Service Manual Evolis

EVOLIS
Service Manual
We reserve the right to make changes in the course of technical development without
previous notice.
EVOLIS, BIO-RAD. All rights reserved.
BIO-RAD
3, boulevard Raymond Poincaré - B.P. 3
92430 Marnes-la-Coquette, France
Neither this manual nor any parts of it may be duplicated or transmitted in any way without the written
approval of BIO-RAD.
Date of issue: September 2004
Version: 1.3
Part No.: 6300000013
We reserve the right to make changes in the course of technical development

without previous notice.
EVOLIS System Manufacturer: BIO-RAD
Software-copy- The software for the EVOLIS has been licensed to BIO-RAD for worldwide distri-
rights bution. The EVOLIS software is the intellectual property of STRATEC Biomedical
Systems AG. Intellectual property rights shall remain with STRATEC Biomedical Sys-
tems AG.
You are entitled to use the EVOLIS software and the printed accompanying material
at your place of work only.
Any violations of property rights or copyright or trademark may be subject to legal ac-
tion.
BIO-RAD
3, boulevard Raymond Poincaré - B.P. 3
92430 Marnes-la-Coquette, France
tel: +33 (0)1 47 95 60 00
fax: +33 (0)1 47 41 91 33
Evolis
Table of Contents
1 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1 Typographical Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.1.1 Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.1.2 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.1.3 Symbol Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.1.4 Special Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.2 Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.2.1 General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.2.2 Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.2.3 Laser Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.2.4 Mechanical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.2.5 Biological Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.2.6 Cleaning the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.2.7 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.3 Positions of Safety Labels and Type Label . . . . . . . . . . . . . . . . 1-10
1.3.1 General Warning Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.3.2 Biological Hazard Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.3.3 Electrical Hazard Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.3.4 Laser Hazard Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.3.5 Type Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1.4 Definitions, Acronyms and Abbreviations . . . . . . . . . . . . . . . . 1-15
2 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Safety and Hints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Mechanical Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.3 Electronic Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 Safety and Hints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.3 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.4 Contents of the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.4.1 Contents of Box A (Analyser) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.4.2 Contents of Box C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.4.3 Contents of Box D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.5 Installation of the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.5.1 Setup of the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.5.2 Installation of the Wash Head . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.5.3 Installation of Waste Bag System . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.5.4 Installation of the Pipetting System. . . . . . . . . . . . . . . . . . . . . . 3-11
3.5.5 Installation of the Side Covers . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.5.6 Installation of the Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.5.7 Installation of System Fluid and Waste Containers . . . . . . . . . 3-17
3.5.8 Installation of Computer and Cable Connections . . . . . . . . . . . 3-18
3.6 Preparations for the User Software . . . . . . . . . . . . . . . . . . . . . . 3-19
3.7 Check of the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3.7.1 Preparations for the Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3.7.2 Check with Service Software . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3.7.3 Check of the Pipettor Positions with the Teacher . . . . . . . . . . . 3-21
3.8 Check with User Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
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3.9 Save System Files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Safety and Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Overview about Maintenance Kits. . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 Half-Yearly and Yearly Maintenance Kits . . . . . . . . . . . . . . . . . . . 4-2
4.3.1 Half-Yearly and Yearly Maintenance . . . . . . . . . . . . . . . . . . . . . . 4-4
4.3.2 Yearly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.4 Lubrication Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.4.1 X-axis: Cleaning and Lubrication of X-Guiding Mechanism. . . . . 4-7
4.4.2 Y-axis: Cleaning and Lubrication of Y-Guiding Mechanism . . . . . 4-8
4.4.3 Z-axis: Lubrication of Z-Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.4.4 X-Axis of Plate Transport: Cleaning and Lubrication of Guiding Rod
4-10
4.4.5 Z-Spindle of Plate Transport: Cleaning and Grease of Z-Spindle . 4-
11
5 Service Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1 Safety and Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Installation of Service Software. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2.2 Global Settings in gSERVICE.INI . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2.3 COM Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3 Replacement of Service Software . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.4 Start of Service Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.4.1 About Service Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.4.2 Load Module Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.4.3 Activate all Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.4.4 Low Level Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.4.5 Write Global Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.4.6 View Global Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.4.7 Hex View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.4.8 Port Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.4.9 Terminate Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.5 Results of the Service Software . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
6 Photometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 Safety and Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.4 Description of Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.5.1 Photometer Adjustment and Testing Tools. . . . . . . . . . . . . . . . . . 6-5
6.5.2 Replacement of the Photometer Module . . . . . . . . . . . . . . . . . . . 6-6
6.5.3 Replacement of Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.5.4 Replacement of Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6.5.5 Replacement of Primary Optics (Lower Optic Block). . . . . . . . . 6-11
6.5.6 Replacement of Fibre Optics . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
6.5.7 Replacement of Photometer X-Movement Motor. . . . . . . . . . . . 6-14
6.5.8 Cleaning of Fibre Optics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6.5.9 Filter Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
6.5.10Replacement of Photometer PCB . . . . . . . . . . . . . . . . . . . . . . . 6-15
6.5.11 Glass Fibre for Plate Detection . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6.6 Adjustment and Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
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6.6.1 Adjustment of Optical Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

