evaporation tube and clean S.G. weight, clean and replace assembly (use new cable tie provided). 34. Refit any removed bottles, check operation of the SG assembly in Production Services. Weight should indicate 105G in air and 38-48G in reagent depending on quality. 10-3

Service Schedule Issue 3

Excelsior AS A82310101

Note Carry out either of the following tests if SG readings are suspect on Engineers Log 35. Auto Test 10 Known Fluid SG Cal (Wet Cal) Auto Test 10 checks and calibrates the specific gravity (SG) assembly using air, water and alcohol of known or measured SG. The test fails if: •

Vref is greater than 192

•

Vref is less than 80

•

Dry sensor is less than 2500

•

Volume is greater than 730ml

•

Volume is less than 702ml

•

Tare is less than 10

OR 36. Auto Test 9 SG Cal (Dry Cal) Test 9 checks and calibrates the specific gravity (SG) assembly using air only. The test will prompt you to load an empty container in the Fix 2 position. Once confirmed the machine will draw A1 into the chamber and drain it to Fix 2. The machine will then allow 600 seconds for the SG weight to dry. Note There is the option to “override” the drying time, but is not recommended unless the A1 bottle was empty to begin with. After the calibration is complete the machine will draw the contents of Fix 2 and return it to the A1 bottle. The test fails if: •

Vref is greater than 192

•

Vref is less than 80

•

Dry sensor is less than 2500

•

Volume is greater than 730ml

•

Volume is less than 702

•

Tare is less than 10

37. Run a short engineer’s test program and flush. Note While the program is running; switch power off at mains outlet. Check that Excelsior switches to backup battery power and process continues for a minimum of 5 minutes. If OK, switch on mains power. If not OK, investigate cause of battery backup failure. 38. Refit any panels or bottles that have been removed. Ensure all earth leads are reconnected. 39. Test instrument for Earth Continuity and Insulation Resistance.

10-4

Excelsior AS A82310101

Service Schedule Issue 3

Note If instrument fails, do not proceed with service until the cause of the failure has been established and the fault corrected. 40. Enter the date that the 1 Year Service was carried out in the 1 Year Service Field in Production Services.

3 Year (36 Month) Maintenance Visit Complete all steps in the previous sections, plus the following: 41. Change out the batteries. 42. Identify battery change in the service log book. Enter the date that the 3 Year Service was carried out in the 3 Year Service Field in Production Services.

10-5

Technical Drawings This section provides technical drawings for Excelsior AS.

Excelsior AS A82310101

Technical Drawings Issue 3

Technical Drawings Introduction This section contains the following circuit diagrams and schematics: •

Digital I/O PCB

(A823-0104)

11-2

•

Specific Gravity PCB

(A784-0108)

11-11

•

Passive I/O PCB

(A823-0103)

11-12

•

Tank Board

(A823-0106)

11-15

•

Detector PCB

(A784-0131)

11-16

•

Emmiter PCB

(A784-0132)

11-17

•

Motor PCB

(A784-0133)

11-18

•

Distribution Board Schematic

(A823-0105)

11-19

•

Electrical Schematic (Service)

(A823-0102)

11-26

•

Pneumatic Schematic

(A784-0114)

11-31

11-1

Technical Drawings Issue 3

Excelsior AS A82310101

Digital I/O PCB Sheet 1/9

11-2

Excelsior AS A82310101

Technical Drawings Issue 3

Sheet 2/9

11-3

Technical Drawings Issue 3

Sheet 3/9

11-4

Excelsior AS A82310101

Excelsior AS A82310101

Technical Drawings Issue 3

Sheet 4/9

11-5

Technical Drawings Issue 3

Sheet 5/9

11-6

Excelsior AS A82310101

Excelsior AS A82310101

Technical Drawings Issue 3

Sheet 6/9

11-7

Technical Drawings Issue 3

Sheet 7/9

11-8

Excelsior AS A82310101

Excelsior AS A82310101

Technical Drawings Issue 3

Sheet 8/9

11-9

Technical Drawings Issue 3

Sheet 9/9

11-10

Excelsior AS A82310101

Excelsior AS A82310101

Technical Drawings Issue 3

Specific Gravity PCB

11-11

Technical Drawings Issue 3

Passive I/O PCB Sheet 1/3

11-12

Excelsior AS A82310101

Excelsior AS A82310101

Technical Drawings Issue 3

Sheet 2/3

11-13

Technical Drawings Issue 3

Sheet 3/3

11-14

Excelsior AS A82310101

Excelsior AS A82310101

Technical Drawings Issue 3

Tank Board

11-15

Technical Drawings Issue 3

Detector PCB

11-16

Excelsior AS A82310101

Excelsior AS A82310101

Technical Drawings Issue 3

Emmiter PCB

11-17

Technical Drawings Issue 3

Motor PCB

11-18

Excelsior AS A82310101

Excelsior AS A82310101

Technical Drawings Issue 3

Distribution Board Schematic Sheet 1/7

11-19

Technical Drawings Issue 3

Sheet 2/7

11-20

Excelsior AS A82310101

Excelsior AS A82310101

Technical Drawings Issue 3

Sheet 3/7

11-21

Technical Drawings Issue 3

Sheet 4/7

11-22

Excelsior AS A82310101

Excelsior AS A82310101

Technical Drawings Issue 3

Sheet 5/7

11-23

Technical Drawings Issue 3

Sheet 6/7

11-24

Excelsior AS A82310101

Excelsior AS A82310101

Technical Drawings Issue 3

Sheet 7/7

11-25

Technical Drawings Issue 3

Electrical Schematic (Service) Sheet 1/5

11-26

Excelsior AS A82310101

Excelsior AS A82310101

Technical Drawings Issue 3

Sheet 2/5

11-27

Technical Drawings Issue 3

Sheet 3/5

11-28

Excelsior AS A82310101

Excelsior AS A82310101

Technical Drawings Issue 3

Sheet 4/5

11-29

Technical Drawings Issue 3

Sheet 5/5

11-30

Excelsior AS A82310101

Excelsior AS A82310101

Technical Drawings Issue 3

Pneumatic Schematic

11-31

Spares Lists This section lists the spares and accessories available for the Excelsior AS instrument.

Excelsior AS A82310101

Spares Lists Issue 3

Spares Lists Structure and Deck Table 1: Excelsior AS Spares – Structure and Deck

Part Number AP14739 A78420103

Item

Description

Quantity

S1

Ball Transfer Unit

1

BP1

Bottle Heating Fan

1

Carcass Insulation Kit: A78410038

A82310050 A78020073

S2

Side Insulation

2

S3

Plinth Insulation

1

A1 Bottle Support Foam Kit S19 DD1

A1 Bottle Support Foam Downdraft Fan Assembly

2 1

Extraction Fan Kit: A82310042

A78420206

S4

Fan Spacer

1

S5

Fan Gasket

1

S6

Extraction Fan

1

DD2

Filter Sensor

1

AP14455

S7

Main Door Sensor (opto interrupter)