6.7 Service Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
6.7.1 Functions of the Photometer Service Software . . . . . . . . . . . . 6-19
6.7.2 Test Procedure for Module Test . . . . . . . . . . . . . . . . . . . . . . . . 6-24
6.7.3 Test Procedure for Board Test . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
6.7.4 Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
6.8 Firmware Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
6.8.1 Firmware Upgrade with Service Software . . . . . . . . . . . . . . . . 6-25
6.8.2 Firmware Upgrade with User Software . . . . . . . . . . . . . . . . . . . 6-26
7 Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1 Safety and Hints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.4 Fluid Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.4.1 Wash Buffer Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.4.2 Instrument Waste Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.5 Description of Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.6.1 Washer Adjustment and Testing Tools . . . . . . . . . . . . . . . . . . . . 7-7
7.6.2 Replacement of Washer Module. . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.6.3 Replacement of Vacuum Switch . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.6.4 Replacement and Cleaning of Wash Head. . . . . . . . . . . . . . . . 7-12
7.6.5 Replacement of Peristaltic Pump Motor and Tubing Cassette . 7-13
7.6.6 Replacement of Plate Transport Belt . . . . . . . . . . . . . . . . . . . . 7-14
7.6.7 Replacement of Aspiration Pump . . . . . . . . . . . . . . . . . . . . . . . 7-15
7.6.8 Replacement of Dispense Pump . . . . . . . . . . . . . . . . . . . . . . . 7-16
7.6.9 Replacement of Dispense Valve . . . . . . . . . . . . . . . . . . . . . . . . 7-17
7.6.10Replacement of Z-motor (Wash Head up and down Motor) . . . 7-19
7.6.11 Replacement of Washer Light Barriers . . . . . . . . . . . . . . . . . . . 7-20
7.6.12Plate in Fibre. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
7.6.13Replacement of Washer PCB . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
7.6.14Internal Waste Bottle and internal Froth Trap Bottle . . . . . . . . . 7-22
7.7 Adjustment and Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
7.7.1 Alignment of Wash Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
7.7.2 Adjustable of Washer Bottles Float Switches . . . . . . . . . . . . . . 7-24
7.7.3 Volume Calibration of the Washer . . . . . . . . . . . . . . . . . . . . . . 7-25
7.8 Washer Service Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
7.8.1 Functions of the Washer Service Software. . . . . . . . . . . . . . . . 7-27
7.8.2 Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
7.8.3 Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
7.8.4 Test Procedure for Module Test . . . . . . . . . . . . . . . . . . . . . . . . 7-34
7.8.5 Test Procedure for Board Test . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
7.9.1 Firmware Upgrade with Service Software . . . . . . . . . . . . . . . . 7-37
8 Plate Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.1 Safety and Hints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.3 Electronic Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8.5.1 Plate Transport Alignment Tools . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

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8.5.2 Replacement of Plate Transport . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

8.5.3 Replacement of Plate Transport PCB . . . . . . . . . . . . . . . . . . . . . 8-9
8.5.4 Replacement of High Flex Cable . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8.5.5 Replacement of Y-Transport Belt . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.5.6 Replacement of X-Transport Belt. . . . . . . . . . . . . . . . . . . . . . . . 8-14
8.5.7 Replacement of X-Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
8.5.8 Replacement of Z-Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
8.5.9 Replacement of X-light barrier (Init Position) . . . . . . . . . . . . . . . 8-16
8.5.10Replacement of Carrier Detect Light Barrier . . . . . . . . . . . . . . . 8-17
8.5.11 Replacement of Z-light barrier (Init Position) . . . . . . . . . . . . . . . 8-17
8.6 Adjustment and Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
8.6.1 Alignment of Plate Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
8.6.2 Use of the Shaft X-Drive Alignment Tool . . . . . . . . . . . . . . . . . . 8-20
8.6.3 Use of the X-Gantry Alignment Plate . . . . . . . . . . . . . . . . . . . . . 8-21
8.7 Teaching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
8.7.1 Start Teaching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
8.7.2 Continue Teaching the Plate Transport . . . . . . . . . . . . . . . . . . . 8-23
8.7.3 Save Plate Transport Coordinates. . . . . . . . . . . . . . . . . . . . . . . 8-25
8.7.4 Load Plate Transport Coordinates . . . . . . . . . . . . . . . . . . . . . . . 8-25
8.7.5 Store Plate Transport Coordinates. . . . . . . . . . . . . . . . . . . . . . . 8-26
8.8 Service Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
8.8.1 Functions of the Plate Transport Service Software . . . . . . . . . . 8-27
8.8.2 Adjust Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
8.8.3 Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34
8.8.4 Test Procedure for Module Tests . . . . . . . . . . . . . . . . . . . . . . . . 8-35
8.8.5 Test Procedure for Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35
8.8.6 XZ-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36
8.9.1 Firmware Upgrade with Service Software . . . . . . . . . . . . . . . . . 8-37
9 Plate Bar Code Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9.1 Safety and Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.3.1 Replacement of Plate Bar Code Scanner . . . . . . . . . . . . . . . . . . 9-2
10 Incubator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.1 Safety and Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.3 Mechanical Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
10.5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
10.5.1Replacement of Incubator Module . . . . . . . . . . . . . . . . . . . . . . . 10-5
10.5.2Replacement of Incubator PCB . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
10.5.3Open Incubator Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
10.5.4Replacement of Incubator Box . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
10.5.5Replacement of Shake PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
10.5.6Replacement of Sensor PCB . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
10.5.7Replacement of Shaking Solenoid. . . . . . . . . . . . . . . . . . . . . . 10-12
10.5.8Replacement of upper Heater . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
10.5.9Replacement of lower Heater . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
10.5.10Replacement of Foam Flap or Flap Spring . . . . . . . . . . . . . . 10-15
10.5.11Replacement of Incubator and Stacker Fan . . . . . . . . . . . . . . 10-15

Evolis
10.6 Adjustment and Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17