1

A78430233

S8

Reagent Bottle Heater Mat

1

A78420204

S9

Reagent Bottle Heater Thermistor

1

A82310051

DD3

Display Complete

1

A82310013

DD4

Pivoting Filter Lid

1

A82310020

DD5

Filter Microswitch Bracket Assembly

1

A82330044

Not Shown

Deck Tray

1

Emergency Vent Plug

1

AP14572

S18

A-1

Spares Lists Issue 3

Excelsior AS A82310101

Wax Baths Table 2: Excelsior AS Spares – Wax Baths

Part Number

Item

Description

Quantity

A82310040

TL3

Wax Bath Assembly

1

A82320084

WT1

Wax Temperature Sensor

1

Wax Heater Kit A82310041

WT2

Wax Heater

1

WT3

Foam Strip

2

Pneumatics Table 3: Excelsior AS Spares – Pneumatics

Part Number

Item

Description

Quantity

A82310004

S10

Pump Plate Assembly

1

A78410015

S11

Pressure Transducer

1

AP14319

S12

Solenoid

1

Bottles Table 4: Excelsior AS Spares – Bottles

Part Number

Item

Description

Quantity

Specific Gravity Bottle Kit: A78410030

SG6

Anti-Evaporation Tube and Gasket

1

SG7

Cable Tie

1

SG8

Specific Gravity Bottle Assembly

1

A78410031

S13

Fixed Reagent Bottle

1

A82310032

S14

Water Flush Bottle

1

A78410113

TL5

Specific Gravity Assembly

1

A78420160

SG6

Anti-Evaporation Tube and Gasket

1

Specific Gravity Linkage Kit: A78410036

SG1

Specific Gravity Weight Assembly

1

SG2

Lift Arm Specific Gravity Unit

1

SG3

Specific Gravity Suspension Bar

1

A78410069

SG5

Specific Gravity Sensor Electrical Assembly

1

AP14414

SG4

Specific Gravity Linear Actuator

1

A-2

Excelsior AS A82310101

Spares Lists Issue 3

Reaction Chamber Table 5: Excelsior AS Spares – Reaction Chamber

Part Number

Item

Description

Quantity

Upper Agitate Coupling Kit: A82310052

A82310053

RC1

Upper Agitate Coupling

1

RC2

Agitate Bearing

1

Agitate Bearing Kit RC2

Agitate Bearing

5

AP14584

RC3

Brush Block

1

A78430109

RC4

Encoder Disk

1

A78420184

RC5

Level Sensor

1

A78430252

RC6

Lid Switch

1

A78410053

RC7

Motor Assembly

1

A82310054

TL2

Reaction Chamber Complete

1

A82310014

RC8

Reaction Chamber Lid Assembly

1

A78430342

RC9

Reaction Chamber Lid Seal

1

A82330035

RC24

Chamber Lid Handle

1

Reaction Chamber Thermistor Kit: A82310055

RC10

Reaction Chamber Thermistor

1

RC22

Insulation Tape (700 mm)

1

RC 14

Cable tie

1

RC Wall Heater Kit:

A82310056

RC11

RC Wall Heater

1

RC12

Heater Insulation

1

RC13

Insulation Tape (200 mm)

1

RC14

Cable tie

3

RC22

Insulation Tape (700 mm)

1

RC23

Heat Dispersion Plate

1

Cable tie (small)

6

Not Shown

Valve Port Seal Kit: A82310057

RC15

Valve Port Seal

1

RC16

Valve Port Insert Static Seal

1

RC21

Screw

4

AP14332

RC17

Rotor Outer Seal

1

A78430232

RC18

Brush Block Insulation

1

A82310058

RC19

Valve Rotor Assembly

1

A-3

Spares Lists Issue 3

Excelsior AS A82310101

Electronics Table 6: Excelsior AS Spares – Electronics

Part Number

Item

Description

A78410058

S15

Battery

2

P13291

Not Shown

UK Mains Lead

1

P13292

Not Shown

USA Mains Lead

1

P13290

Not Shown

European Mains Lead

1

AP15410

Not Shown

Chinese Mains Lead

1

A82310045

EB1

Processor PCB

1

A82310046

EB2

Digital IO PCB

1

A82310047

EB3

Distribution PCB

1

A82310048

EB4

Passive PCB

1

A82310049

RC20

Tank PCB Kit

1

A78410047

SG9

Specific Gravity PCB

1

A81510048

DD6

Display Driver PCB

1

A81510047

DD7

Display Inverter PCB

1

A78420081

EB7

Speaker

1

AP15314

S16

Battery On/Off Switch

1

A82310018

EB6

Power Supply Unit

1

A78420149

S17

Reaction Chamber Heater Cut-out - 80V DC, 30A

1

P13272

EB5

Mains On/Off Switch

1

A-4

Quantity

Excelsior AS A82310101

Spares Lists Issue 3

General Instrument Servicing Table 7: Excelsior AS Spares – General Instrument Servicing

Part Number

Item

Description

Quantity

8mm Coupling Kit:

A78410040

Not Shown

Coupling - equal straight

1

Coupling - equal elbow

1

Coupling - equal T

1

Coupling - bulkhead

1

Coupling - 1/4" Stem and O-ring

1

12mm Coupling Kit:

A78410041

Not Shown

Clip

7

Coupling - equal straight

1

Coupling - equal elbow

1

Coupling - equal T

1

Coupling - bulkhead

1

Fitting - 3/8" BSP

1

Grommet

5

12mm Elbow Coupling Kit: A82310059

A82310060

Not Shown

Not Shown

Coupling - equal elbow

9

Red anti-push cover

9

Fuse Kit: Remote Alarm Remote Alarm Fuse

4

Remote Alarm Connector

2

A78430262

Not Shown

Castor Adjustment Rod

1

AP14590

BP2

Instrument Moving Handle

1

A78430308

Not Shown

Spanner 19 mm A/F

1

AP17225

Not Shown

Packaging

1

Annual Service Kit

A82310043

RC15, RC16, RC21

Port Seal Kit

1

RC2

Agitate bearing

1

SG7

Cable Tie

1

Level Sensor Cleaning Pad

1

A-5

Spares Lists Issue 3

Excelsior AS A82310101

Pipes Table 8: Excelsior AS Spares – Pipes

Part Number

Item

Description

Quantity

User Bottle Pipe Kit

A82310061

Not Shown

Fixative Pipe Assembly

2

Exchange 1 Pipe Assembly

1

Exchange 2 Pipe Assembly

1

Flush 1 Pipe Assembly

1

Flush 2 Pipe Assembly

1

Flush 3 Pipe Assembly

1

Chamber Pipe Kit

A82310062

Not Shown

Fix 1 Elbow (Blue)

A82330226

1

Fix 2 Elbow (Blue)

A82330224

1

A1 Elbow (Blue)

A82330223

1

EX1 Elbow (Blue)

A82330222

1

A2 Elbow (Red)

A82330229

1

A3 Elbow (Red)

A82330230

1

A4 Elbow (Red

A82330232

1

A5 Elbow (Red)

A82330231

1

A6 Double Elbow (Red)

A82330179

1

X1 Double Elbow (Red)

A82330180

1

EX2 Elbow (Green)

A82330235

1

X2 Double Elbow (Red)

A82330181

1

X3 Double Elbow (Red)

A82330182

1

F1 Elbow (Green)

A82330234

1

F2 Elbow (Green)

A82330233

1

F3 Elbow (Blue)

A82330225

1

8 mm Diameter Nylon tube

1 Metre

Back Bottle Dip Pipe Kit

A82310063

Not Shown

A1 Dip Pipe (Blue)

A82330243

1

A2, A5 Dip Pipe (Blue)

A82330240

2

A3, A4 Dip Pipe (Blue)

A82330241

2

A6 Dip Pipe (Blue)

A82330242

1

X1, X2, X3 Dip Pipe (Red)

A82330245

3

8 mm Diameter Nylon tube

1 Metre

A82320090

Not Shown

Wax 1 Heated Pipe Assembly

1

A82320091

Not Shown

Wax 2 Heated Pipe Assembly

1

A82320092

Not Shown

Wax 3 Heated Pipe Assembly

1

A82320093

Not Shown

Wax Waste Heated Pipe Assembly

1

A82310036

Not Shown

Back Bottle Air Pipe Kit (Blue)

1

A82310037

Not Shown

Back Bottle Air Pipe Kit (Red)

1

A-6

Excelsior AS A82310101

Spares Lists Issue 3

Special Tools Table 9: Excelsior AS - Special Tools

Part Number

Item

T61452

Description

Quantity

9mm AF Allen Key

1

Emergency Vent Plug

1

T61401

Valve Alignment Pin

1

T-20H

Security Torx Bit

1

P01913

Silicone Grease

1

P12580

Trident Pin Extractor

1

T61449

10mm Socket for Chamber Lid Switch

1

T61450

19mm Socket for Chamber Temperature Sensor

1

T61451

26mm Socket for Chamber Level Sensor

1

55mm AF Socket

1

AP14572

S18

Accessories Table 10: Excelsior AS – Accessories Baskets

Part Number

Accessory

Quantity

A78410021

Random Basket

1

A78410025

Organised Basket

6

A82310038

Organiser 50 Cassette Segment basket kit

6

A82310071

SecureSette segment basket kit

6

A78420156

Basket Lid

1

A78420158

Large Black Metal Divider (for random basket)

1

A78410095

Level Sensor Cleaning Pad

1

Table 11: Excelsior AS – Accessories Extraction Adaptor Kits

Part Number

Accessory

Quantity

A82310033

Downdraft Extraction Duct Adaptor Kit

1

A78410024

Main Air System Duct Adaptor Kit

1

Table 12: Excelsior AS – Accessories Filters

Part Number

Accessory

Quantity

9990610

Vapour Filter (carbon)

1

7411258

Carbon Filter Pack of 6

6

9990612

Formaldehyde Filter

1

Formaldehyde Filter Pack of 6

6

B9990612CS

A-7

Spares Lists Issue 3

Excelsior AS A82310101

Table 13: Excelsior AS – Accessories Reagent Bottles

Part Number A78410026 8300

Accessory

Quantity

5 Litre Reagent Bottle (empty) Pack of 6

6

Wax Waste Tray

5

Table 14: Excelsior AS – Accessories General

Part Number

Quantity

A82310100

Operator Guide

1

A82310101

Service Manual

1

Spatula

1

1 GB USB Flash Drive

1

P09046 AP17385

A-8

Accessory

Excelsior AS A82310101

Spares Lists Issue 3

A-9

Service Fault Codes This section lists the service fault codes for the Excelsior AS instrument.