10.6.1Calibration of the Shake Function. . . . . . . . . . . . . . . . . . . . . . 10-17
10.7 Service Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
10.7.1Functions of the Incubator Service Software . . . . . . . . . . . . . 10-20
10.7.2Calibrations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
10.7.3Shake Status Details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
10.7.4Temperature Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
10.7.5Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
10.7.6Test Procedure for Module Tests . . . . . . . . . . . . . . . . . . . . . . 10-27
10.7.7Test Procedure for Board Test . . . . . . . . . . . . . . . . . . . . . . . . 10-27
10.8 Firmware Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29
10.8.1Firmware Upgrade with Service Software . . . . . . . . . . . . . . . 10-29
10.8.2Firmware Upgrade with User Software . . . . . . . . . . . . . . . . . . 10-29
11 Pipettor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
11.1 Safety and Hints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
11.3 Fluid Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
11.4 Description of Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7
11.5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9
11.5.1 Replacement of Disposable Tip Adapter . . . . . . . . . . . . . . . . . 11-9
11.5.2 Replacement of Pipettor Tubing . . . . . . . . . . . . . . . . . . . . . . . 11-10
11.5.3 Replacement of Wash Pump . . . . . . . . . . . . . . . . . . . . . . . . . 11-12
11.5.4 Replacement of Dispense Pump . . . . . . . . . . . . . . . . . . . . . . 11-13
11.5.5 Replacement of Syringe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15
11.5.6 Replacement of three way Valve . . . . . . . . . . . . . . . . . . . . . . 11-16
11.5.7 Replacement of Pipettor Bridge . . . . . . . . . . . . . . . . . . . . . . . 11-18
11.5.8 Replacement of X-Sledge. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19
11.5.9 Replacement of Bridge High Flex Cable. . . . . . . . . . . . . . . . . 11-20
11.5.10Replacement of Y-Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-21
11.5.11Replacement of Y-Motor/Encoder . . . . . . . . . . . . . . . . . . . . . 11-22
11.5.12Replacement of Waste Pump (on the back Side) . . . . . . . . . 11-24
11.5.13Replacement of Waste Pump (on the left Side) . . . . . . . . . . 11-25
11.6 Adjustment and Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-27
11.6.1 Adjustment of the X- and Z-Axis . . . . . . . . . . . . . . . . . . . . . . . 11-27
11.6.2 Adjustment of the X-Axis Roller . . . . . . . . . . . . . . . . . . . . . . . 11-30
11.6.3 Adjustment of the Y-Axis Roller . . . . . . . . . . . . . . . . . . . . . . . 11-32
11.6.4 Adjustment of Timing Y-Belt Tension . . . . . . . . . . . . . . . . . . . 11-35
11.6.5 Free Movement of the Bridge on the Guiding Mechanism . . . 11-37
11.6.6 Free Movement of the Upper Rollers on Guiding Mechanism 11-38
11.6.7 Wear of the Roller Bearings on the Bridge Holder . . . . . . . . . 11-39
11.6.8 Alignment of Z-Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-40
11.7 Teaching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-44
11.7.1 Teaching Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-44
11.7.2 Start of Teacher Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-45
11.7.3 Mechanical Z-Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-48
11.7.4 Teaching Reference Position . . . . . . . . . . . . . . . . . . . . . . . . . 11-48
11.7.5 Teaching Tip Type Determination Position . . . . . . . . . . . . . . . 11-50
11.7.6 Teaching Disposable Tip Racks . . . . . . . . . . . . . . . . . . . . . . . 11-50
11.7.7 Teaching Dilution Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-51
11.7.8 Teaching Pipette Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-52
11.7.9 Teaching Eject Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-52
11.7.10Teaching Wash/Waste Position . . . . . . . . . . . . . . . . . . . . . . . 11-53
11.7.11Teaching Sample and Reagent Area. . . . . . . . . . . . . . . . . . . 11-54
11.7.12Teaching MTP's. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-55

Evolis
11.7.13Teaching Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-57

11.8 Check and Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-62
11.8.1 Check Function of Disposable Tip Adapter . . . . . . . . . . . . . . . 11-62
11.9 Service Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-63
11.9.1 Functions of the Pipettor Service Software . . . . . . . . . . . . . . . 11-65
11.9.2 Pipettor Dialogue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-66
11.9.3 Pumps Dialogue. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-70
11.9.4 Coordinates Dialogue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-72
11.9.5 Prime Dialogue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-74
11.9.6 Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-75
11.9.7 Automatic Module Test Dialogue . . . . . . . . . . . . . . . . . . . . . . . 11-77
11.10.1Firmware Upgrade with Service Software . . . . . . . . . . . . . . . 11-78
11.10.2Firmware Upgrade with User Software . . . . . . . . . . . . . . . . . 11-78
12 Pipetting Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

12.1 Safety and Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
12.3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
12.3.1Replacement of Light Barriers . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
13 Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
13.1 Safety and Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
13.3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2
13.3.1Replacement of Light Barriers . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2
14 Rack System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1

14.1 Safety and Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
14.4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-4
14.4.1Replacement of Rack System . . . . . . . . . . . . . . . . . . . . . . . . . . 14-4
14.4.2Replacement of Bar Code Scanner . . . . . . . . . . . . . . . . . . . . . . 14-4
14.4.3Replacement of Rack Insert Light Barrier . . . . . . . . . . . . . . . . . 14-5
14.4.4Replacement of Door Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-6
14.5.1Functions of the Rack System Service Software . . . . . . . . . . . . 14-8
14.5.2Initialise and Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-11
14.5.3Test Procedure for Module Tests . . . . . . . . . . . . . . . . . . . . . . . 14-12
15 CPS Module (COP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1

15.1 Safety and Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
15.3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4
15.3.1DIP-Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4
15.3.2Replacement of COP PCB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4
15.4.1Functions of the COP Service Software . . . . . . . . . . . . . . . . . . 15-6
15.4.2Test Procedure for Module Test . . . . . . . . . . . . . . . . . . . . . . . . 15-10
15.4.3Test Procedure for Board Test . . . . . . . . . . . . . . . . . . . . . . . . . 15-11
15.5.1Firmware Upgrade with Service Software . . . . . . . . . . . . . . . . 15-13

Evolis
15.5.2Firmware Upgrade with User Software . . . . . . . . . . . . . . . . . . 15-13
16 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1

16.1 Safety and Hints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
16.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
16.2.1Replacement of the Power Supply . . . . . . . . . . . . . . . . . . . . . . 16-1
17 Troubleshooting and Error Messages . . . . . . . . . . . . . . . 17-1

17.1 Error Messages of the User Software . . . . . . . . . . . . . . . . . . . . 17-1
17.2 Plate System Error Messages. . . . . . . . . . . . . . . . . . . . . . . . . . 17-12
17.2.1Received String. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-13
17.2.2ASCII Codes used in Plate System Error Messages . . . . . . . 17-14
17.2.3Virtual Module Errors (Module ID 41) . . . . . . . . . . . . . . . . . . . 17-14
17.2.4Plate Transport Errors (Module ID 42) . . . . . . . . . . . . . . . . . . 17-15
17.2.5Photometer/Colorimeter Errors (Module ID 43) . . . . . . . . . . . 17-16
17.2.6Washer Errors (Module ID 44) . . . . . . . . . . . . . . . . . . . . . . . . 17-17
17.2.7Incubator Errors (Module ID 45) . . . . . . . . . . . . . . . . . . . . . . . 17-18
17.3 COP and Sample Rack Scanner Error Messages . . . . . . . . . . 17-19
17.3.1COP Errors (Module ID 00) . . . . . . . . . . . . . . . . . . . . . . . . . . 17-19
17.3.2Sample rack scanner errors (Module ID 00). . . . . . . . . . . . . . 17-20
17.4 Pipettor Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-20
17.4.1Pipettor Errors (Module ID FD) . . . . . . . . . . . . . . . . . . . . . . . . 17-21
17.4.2Pipettor Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-24
18 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1

18.1 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1
18.2 Mains Voltage and Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1
18.3 Laser of the Bar Code Scanner . . . . . . . . . . . . . . . . . . . . . . . . . 18-1
18.4 Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-2
18.4.1System with Packaging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-2
18.4.2System without Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-2
19 Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1

19.1 Photometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1
19.2 Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-8
19.3 Plate Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-16
19.4 Incubator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-24
19.5 Pipettor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-31
19.6 Rack System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-33
19.7 CPS Module (COP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-34