Excelsior AS A82310101

Service Fault Codes Issue 3

Service Fault Codes Fault Code

Number

Fault Status Warning

In Use/Not in use

AL_DISC_DRIVE

1

OK USB Drive

Not in use

AL_DOWNDRAFT_FAN_LEFT

2

OK Downdraft fan – Left

Not in use

AL_DOWNDRAFT_FAN_RIGHT

3

OK Downdraft fan - Right

Not in use

AL_EXTRACT_FAN

4

OK Extract fan

Not in use

AL_REAGENT_HEAT_FAN

5

OK Reagent heating fan

Not in use

AL_UNDERFILL

6

OK Underfill

AL_MAINS_FAIL

7

OK Mains Fail

AL_BATTERY_ISOLATOR

8

OK Battery Isolator

AL_BATTERY_LOW

9

OK Battery Low

Not in use

AL_PSU_SELF_TEST

10

OK PSU self test

Not in use

AL_MICRO_SELF_TEST

11

OK Micro IO self test

Not in use

AL_PROCESS_LEFT_ON_HOLD

12

OK Process left on hold

AL_LID_OPEN_ALARM

13

OK Lid open alarm

AL_OVERFILL

14

OK Overfill

Not in use

AL_OVERTEMP

15

OK Over temperature

Not in use

AL_CHAMBER_HEAT_CUTOUT

16

OK Chamber heater cut-out

AL_CHAMBER_HEAT_MAT

17

OK Chamber heater mat

AL_WAX1_HEATER_MAT

18

OK Wax 1 heater mat

AL_WAX2_HEATER_MAT

19

OK Wax 2 heater mat

AL_WAX3_HEATER_MAT

20

OK Wax 3 heater mat

AL_REAGENT_HEATER_MAT

21

OK Reagent heater mat

AL_WAX_UNDER_TEMP

22

OK Wax under temperature

AL_LEVEL_SENSOR

23

OK Level sensors

AL_AIR_PUMP

24

OK Air pump

AL_ROTARY_VALVE

25

OK Rotary valve

AL_SPECIFIC_GRAVITY

26

OK Specific gravity

AL_PNEUMATIC_VALVES

27

OK Pneumatic valves

AL_AIR_LEAK

28

OK Air leak

AL_CHAMBER_BOT

29

OK RC wall heater 1

AL_CHAMBER_MID

30

OK RC wall heater 2

AL_CHAMBER_TOP

31

OK RC wall heater 3

AL_PIPE

32

OK Pipe heater

AL_WAX1_LEVEL

33

OK Wax 1 level

AL_WAX2_LEVEL

34

OK Wax 2 level

AL_WAX3_LEVEL

35

OK Wax 3 level

AL_RC_TRIP_OUT

36

WARN RC trip out

AL_I2C_FAULT

37

OK I2C fault

Not in use

Not in use

B-1

Repacking Instructions This section describes how to repack the Excelsior AS instrument for relocation.

Excelsior AS A82310101

Repacking Instructions Issue 3

Repacking Instructions If the instrument is to be transported, follow these packaging instructions, after unloading ALL reagents and wax and switching the instrument off. Refer to the Operator Guide for more information. When moving Excelsior AS , use safe lifting practices. Excelsior AS weighs approximately 165 kg (364 lb) when empty and 200 kg (440 lb) when full. At least two people are needed to safely move the instrument. Note Use ALL original packaging and keep the instrument upright at ALL times.

1. Place the base of the packaging in a clear area. Note Three metres is required in front of the packaging for the ramp and approximately one metre is required behind the packaging. 2. Lower the packaging ramp.

3. Fit the handles to the back of the instrument. 4. Carefully wheel the instrument up the ramp until it sits securely in the base.

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Repacking Instructions Issue 3

5. Remove the handles from the back of the instrument and secure them at the back of the instrument.

6. Put the foam pieces in place.

7. Raise the ramp and secure the ramp to the instrument with tape.

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Excelsior AS A82310101

Excelsior AS A82310101

Repacking Instructions Issue 3

8. Fit the outer cover.

9. Turn the three fasteners to secure the outer cover in place.

10. Fit the lid over the outer cover.

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Repacking Instructions Issue 3

Excelsior AS A82310101

11. Secure the packaging using two bands through the palette and over the lid.

After packaging, ensure that the instrument is kept upright at all times while it is being transported.

C-4

Approved Reagents This section lists the reagents specified by Thermo for use with the Excelsior AS instrument.

Excelsior AS A82310101

Approved Reagents Issue 3

Approved Reagents All the reagents specified by Thermo for use with the Thermo Scientific Excelsior AS tissue processor are listed below. If you want to use a reagent not included in this list, contact your Thermo agent for advice. Do not use Bouin's fixative, acetone, formal saline, chloroform, or any reagents containing calcium chloride. Waxes containing DMSO may damage painted surfaces – in particular if the painted surface is scratched Refer to the Material Safety Data Sheets when handling the reagents listed in Appendix E.

Type Fixatives

Approved Reagents 10% Neutral Buffered Formalin (Phosphate Buffers) Richard-Allan Scientific Pen-Fix Ethanol

Dehydrants

Reagent grade alcohol (RGA) / industrial methylated spirit (IMS) – up to 5% methanol in ethanol Isopropyl alcohol Richard-Allan Scientific Flex 100 (up to 40% methanol in isopropyl alcohol) Xylene

Clearants

Toluene Shandon Xylene Substitute Richard-Allan Scientific Clear-Rite 3 Shandon Histoplast Shandon Precision Cut

Infiltrants

Richard-Allan Scientific Histoplast PE Richard-Allan Scientific Histoplast LP RA Lamb VA5 Richard-Allan Scientific Type 1, Type 3, Type 6, Type 9, Type L and Type H Any of the named clearants (max 65° C)

Flush

Any of the named dehydrants Water

Surface Cleaning

Sodium Hypochlorite (10% in water used at ambient temperature)

D-1

Cleaning and Maintenance This section describes how to clean and maintain the Excelsior AS instrument.

Excelsior AS A82310101

Cleaning and Maintenance Issue 3

Cleaning and Maintenance This section covers the following cleaning and maintenance tasks: •

Cleaning safety

•

Clearing spillages

•

Daily and weekly cleaning tasks

•

Discarding used wax

•

Cleaning the wax bath

•

Cleaning the reagent supply bottle dip tubes

•

Cleaning the flush 3 water bottle

•

Cleaning the touch screen display

•

Changing filters

•

Regular Maintenance checks

E-1

Cleaning and Maintenance Issue 3

Excelsior AS A82310101

Cleaning safety and tasks Cleaning Safety Normal standards of laboratory hygiene and routine maintenance procedures are all that is necessary to keep the Thermo Scientific Excelsior AS in good and serviceable condition. Before using any cleaning or decontamination method, except those recommended by the manufacturer, users should check with the manufacturer that the proposed method will not damage the equipment. Inspect the instrument for obvious damage or wear whenever you clean or use it. Always wipe up any spills immediately. In the event of a major spillage, disconnect the instrument from the mains supply without delay and do not reconnect and switch on until the instrument has been thoroughly dried out and checked by a Service Engineer. If hazardous material is spilt on, or inside, the instrument you must carry out the appropriate decontamination. Do not use abrasive compounds or metal components to clean Excelsior AS or its components and accessories. Always take the necessary safety precautions when you clean or decontaminate Excelsior AS to protect yourself against the effects of chemicals. As with all scientific equipment, due care and good laboratory practice must be employed when dealing with chemicals, and consideration must be given to the potential for hazard when dealing with particular chemicals. Unless otherwise stated, only use reagents that appear on the approved list (Appendix D) to clean Excelsior AS.

E-2

Excelsior AS A82310101

Cleaning and Maintenance Issue 3

Clearing Spillages Any reagent spills within the instrument will be contained. Small spills, such as drips from the reagent tubes when the reagents are changed, will evaporate and be extracted. Some chemicals which may be used during operation are flammable – do not use sources of ignition in the vicinity of the instrument when it is loaded with reagents. Harmful chemical vapours such as xylene and toluene may be emitted during the normal operation of some instruments, and the operator should be aware of suitable precautions and safety measures. To clean large spills: •

Remove all the reagent bottles from the Reagent Storage Area.