Evolis

Evolis Intended Use
1 Intended Use
The purpose of this document is to guide trained field service engineers on installa-
tion, adjustment, maintenance service and troubleshooting of the Evolis, a fully au-
tomated microplate based ELISA analyser.
It has to be pointed out that the service procedures on the Evolis are designed to be
handled in a module exchange fashion in the field. Only limited adjustments and re-
pairs of modules will be performed in the field. Faulty modules are repaired by the
manufacturer or national repair centres. Therefore the scope of this document does
not reach into every detail of the modules.
In addition certain functionality of the software used by service engineers are imple-
mented by and for development engineers to perform their tasks of concurrent engi-
neering or for manufacturing tests. Although available to field service engineers
these functionality need and should not be used in field service and are therefore
only described in limited detail in this document.
This document is intended for field service engineers for training and per-
forming field service.
Evolis is a fully automated microplate analyser including such functions as sample

preparation, photometric analysis and data evaluation.
Evolis is designed and manufactured in accordance with the safety requirements for
electronic and medical systems. If the law lays down regulations on the installation
and/or operation of microplate analysers, then it is the operator's responsibility to ad-
here to them.
The manufacturer has done everything possible to guarantee that the equipment
functions safely, both electrically and mechanically. The systems are tested by the
manufacturer and supplied in a condition that allows safe and reliable operation.
The service personnel has to observe the information and warnings contained in this
service manual in order to ensure safe operation of the instruments.
EVOLIS - Service Manual - Version 1.3 1-1

Intended Use Evolis
Typographical Conventions
1.1 Typographical Conventions
Please consider the following typographical conventions.
1.1.1 Warning Messages
Warning messages are indicated with a safety symbol and printed in special types.
For special situations were used the following security symbols.
Caution, risk of danger! Consult instructions for use!
Biological hazard!
Electrical hazard!
Caution, hot surface!
Mechanical hazard!
Laser hazard!
Automatic start-up!
1-2 EVOLIS - Service Manual - Version 1.3

Evolis Intended Use
1.1.2 Notes
Notes are indicated with a symbol and printed in special types. For special situations
were used the following symbols.
Consult instructions for use!
General notes!
Disconnect mains power connector before servicing!
1.1.3 Symbol Keys
Manufactured by
In Vitro Diagnostic Medical Device
Lot Number
Expiration Date
Storage Temperature
CE Mark
Catalogue Number

Intended Use Evolis
1.1.4 Special Types
LEDs LEDs (light emitting diode) are printed in special type.

Example: PWR LED, ERR LED
Menu items and Menu items and fields are spaced type.
fields Example: F i l e Menu
Buttons Buttons are printed in spaced type.

Example: Open button.
Keys Keys are printed in slanted type.

Example: Press Enter
File examples File examples are printed in typewriter font.

Example: DRIVER=C:\SERVICE\DRIVERS

Evolis Intended Use
Safety Instructions
1.2 Safety Instructions
Read all of these instructions! Save these instructions for later use!
Please always act according to the following safety instructions, before as

well as during operation of the system!
The operating manual must be kept near the system and must be accessible
for the user at any time.
1.2.1 General Safety
Follow all warnings and instructions marked on the product and in this manu-
al.
The instrument must only be operated by personnel who have been trained on
the use of the system.
It is strongly recommended that all first time personnel read this manual prior to use.
Use the system only for the designated application.

Use only the consumables and accessory prescribed herein (e. g. microplates, pri-
mary tubes, disposable tips, etc.).
The manufacturer assumes no liability for any damages, including those to third par-
ties, caused by improper use or handling of the system.
The service personnel may only perform the maintenance work described in
this manual.
Use only the parts prescribed in this manual for servicing.
The tests and maintenance work defined by the manufacturer should be performed
to make sure that the operator remains safe and that the instrument continues to
function correctly.
Any service and maintenance work not described in this manual must be performed
by authorized service personnel and technicians.
Any changes on the system witch are not authorized by the manufacturer lead to the
lost of guarantee obligation.
The system was developed and tested according to the regulations of the IvD
directive.
Any changes on the system which are not authorized by the manufacturer lead to the
loss of the validity of the conformity with the applicable regulations the manufacturer
has declared. In this case, the customer is responsible for the fulfilment of the appli-
cable regulations.