•

To access the spillage containment area, lift and remove the metal shelf in the base of the Reagent Storage Area.

•

Clean any liquid from this area and dispose of in accordance with any local procedures or regulations.

•

Replace the metal shelf and the reagent bottles.

Note Ensure that the metal shelf is the correct way up; the folded edge must be on the top.

Daily and Weekly Cleaning Tasks The following cleaning tasks should be performed on a daily and weekly basis.

Daily Checks Check the following on a daily basis: •

General instrument cleanliness.

•

Reagent bottle contents.

•

Wax bath contents.

•

Clean level sensors.

Weekly Checks Check the following on a weekly basis: •

Spillage containment area.

•

Level sensors; clean as required with the level sensor cleaning pad provided.

E-3

Cleaning and Maintenance Issue 3

Excelsior AS A82310101

Wax and Wax Baths Ensure that you wipe out Wax Bath 3 (which is used to load new wax into the instrument) after wax is rotated and discarded into the waste wax tray.

Discarding Used Wax When the wax is changed (using the Excelsior AS rotation technique), the oldest wax is discarded into the consumable waste wax tray. To discard used wax: •

Excelsior AS prompts you, via the Quality Control screen, to confirm that the waste wax tray is in place above the two right-hand wax baths.

•

Ensure that there is a consumable waste wax tray and lid fitted into the instrument.

Waste wax tray fitted above W1 and W2

•

Open the wax door and carefully slide the consumable waste wax tray from the instrument. The waste wax tray contains hot molten wax.

•

Place the tray in a cool, well ventilated area away from the instrument and allow the wax to set. When the waste wax has set, discard the entire waste wax tray and solid wax in accordance with local procedures and regulations.

•

Fit a new consumable waste wax tray into the instrument into position above the wax baths and close the access doors. Ensure that there is always an empty waste wax tray in the instrument.

Cleaning the Wax Bath After the old wax is discarded, wax bath 3 is empty.

E-4

Excelsior AS A82310101

Cleaning and Maintenance Issue 3

To clean the wax bath •

Open the left-hand wax access door.

•

Use absorbent paper to wipe out any remaining wax from the wax bath.

•

Make sure that no paper is left in the wax bath. The base of the wax baths is hot. Always wear protective gloves.

Reagent and Flush Bottles Ensure that you clean the reagent dip tubes when reagents are rotated. The Flush 3 bottle should be cleaned and refilled when flush reagents are renewed.

Cleaning the Reagent Supply Bottle Dip Tubes The dip tubes supplying the following should be cleaned each time the reagents are changed or discarded: •

Fixative 1 (Fix1)

•

Fixative 2 (Fix2)

•

Exchange 1 (Ex1)

•

Exchange 2 (Ex2)

•

Flush 1 (F1)

•

Flush 2 (F2)

•

Flush 3 (F3)

To clean reagent supply bottle dip tubes: •

Carefully remove the dip tubes from the reagent bottles.

•

Clean any contamination from the surface of the tubes with a lint-free cloth.

•

Remove the bottles from the instrument and replace their caps.

•

Dispose of the used reagents in accordance with your local regulations and procedures.

•

Replace reagents according to the Quality Control and Reagent Renewal procedures in the Operator Guide.

Cleaning the Flush 3 Water Bottle The Flush 3 (F3) bottle is located in the cabinet, below the F1 and F2 bottles. To remove the F3 water bottle: •

Remove the F1 and F2 bottles.

•

Remove the green reagent tube from the rear of the F3 bottle and carefully lift and slide the bottle out of the Reagent Storage Area.

•

Remove the cap and dispose of the water in accordance with any local procedures and regulations. Keep the Flush 3 bottle level to avoid any spillage. The Flush 3 bottle must be cleaned before it is refilled with water. E-5

Cleaning and Maintenance Issue 3

Excelsior AS A82310101

To clean the F3 water bottle: •

Rinse the bottle with clean water and mild detergent.

•

Use a bottle brush if required. Do not use temperatures higher than 60°C.

To refill and refit the F3 water bottle: •

Refill the F3 bottle with water up to the underside of the fill-line (approximately 5 litres).

•

Replace the cap.

•

Place the water bottle in the Reagent Storage Area with the cap towards the front of the instrument.

•

Fit the green tube into the open pipe at the rear of the F3 water bottle.

•

Make sure that the tube is fully inserted into the water bottle (so that it sits on the bottom of the bottle) and that there are no kinks in the flexible section of tube.

•

Replace the F1 and F2 bottles.

F3 Water bottle with the fill-line visible

General Cleaning and Maintenance Cleaning the Touchscreen Display The touch screen display should be cleaned on a regular basis. Ensure that the screen is locked before it is cleaned. To clean the display: •

Lock the screen. To do this, press and hold the Thermo Scientific logo in the bottom right of the screen until the 'locked screen' icon appears.

•

Gently wipe the touch screen with a soft damp cloth.

•

Unlock the touch screen. To do this, press and hold the Thermo Scientific logo in the bottom right of the screen until the 'locked screen' icon disappears. Do not use solvents to clean the touch screen.

Changing Filters Change the filters every 13 weeks.

E-6

Excelsior AS A82310101

Cleaning and Maintenance Issue 3

Regular Maintenance Checks The following table describes items that should be checked on a regular basis: Area

Item

What To Do

How Often

Wax baths

Level

Check wax levels in all wax baths.

Daily

Seal

Clean the Reaction Chamber and keep the lid and seal clear of solid wax deposits.

After each processing run

Level Sensors

Carefully clean with tissue or the level sensor cleaning pad that is provided.

After each flush cycle

Latch

Check that the lid latch operates correctly. The downdraft system should operate and the display should show the lid open.

Whenever the lid is opened

Reagent Tubes

Check that the flexible parts of the reagent tubes in the front of the cabinet are not damaged or collapsed.

When loading or unloading reagents

Lid/Reaction Chamber

Reagent Storage Area

Reaction Chamber Heater Trip

Battery Isolation Switch

•

Press the Push-to-Test switch next to the Heater Reset.

•

Switch in the Reagent Storage Area. The Heater Reset switch should operate and the Reaction Chamber Heater trip icon will be displayed on the screen.

•

Press the Heater Reset Switch fully in to reactivate the Reaction Chamber heaters. The Reaction Chamber Heater Fault icon will disappear from the screen.

•

Check the operation of the Battery Isolation Switch during a flush cycle.

•

When the O side is pressed (OFF), the Battery Fault icon should be displayed.

•

When the (I) side of the switch is pressed (ON), the icon should disappear.

Monthly

Monthly

E-7

Engineers Log Evaluation and Netmon This section describes the use of Netmon on the Excelsior AS instrument.

Excelsior AS A82310101

Engineers Log Evaluation and Netmon Issue 3

Engineers Log Evaluation and Netmon Introduction Excelsior AS Netmon provides remote access to Excelsior AS tissue processors via the internet. Excelsior AS Netmon provides a fully interactive demonstration of the Excelsior AS user interface screens. This chapter contains the following sections: •

Installation Requirements.

•

Setting up and configuring Netmon at Customer Sites.

•

Accessing the Excelsior AS Netmon Functions.

•

Basic Operation.

•



Contact Fields.



Buttons on the Address Book Screen.



Adding a New Contact to the Address Book.



Editing an Existing Contact.



Removing a Contact from the Address Book.



Connecting to a Netmon Contact.

Downloading Engineers Log onto USB device. 

USB contents when Engineers Log Downloaded.

•

Downloading Engineers Log Remotely via Netmon.

•

To uncompress or expand Log.823 or Log.txt from USB device.

•

Event Log Evaluation. 

•

•

Interpreting Log Files. 

Event Log Records in Long Term Archive (Stored for Longest Period).



More Detailed Event Log Records (Stored for Shorter Period).

Explanation of Additional Data on Key Press Events. 

•

Running and Viewing Logs Directly from the Excelsior AS.

Three Additional Data Numbers.

Notes for Interpretation of Excelsior AS Rotary Valve Errors. 

Rotary Valve Error-Initialisation.



Processing / Flush Run Rotary Valve Errors.



Processing / Flush Run Rotary Valve Errors.

Do not log onto an instrument when it is processing tissue as actions may cause processing to be interrupted. If the Excelsior AS is processing tissue or in any other ‘non idle’ state, log off. However with the customers agreement it is permissible to download a log file while the instrument is processing before logginf off. F-1

Engineers Log Evaluation and Netmon Issue 3

Excelsior AS A82310101

When logged in check the serial number and IP address on the customer services screen to ensure the correct Excelsior AS has been contacted. If a Netmon diagnosis has corrected problems with the instrument that need to be checked physically, contact the customer to perform the checks (if appropriate) or schedule a service call.

F-2

Excelsior AS A82310101

Engineers Log Evaluation and Netmon Issue 3

Installation Requirements The Excelsior AS tissue processor requires access to the company’s internet connection via our router for internet access. In addition you will need to connect the Perle IOLAN SDS1 to the same router that the Excelsior AS is connected to. This enables access to Excelsior AS through the Netmon application.

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Engineers Log Evaluation and Netmon Issue 3

Excelsior AS A82310101

Setting Up and Configuring Netmon at Customer Sites In order to install the Excelsior AS Netmon Hardware do the following: •

Unpack and power up the supplied router.

•

Unpack and power up the supplied Perle IOLAN box.

•

Allow 5 minutes for the IOLAN to fully boot up. (When the power light changes from green to orange then back to flashing green).

•

Remove the Back Panel from the instrument and then remove the Rear Panel from the Electronics Box.

•

Remove the grommet from the Electronics Box Panel.

•

Feed the Excelsior Ethernet Cable through the hole in the Electronics Box Panel and secure the new grommet in place.

•

Connect the Ethernet connector to the Ethernet Port on the Processor PCB.

•

Refit the Electronics Box Panel onto the instrument.

•

Refit the back Panel onto the instrument.

•

Secure the cable to the panel using the cable clip provided in the back panel.

•

Connect the hospitals internet connection to the routers blue WAN connection using the Blue cable provided. Ensure the WAN light on the router is lit before continuing.

Note It is important that you connect the IOLAN first. • F-4

Take the short Yellow Ethernet cable and connect the IOLAN’s Ethernet connection to Port 4 of the router.

Excelsior AS A82310101

Engineers Log Evaluation and Netmon Issue 3

•

Enter production services on the Excelsior AS and type in the appropriate IP address. IP addresses can range from 101 to 103 – where the first part is fixed to 172.16.13. The server IOLAN will be mapped (via a port number) to look for the specific Excelsior address.

•

Connect the Excelsior Ethernet Cable to Port 1 of the router.

•

It may take several minutes for the IOLAN to fully connect to the IOLAN Server.

•

Add additional Excelsior AS instruments to Port 2 and Port 3 of the Router if required.

Note Each Excelsior As on the same Router MUST have a different IP Address:-

172.16.13.101 172.16.13.102 172.16.13.103 are to be used.

Background information The IOLAN at the customer site will connect to the IOLAN server at Runcorn. Each Customers IOLAN box will have a unique tunnel name assigned which can support up to 3 Excelsior AS machines. The IOLAN server will assign a unique port to each of the three Excelsior AS IP addresses. After configuration return the Excelsior AS – Netmon Customer Details information as over the page:

F-5

Engineers Log Evaluation and Netmon Issue 3

F-6

Excelsior AS A82310101

Excelsior AS A82310101

Engineers Log Evaluation and Netmon Issue 3

Accessing the Excelsior AS Netmon Functions To Install Netmon Software Note Default setup location for Netmon is to your desktop, this is required for Netmon to operate correctly. •

Run setup.exe (A82320115) and follow the onscreen instructions.

To start the Excelsior AS Netmon program after the initial software installation: •

Open the Netmon folder that was installed onto the PC containing the Netmon program.

•

Double click on the ‘NetMonV2’ application.

•

Alternatively click the ‘NetmonV2 link’ in the start menu.

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Engineers Log Evaluation and Netmon Issue 3

Excelsior AS A82310101

Basic Operation

On each initial start up of Netmon you will be presented with a Connection password dialog. If you wish to connect to an instrument or edit the address book you must first enter the password into the box and press OK. No password is required to convert Log Files and generate reports.

In order to access the Netmon functions, press the ‘File’ button and select ‘New Connection’. A new window will appear showing the Address Book screen.

The right hand side of the screen is mostly the Contact Address section. In this section are listed all the Excelsior AS contacts that are currently on the Netmon application. When you highlight a particular contact, the details for that particular contact are displayed on the left hand side of the instrument.

Contact Fields For each contact on Address Book there are multiple information fields containing information about that particular contact. These include the following: Information Field

Description

IP Address

This is the IP address of the IOLAN server at Thermo Fisher.

Port Numbers

These are used to connect to a specific customer as defined on the IOLAN server

Address Entry

The name given to the address book entry.

Customer Name / Details

Name of the customer at the contact address

Hospital Name

Name of the business that the Excelsior As is located

Location

Location of contact business

Excelsior Serial Number

Serial number of the Excelsior AS used at contact address

F-8

Excelsior AS A82310101

Engineers Log Evaluation and Netmon Issue 3

The IP Address field can be left blank (recommended) or if you are connected locally to the Server then you can type 192.168.1.101. The port numbers define the Excelsior instrument you are going to connect to. The serial number of the excelsior will be used when extracting logs. Information about the customer from the address book will be placed at the top of each log file only if the serial number in the log can be matched to that of one in your address book.

Buttons on the Address Book Screen Screen Button

Description

Add New Contact

This button creates a new row in the contact list and enables you to enter data for the contact and the Excelsior AS instrument used at that location.

Remove Selected Contact

This button allows you to remove a currently selected contact from the list.

Save Contacts

Once you have input new contact details after creating a new contact, if you press ‘Save’ this contact will then be added to the contact list for future use.

Cancel

Pressing ‘Cancel’ closes the Address Book screen.

Connect

Pressing ‘Connect’ once you have selected a contact will then start the process of logging onto the clients Excelsior AS at their location.

Adding a New Contact to the Address Book In order to add a new contact to the Address book, you must carry out the following: •

Click on ‘File’ at the top of the Netmon screen.

•

From the drop down menu click ‘New Connection’.

•

Once the Address Book screen appears, click on ‘Add New Contact’.

You will then see a new contact appear in the contact list. This will have the default name of 001. •

In the TCP IP Settings section, enter the ‘IP Address’ for the Server IOLAN (Recommended to leave blank) and the port numbers ‘Port A & Port B’

•

In the Customer Information section, click in the ‘Address Entry’ field and enter the name of the new contact that you are creating.

•

Then in the ‘Customer Name / Details’ enter the contact details.

•

In ‘Hospital Name’ enter the name of the hospital where the Excelsior As will be located.

•

In ‘Location’ enter the area where the contact resides.

•

In ‘Excelsior Serial Number’, enter the serial number of the Excelsior As that you are trying to connect with.

•

Once you have completed all the relevant sections, click on ‘Save Contacts’.

Editing an Existing Contact If you make an error when inputting the information for the new contact, carry out the following: •

Select the contact you want to edit from the contact list.

•

Highlight the section you want to change and enter the correct information.

•

Once you have entered the correct information, click on ‘Save Contacts’ before you leave the new contacts page. F-9

Engineers Log Evaluation and Netmon Issue 3

•

Excelsior AS A82310101

When you click on Save Contacts a new dialogue box will appear asking you to Override Current Settings. Click ‘Yes’ to confirm the change.

Removing a Contact from the Address Book In order to remove a contact from the Existing Address book, carry out the following: •

Open the Netmon application and enter the password.

•

Click on ‘File’.

•

From the drop down menu select ‘New Connection’.

•

Select the required contact from the Address Book.

•

Click on ‘Remove the Selected Contact’.

Carrying out this function will permanently remove this contact from the Netmon application. If you delete this in error you will need to create a new contact and fill out all the required information again.

Connecting to a Netmon Contact If you want to connect to a contact from the Existing Address Book, carry out the following: •

Open the Netmon application and enter the password then click ‘OK’.

•

Click on ‘File’.

•

From the drop down menu select ‘New Connection’.

•

Select the required contact from the Address Book.

•

Click on ‘Connect!’.

•

The Netmon application will then connect to the required Excelsior AS. This could take a few minutes.

•

Once it is connected you will get the user Interface for the Excelsior AS.

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Excelsior AS A82310101

Engineers Log Evaluation and Netmon Issue 3

•

Once connected you will see the “Server IOLAN IP address”, connection time at the top of the Excelsior AS screen & customer address book contact entry.

•

The Excelsior AS can then be used via the Netmon application using the mouse on your PC.