Intended Use Evolis
Safety Instructions
The instrument should be opened, serviced and repaired by qualified and au-
thorized service personnel only.
1.2.2 Electrical Safety
Country-specific regulations regarding safe electrical operation of the in-

stalled system have to be observed.
Check that the operating voltage is set correctly on all system components be-
fore you connect the system to the mains supply.
This product must be operated from the type of power source indicated on the type
label. If you are not sure of the type of power available, consult an authorized sales
person or your local electric power company.
Use a 3-wire grounding type plug to connect all instrument and peripherals to
mains supply.
Use only extension cables with a protective conductor and grounded contact.
Grounding of the instrument, computer and its peripheral devices to the same pro-
tective earth potential must be ensured.
Never knowingly interrupt the grounding contacts.
There is the risk of an electrical shock if the protective conductor is interrupted within
or outside the device, or has been disconnected.
The instrument must be connected with a delivered connection cable to dedi-

cated socket. The use of a multi plug is not allowed!
Do not allow anything to rest on the power cord.
If you can see that the unit has become unsafe to use, switch it off and discon-
nect it from the mains supply.
If liquid gets inside the instrument, switch it off and disconnect it from the
mains supply. Clean, and dry the respective parts.
Surfaces (floors, work table) must be dry when you are working with the sys-
tem.
Only use the bottles, tubing and components supplied and recommended for con-
taining liquids on the system.
Spare fuses must match the values (nominal voltage, nominal current, and
type) specified by the system manufacturer.
Always replace blown fuses, don't try to repair them.
Never short-circuit the fuse holder.
Switch the instrument off and disconnect it from the mains supply before serv-
icing.

Evolis Intended Use
Safety Instructions
Only when directed to do so, should power be applied. If power is applied while any
covers are removed, use extreme caution while servicing the system.
Never remove protective guards or secured components since you could ex-
pose live parts in this way.
Electrical connection contacts (plugs, sockets etc.) can be electrically live.·Even af-
ter the device has been switched off, components (e.g. capacitors) can be under volt-
age as the result of an electrical charge.
All current-carrying parts are sources of danger for an electrical shock.
Don't position the equipment so that it is difficult to operate the disconnecting

device (power supply switch, mains power connector)!
1.2.3 Laser Safety
Care must be taken when operating and testing the bar code scanners as they
use a laser class 2. Never look directly into the laser beam!
Output causes irritations of the eye if stared into the beam for long periods of time.
See chapter 18.3 on page 18-1 for technical data of the laser (bar code scanner).
For operating and testing the laser, no optical devices may be used.
For operating and testing the laser, watches and mirroring jewellery should be re-
moved.
Use of controls or adjustments or performance of procedures other than those

specified herein may result in hazardous radiation exposure.
1.2.4 Mechanical Safety
Do not place the system on a unstable table, cart, or similar.

The system may fall, causing serious damage to the system or injure the user.
Don't load the complete opened drawer! The analyser is able to upset!
Never open screw-attached housing parts while the instrument is on.

There is a risk of injury due to moving parts (fan, motor drives).
Only when directed to do so, should power be applied. If power is applied while any
covers are removed, use extreme caution while servicing the system.
Do not take off the protective cover during a run and do not reach into the
working area.
Improper handling may cause serious damage to the system or injure the user.
If you open the flap or cover, verify that the movement of the pipettor has stopped
before you reach in the working area.
Avoid touching the pipettor and other moving parts while the system is in operation.
Notice that it is possible that the system continues processes independently, even
without computer.

Intended Use Evolis
Safety Instructions
Slots and openings are provided for ventilation.