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Engineers Log Evaluation and Netmon Issue 3

Excelsior AS A82310101

Downloading Engineers Log onto USB Device In order to extract an Engineers Log from the Excelsior AS, carry out the following: •

Ensure the Excelsior AS is powered on.

•

Insert a USB device into the Excelsior AS.

•

From the Main screen press ‘Options’.

•

From the options screen press ‘File Operations’.

•

Press the ‘Save Engineers Log’ button.

While the Log is being downloaded onto the USB device, the ‘Save Engineers Log’ button will be greyed out.

Once the Log.823 has been downloaded onto the USB device, the ‘Save Engineers Log’ button will turn blue again. It is then safe to remove the USB device from the instrument.

USB contents when Engineers Log Downloaded When an Engineers Log is downloaded it will contain the following: •

LOG.823

COMPRESSED EVENT LOG FILE

•

LOG.TXT

UNCOMPRESSED EVENT LOG FILE

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RAMFLOGLOG.TXT

For Engineering Development Use Only

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SERVICES.823

For Engineering Development Use Only

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SETUP.823

For Engineering Development Use Only

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XLPLUS.823

For Engineering Development Use Only

F-12

Excelsior AS A82310101

Engineers Log Evaluation and Netmon Issue 3

Downloading Engineers Log Remotely via Netmon In order to download a Log remotely using Netmon, carry out the following: •

Run the Excelsior AS Netmon application (A82320115).

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Enter the password in to the password dialog. Open a new connection to an Excelsior AS. Press the ‘File’ button on the Netmon screen.

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Select the ‘New Connection’ tab from the drop down menu.

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Select the desired customer from right hand side panel (address book).

Note Once a customer has been selected from the address book list, you can then edit any information in the appropriate address entry field. Once complete press the ‘Save Contacts’ button.

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Click on the desired customer and the “customer’s information” will be highlighted in the relevant fields on the address book page.

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Once a connection has been made to the relevant customer, you will see the Excelsior AS display appears on the Netmon screen. On this screen you will see the “Server IOLAN IP” address, connection time & address book entry in the top task bar. You can now operate the Excelsior As manually using your mouse.

•

To download a Log you must click on the ‘Download Log.823’ button at the top of the Excelsior AS display on the Netmon screen.

Note While Log.823 is downloading no screen updates can take place. Normal download time typically takes 20 seconds. F-13

Engineers Log Evaluation and Netmon Issue 3

Excelsior AS A82310101

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Once you press the ‘Download Log.823’ button the Log.823 will begin downloading. A progress bar will be shown once the download begins - this shows the download progress.

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The Log.823 that has been downloaded will be put into a folder named EXxxxxx_MMDDYYY_HHMM which will be in the source folder that you opened the Netmon PC application from (Current user Desktop)

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The log download location should automatically appear on your pc screen after download and extraction is complete.

Note The folder name is separated into 3 sections, the first being the serial number of the instrument (or default if no serial entered), the second being the date of the download and the third being the time of the download. •

If you entered a serial number for the Excelsior AS prior to downloading Log.823, you will get the following file:  SERIAL_MMDDYYYY_HHMM

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If you did not enter a serial number for the Excelsior As prior to downloading Log.823, you will get the following folder:  DEFAULT_MMDDYYYY_HHMM

To close a Netmon Session

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Once you have completed your download and you no longer require access to the customer’s Excelsior AS, click on the ‘x’ button in the top right hand corner of the display screen to close the session.

Note A message will be displayed in the title bar informing you to wait whilst all connections are properly closed. Closing a session may take up to 20 seconds.

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Excelsior AS A82310101

Engineers Log Evaluation and Netmon Issue 3

Expanding Log.823 or Log.txt into Additional Sub Logs In order to expand the Log.txt or Log.823 file, carry out the following: •

Launch the Excelsior AS Netmon application (A82320115).

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Drag ‘LOG.txt’ or ‘LOG.823’ file from its source folder into the Excelsior AS Netmon application window.

Note Drag the file into Netmon’s main window and not a session window. The following reports are automatically generated and copied back into the source folder in addition to the original files following download of Log.823: •

FullLog.txt

The full event log listing in text format

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DrawPorts.txt

A listing of process start and draw events only

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Summary.txt

A summary of log analysis

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BriefLog.txt

The brief event log listing in text format

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TempLog.csv

Temperature logging events in a spreadsheet-friendly format

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Log.txt

This will be generated if you dragged log.823 file

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Engineers Log Evaluation and Netmon Issue 3

Excelsior AS A82310101

Event Log Evaluation Introduction To analyse the performance and history of the Excelsior AS tissue processors, each instrument maintains an event log, detailing its use and activity. Some of the log data is sorted as long-term details (reagent loading and use data) and kept for about 3 months. Detailed records of all key presses, wax temperatures and the details of each process stage and flush activity typically cover 6 weeks use, depending on the usage pattern of the unit. Log files can be automatically downloaded, converted and analysed by the Excelsior AS Netmon program. For details of how to interpret the files, refer to section Interpreting Log Files. This section explains how files can be manipulated manually and when it is appropriate to do so.

Running and Viewing Logs Directly from the Excelsior AS Various reports are available to help you assess instrument performance and reagent usage. Reports comprise a range of different event logs that are presented together in order to provide information on specific system events, for example, temperature readings. Reports can be generated according to the time at which events occurred and the event log types. You can generate a report by selecting a time period and then choosing a report type. Reports can be viewed on screen or saved onto a USB memory stick for viewing on a computer. Note Some reports can be large and may be truncated before they are displayed on screen. To see the full report, save the report to USB and view it on a computer. The following time periods can be specified: •

Last Run:

Retrieves the event logs for a chosen report that were generated from the time the last process run was started through to the present time.

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Last 24 Hours:

Retrieves all of the event logs for the chosen report that were generated over the previous 24 hours and up to the present time.

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Last 7 Days:

Retrieves all of the event logs for the chosen report that were generated over the previous seven days and up to the present time.

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All Data

Retrieves all of the event logs for a chosen report that were generated from the last instrument reset up to the present time.

The following reports are available to view: •

Program Printouts:*

A list of all programs and their parameters that are currently installed on the instrument. A log of every event generated from the last instrument reset to the present time.

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Full Event Log:

Note This report will be very large.

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Concise Event Log:

A reduced version of the full event log containing only process log events.

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Quality Control Status:*

A single page report showing information about the usage of the reagent bottles and wax baths.

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Excelsior AS A82310101

Engineers Log Evaluation and Netmon Issue 3

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Quality Control History:

Rotation and reagent management event logs, for example, specific gravity readings.

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Temperature Status:*

This captures immediate temperature data for the wax and reaction chamber and current fluid levels.

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Temperature History:

Shows a range of temperature readings for process and flush cycles.

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Instrument Setup:*

Shows the complete set of configuration settings, in text form, that are currently being used on the instrument.

* These reports are independent of the specified time period. To view reports: •

Select ‘Quality Control > Reports’ to display the Quality Control - Reports screen.

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Choose the time period for the report.

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To display a single report on the screen, press ‘View’ next to the report that you require. The report is displayed on the screen.

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Use your fingertip on the touch screen to scroll down through the report.

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Press ‘OK’ to exit. Quality Control – Reports screen

Saving reports Note Before saving reports, ensure that a USB device is in place in the instrument. •

Select an individual report or multiple reports. After selection, reports are highlighted in yellow.

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Press ‘OK’ to save and exit from the screen. The light on the USB device flashes while saving is in progress.

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Press ‘OK’ to return to the Main menu.

Note OK will appear shaded if a USB device is not inserted.

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Engineers Log Evaluation and Netmon Issue 3

Excelsior AS A82310101

Interpreting Log Files The log files are maintained in date and time order, though some events are recorded as a group of events that all show the same time. When this occurs, the events are deemed to have happened at the same time – there is no significance in an event being listed first. To help you understand the log entries, examples are shown here with explanations of the data associated with each event record.

Event Log Records in Long Term Archive (Stored for Longest Period) Log Entry

Explanation

SG BOUNDS 86-> 92 TEMP 29 SG 932

Specific Gravity is moving between the bounds of 860 (0% used) to 920 (100% used) and has reached 932, that is, the 100% point has been passed.

FM LOAD 22 F3

Fluid Monitoring – User has loaded bottle Flush 3 (internally Flush 3 is vessel 22).

FM USE X1 (prog 1 step 8 baskets 4) uses 2

Fluid Monitoring – The X1 bottle is being used for the second time to process Step 8 of Program 1. The level was set to two levels (4 organised baskets).

FM MOVE A1 (prog 1 step 2 baskets 6) to EX1

Fluid Monitoring – Program 1 Step 2 was run on a discard run and moved fluid from A1 to EX1. Three layers of organised baskets present.

FM UNLOAD 16 WW

Fluid Monitoring – Wax waste has been unloaded by the user (internally wax waste is vessel 16).

A1 LIMIT 75 0

The alcohol is 75% used.

More Detailed Event Log Records (Stored for Shorter Period) Log Entry

Explanation

KEYPRESS “Confirm Loaded” 9596 UIF 1 0 0 (0, 1, 11)

The context sensitive button on the keypanel associated with the label ‘Confirm Loaded’ is pressed.

LOGON logon ADMIN

User named ‘ADMIN’ logged on.

LOGOFF logoff ADMIN

User named ‘ADMIN’ logged off.

PROCESS START “Routine Overnight” (prog 1) DLY STEP 1 B2

Process number 1 started in step 1. Currently program 1 is called ‘Routine Overnight’ – though this may have been changed since the log event was stored. Two organised baskets were showing on the chamber mimic. There was a delay on the first step.

PROCESS END TIME “Routine Overnight” (prog 1) END TIMEA 10/22/03 09:00:05

The delay was such that the program would finish at 9am on the day shown.

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Excelsior AS A82310101

Engineers Log Evaluation and Netmon Issue 3

Log Entry

Explanation

FLUSH START “Standard Flush”

The flush program shown was started.

ERROR 25 Specific Gravity 1 WARN 0008

The named error has changed state to either ‘WARN’ or ‘ERROR’ or ‘OK’. 25 refers to the position of the fault status screen.

POWER ON MAINS FAIL BATTERY LOW SHUTTING DOWN VALVE OPEN DEST EX2 AGIT 0 DIR CLOSEST AT A2

Monitoring of rotary valve as it opens at ‘EX2’. Currently it is at ‘A2’. It will travel in the direction that gives the shortest travel. When it arrives it will not agitate.

VALVE CLOSE DEST C-X1 AGIT 4 DIR FWD AT EX2

Monitoring of rotary valve as it closes next to the ‘X1’ port. Currently it is as ‘EX2’. It will travel forward to get there (counter clockwise when viewed into the chamber). Once it arrives it will then start agitating with a double stir action.

SETTEMP HTR WAX3 OLD 37 NEW 60

Heater setpoint temperature being changed from 37 to 60°C on ‘wax 3’.

BASE TEMP. RC 30 WAX 63 60 74

Heater mat temperature measured in the reaction chamber and each waxbath.

FLUID TEMP. RC29 WAX 57 57 59

Liquid temperatures measured in the reaction chamber and each wax bath.

07/05/13 16:00:00 LEVEL TEMP. WAX 1:62 2:62 3:62

Temperature of the ‘wax 3’ level sensor dip probes.

07/05/13 16:00:00 WALL TEMP. B:20 M:20 T:20

Temperature of the 3 RC wall heater mat sensors.

CURRENT (.1A)RC 75 WAX 31 30 32

When a heater cut-out is detected the current through each heater is recorded. Chamber = 7.5A, Wax1 = 3.1A &c.

DRAW PORT EX2 STATE BUBDET 888mB 0 -> 1 29 1 ->2 22 2-?3 19

Fluid transfer characteristics transferring from ‘EX2’ to reaction chamber. Time to reach first level sensor 29s. Level 1 to Level 2 21s. End of transfer due to bubble detection. (Could have been BUSY if reached required level or BLOCKED). Time above level 2 before bubbles detected was 19s.

BLOW PORT A6 STATE NO_ERR 3 ->2 16 2 ->1 221

Timing for transfer from Reaction chamber to ‘A6’.

STATE CHANGE 26 27 STD21B

The internal software control for system 21B has changed from state 26 to 27. Only shown in enhanced log history files. For development engineers use only.

FLAGS CHANGE vtc 0502:0208

Internal software monitors. Only shown in Enhanced log history files. For development engineers use only. F-19

Engineers Log Evaluation and Netmon Issue 3

Excelsior AS A82310101

Log Entry

Explanation

UNDERFILL 17 W1 77 54 30 Wax

Waxbath 1 (internally vessel 17) underfilled by only reaching 54% up the chamber when the process demand was for 77% full (just over the third level sensor). The waxbath was programmed to hold reagent 30 (wax).

FILTER CHANGE 0 Downdraft filter

The named filter has been replaced. (The number is the internal index for each of the 3 filters).

LEVEL SENSOR 1 (2) ftl3 p_ststae3 level50

Level sensor 1 has not operated with the expected time. (2) implies it showed no liquid when it should have been covered). Ftl and p_state are internal state variables for development engineers use only. The chamber mimic showed 50% full when this warning was recorded.

LEVEL SENSOR 1 (1) ftl3 p_ststae3 level50

Level sensor 1 has not operated with the expected time. (1) implies it showed liquid when it should have been clear. Ftl and p_state are internal state variables for development engineers use only. The chamber mimic showed 50% full when this warning was recorded.

VERSION 2418

The software version number is reported at the start of each run.

SSR LEAK #h #c

The chamber heater trip has been forced out by the software because it detected a fault in the SSR switching circuit.

PUMP_SPEED 100%

The pneumatic pump has gone to full power to overcome a poor pressure fall characteristic. Possible causes are contaminated lid seals, other leaks, and slow solenoids and pump head degradation. The reported pressure for the fluid draw can be low, but not because of a constriction! The times should be faster.

Other events may be shown with self explanatory text (for example, POWER ON).

F-20

Excelsior AS A82310101

Engineers Log Evaluation and Netmon Issue 3

Notes for Interpretation of Excelsior AS Rotary Valve Errors When an Excelsior AS Rotary Valve Error occurs the full log will show the following UNK events. These events show when a valve has stalled and re-tried and when a valve movement has been successful. The VALVE_LOG events are classified as follows:

Rotary Valve Error-Initialisation VALVE_LOG60 06 VALVE_LOG60 01 VALVE_LOG60 02

These typically occur on valve initialisation where reversal can’t take place. Watch in process to make sure valve is reversing properly.

Processing / Flush Run Rotary Valve Errors VALVE_LOG60 03, 04, 05, 01, 02 05/24/04 09:22:58 VALVE_LOG60 03 3B 6A 47 C9

03 is where the valve has tried to rotate in the direction shown in the log (Forward or Reverse) and stalled. The valve then reverses for a timed period.

05/24/04 09:22:59 VALVE_LOG60 04 3F E9 FE 16

04 is the end of the timed period and the valve sets off back in the original direction of travel.

05/24/04 09:23:02 VALVE_LOG60 05 3B 92 47 C9

05 is when the valve catches up to the original position after the reversal and stalls again.

05/24/04 09:23:02 VALVE_LOG60 01 3B 92 47 C9

01 is a shutdown request which actions the Rotary Valve Warning.

05/24/04 09:23:12 VALVE_LOG60 02 3B 92 47 C9

02 is a 10 second timeout period before auto recovery takes place.

Processing / Flush Run Rotary Valve Errors VALVE_LOG60 03, 04, 07 05/24/04 09:22:58 VALVE_LOG60 03 3B 6A 47 C9

03 is where the valve has tried to rotate in the direction shown in the log (Forward or Reverse) and stalled. The valve then reverses for a timed period.

05/24/04 09:22:59 VALVE_LOG60 04 3F E9 FE 16

04 is the end of the timed period and the valve sets off back in the original direction of travel.

05/24/04 09:23:02 VALVE_LOG60 07 3B 92 47 C9

07 is when the valve moves to the next position.

Samples of these Rotary Valve Errors are shown in the log below. You can ignore any single VALVE_LOG60 03, 04, 07 events as long as they are not paired with multiple VALVE_LOG60 03, 04, 05 events and the VALVE_LOG60 03, 04, 07 events are in well spaced time frames, i.e. some VALVE_LOG60 03, 04, 07 events happen every day or alternate days at the same position (wax, flush). This may be due to the valve being slightly stiffer to move in those positions due to cooling wax or flush residue around the valve. 05/24/04 09:21:44 FM USE F1 (prog 14 step 1 baskets 0) uses 5 05/24/04 09:21:44 VALVE OPEN DEST F1 AGIT 0 DIR CLOSTEST AT C-W3 05/24/04 09:21:48 SETTEMP HTR CHAMBER OLD 62 NEW 60 05/24/04 09:22:56 VALVE CLOSE DEST C-F1 AGIT 4 DIR REV AT F1 05/24/04 09:22:56 DRAW PORT F1 STATE BUSY 904mB 0->1 24 1->2 16 2->3 18 F-21

Engineers Log Evaluation and Netmon Issue 3

Excelsior AS A82310101

05/24/04 09:22:58 VALVE_LOG60 03 3B 6A 47 C9 05/24/04 09:22:58 ERROR 25 Rotary Valve

1 Warn 0000

05/24/04 09:22:59 VALVE_LOG60 04 3F E9 FE 16 05/24/04 09:23:02 VALVE_LOG60 05 3B 92 47 C9 05/24/04 09:23:02 VALVE_LOG60 01 3B 92 47 C9 05/24/04 09:23:02 ERROR 25 Rotary Valve

1 Warn 0002

05/24/04 09:23:12 VALVE_LOG60 02 3B 92 47 C9 05/24/04 09:23:12 ERROR 25 Rotary Valve

1 Warn 0008

05/24/04 09:23:13 VALVE_LOG60 03 3B 92 47 C9 05/24/04 09:23:13 ERROR 25 Rotary Valve

1 Warn 0000

05/24/04 09:23:14 VALVE_LOG60 04 40 13 FD F1 05/24/04 09:23:17 VALVE_LOG60 05 3B 8D 47 C9 05/24/04 09:23:17 VALVE_LOG60 01 3B 8D 47 C9 05/24/04 09:23:17 ERROR 25 Rotary Valve

1 Warn 0002

05/24/04 09:23:27 VALVE_LOG60 02 3B 8D 47 C9 05/24/04 09:23:27 ERROR 25 Rotary Valve

1 Warn 0008

05/24/04 09:23:28 VALVE_LOG60 03 3B 8D 47 C9 05/24/04 09:23:28 ERROR 25 Rotary Valve

1 Warn 0000

05/24/04 09:23:29 VALVE_LOG60 04 40 10 FD EB 05/24/04 09:23:32 VALVE_LOG60 05 3B 85 47 C9 05/24/04 09:23:32 VALVE_LOG60 01 3B 85 47 C9 05/24/04 09:23:32 ERROR 25 Rotary Valve

1 Warn 0002

05/24/04 09:23:42 VALVE_LOG60 02 3B 85 47 C9 05/24/04 09:23:42 ERROR 25 Rotary Valve

1 Warn 0008

05/24/04 09:23:43 VALVE_LOG60 03 3B 85 47 C9 05/24/04 09:23:43 ERROR 25 Rotary Valve

1 Warn 0000

05/24/04 09:23:44 VALVE_LOG60 04 40 0D FD D8 05/24/04 09:23:47 VALVE_LOG60 05 3B 6F 47 C9 05/24/04 09:23:48 VALVE_LOG60 01 3B 6F 47 C9 05/24/04 09:23:48 ERROR 25 Rotary Valve

1 Warn 0002

05/24/04 09:23:58 VALVE_LOG60 02 3B 6F 47 C9 05/24/04 09:23:58 ERROR 25 Rotary Valve

1 Warn 0008

05/24/04 09:23:59 VALVE_LOG60 03 3B 6D 47 C9 05/24/04 09:23:59 ERROR 25 Rotary Valve

1 Warn 0000

05/24/04 09:24:00 VALVE_LOG60 04 3F F0 FE 04 05/24/04 09:24:02 VALVE_LOG60 07 3B 33 01 90 F-22

Excelsior AS A82310101

Engineers Log Evaluation and Netmon Issue 3

05/24/04 09:24:02 ERROR 25 Rotary Valve

Excelsior ES Codes versus Excelsior AS Codes Excelsior ES Codes

Excelsior AS Codes

Description

UNK (32)

VALVE_LOG50

Opto Disk discrepancies

UNK (33)

VALVE_LOG51

More data from VALVE_LOG50

UNK (34)

VALVE_LOG52

Opto or Disk discrepancies when initialising

UNK (35)

VALVE_LOG53

More data from VALVE_LOG52

UNK (3C)

VALVE_LOG60

Stall Reversal Errors

UNK (3D)

VALVE_LOG61

Mismatch between analogue and digital GCB sensor signals

Excelsior AS - Rotary Valve Error Netmon User Guidance Rotary Valve Errors (Netmon Logs) a) If Valve has single stall and recovery event; take no immediate action. b) If Valve has had up to two stall and recovery events at either the start of a program, the start of the Flush Cycle or Drain, or any time when the valve has been stationary, then take no action other than to monitor the situation. Note The Valve will be at its stiffest after it has been stationary or after wax has been in the chamber and allowed to solidify (dirty flush). Once the Valve has started to move it should become less stiff. c) If evidence of fluid on Opto Disk or Motor, (leaking through middle of valve), see section H of SB04366. If there are no signs of fluid on Opto Disk or Motor and the valve has more than a single stall and recovery event in the middle of a program, or more than two stall and recovery events at the start of a program, then replace the motor and investigate the Digital I/O board for damage.

Valve Does Not Turn (appears to be jammed) a) Take an Engineers Log from the Excelsior and check the following If evidence of valve moving in the logs, I.e. multiple instances of Error 25, VALVE_LOG51 02 2C 52 32 00 as per the example below. Note Ensure that the customer inspects all reagents and waxes using the “Inspect Reagents and Waxes” menu. Reagents may be cross contaminated by a valve moving whilst the chamber was full of reagent. 03/25/13 15:54:44 ERROR 25 Rotary valve

0 OK 0000

03/25/13 15:54:44 ERROR 25 Rotary valve

0 OK 0000

03/25/13 15:54:44 ERROR 25 Rotary valve

0 OK 0000

03/25/13 15:54:44 ERROR 25 Rotary valve

0 OK 0000

03/25/13 15:54:44 ERROR 25 Rotary valve

0 OK 0000

03/25/13 15:54:45 VALVE_LOG51 02 2C 52 32 00 F-23

Engineers Log Evaluation and Netmon Issue 3 03/25/13 15:54:45 ERROR 25 Rotary valve

Excelsior AS A82310101 1 WARN 0008

03/25/13 15:54:46 KEYPRESS "LID OPEN" 8002 UIF 0 4 5 (0,1,11) 03/25/13 15:54:46 ERROR 25 Rotary valve

0 OK 0000

03/25/13 15:54:46 ERROR 25 Rotary valve

0 OK 0000

03/25/13 15:54:46 ERROR 25 Rotary valve

0 OK 0000

03/25/13 15:54:46 ERROR 25 Rotary valve

0 OK 0000

03/25/13 15:54:46 ERROR 25 Rotary valve

0 OK 0000

If an Engineers Log cannot be obtained because of the Rotary Valve Errors and control of the Rotary valve is regained. Check and verify the hexadecimal value of each Rotary Valve position in the open and closed position, see “Excelsior Valve Position Check Sheet” on Pathfinder. Note Ensure that the customer inspects all reagents and waxes using the “Inspect Reagents and Waxes” menu. Reagents may be cross contaminated by a valve moving whilst the chamber was full of reagent. 01/07/10 09:54:29 VERSION 2418 01/07/10 09:54:29 PROCESS START "

" (prog 3)

STEP 1 B8

01/07/10 09:54:29 VALVE CLOSE DEST C-FIX2 AGIT 0 DIR FWD AT C-FIX2 01/07/10 09:54:30 LID SEAL 01 01 EC 40 00 01/07/10 09:54:35 LID SEAL 01 1A B5 40 30 01/07/10 09:54:35 FM USE FIX1 (prog 3 step 1 baskets 8) uses 27 First no

1/2/3/4 indicates what was happening in the process start/process restart after pause/flush start/flush restart sequence for when lid checks are run

Second no

Timer in 1/5 seconds since pump turned on

Third no

Pressure transducer – 300(hex)

Fourth no

Pump demand 40=25% 80=50% C0 = 75%

Fifth no

Pump speed as measured by the feedback electronics.

Note The 5 fields are all are hexadecimal in the log. So in the example above when the process is started at 9:54:29 it takes a while to set the process data and valve at 9:54:30 – first pump data. Pump asked to run at 25% (4th no. = 40) but not yet moving (5th no. = 0) when 1/5th second into the lid check (2nd no. = 1). Chamber pressure = 300+3rd no. = 3EC (hex) or 1004(decimal) i.e. good start by 9:54:35 the pump is running at 30, we are actually 1A-01 timer ticks into the lid check (1A-1 = 19(hex) = 25(decimal) = 25/5 seconds and the pressure has gone down to 3B5 (hex) = 949mB (decimal).

F-24