To ensure reliable operation of the instrument and to protect from overheating, these
openings must not be blocked or covered.
1.2.5 Biological Safety
Risk of infection! Handling of samples and reagents:

Avoid contact between skin/mucous membrane and samples/test reagents or parts
of the instrument which were in contact with samples/test reagents.
The above-mentioned parts are to be treated as being potentially infectious.
Reagents can lead to irritation of the skin and mucous membranes.
Use appropriate hand gloves!
Observe the instructions in the package inserts for a correct use of the reagents.
If sample material is spilled in the system, clean and disinfect it immediately

by the use of a validated method.
For reagent containers and tubings (system liquid and waste), no guarantee
can be provided for any resistance against organic solvents.
For this reason, do not use any organic solvents unless such solvents are expressly
authorized.
It is not possible to autoclave the containers for liquids and waste!
1.2.6 Cleaning the System
Switch the instrument off and disconnect it from the mains supply before
cleaning, disinfection or decontamination.
Liquid detergents, disinfectants or decontamination liquids may not be poured

into the system or sprayed inside the system.
For the cleaning, disinfection or decontamination, a cloth moistened with detergent,
disinfectant or decontamination liquid should be used.
Only approved detergents, disinfectants or decontamination liquids may be used.
Only approved cleaning, disinfection or decontamination methods may be used.
For cleaning, disinfection or decontamination, the regulations of the local authorities
must be observed.

Evolis Intended Use
Safety Instructions
1.2.7 Disposal
Potential infectious material and all parts that may come in contact with poten-
tial infectious material must be disposed according to national legislations.
All parts which have been replaced, must be disposed according to national
legislations.
Disposal of the instrument according to national legislations.
Disposal of the packaging material according to national legislations.
Containers intended for single-trip use may not be used repeatedly.

Intended Use Evolis
Positions of Safety Labels and Type Label
1.3 Positions of Safety Labels and Type Label
If any label gets lost, replace it by a equivalent label!
1.3.1 General Warning Labels
General warning labels are positioned on:

• on the flap of the rack system (see figure 1-1: on page 1-10), and
• on the flap of the plate transport system (see figure 1-2: on page 1-11).
Figure 1-1: Warning label on the rack system flap

Evolis Intended Use
Figure 1-2: Warning label on the plate transport system flap
1.3.2 Biological Hazard Labels
Biological hazard labels are positioned on:

• on the washer waste bottle (see figure 1-3: on page 1-11),
• on the washer foam bottle (see figure 1-3: on page 1-11), and
• on the waste container (see figure 1-4: on page 1-12).
Figure 1-3: Biological hazard labels on the waste bottle and the foam bottle

Intended Use Evolis
Figure 1-4: Biological hazard labels on the waste container
1.3.3 Electrical Hazard Labels
Electrical hazard labels are positioned on:

• on the back side of the instrument near by the mains switch (see figure 1-7: on
page 1-14).
1.3.4 Laser Hazard Labels
Laser hazard labels are positioned on:

• next to the rack system bar code scanner outlet (see figure 1-5: on page 1-13), and
• next to the microplate bar code scanner outlet (see figure 1-6: on page 1-13).

Evolis Intended Use
Figure 1-5: Laser hazard labels next to the rack system bar code scanner
outlet
Figure 1-6: Laser hazard labels next to the microplate bar code scanner
outlet

Intended Use Evolis
1.3.5 Type Label
The type label is positioned on the back side of the instrument (near by the mains
switch).
Figure 1-7: Type label and electrical hazard label

Evolis Intended Use
Definitions, Acronyms and Abbreviations
1.4 Definitions, Acronyms and Abbreviations
Abbreviation: Definition: Explanation:
A Ampere
COP Central opera- Central host processor in Evolis distributing
tion processor worklist commands to the module's proces-
sors.
DC Direct current E.g.: DC-motor
EEPROM Electrically
erasable pro-
grammable
read only mem-
ory
ID Identification
LED Light Emitting A LED can be bicoloured, i.e. it can be con-
Diode trolled to either emit green or red light (theo-
retically also mixed orange light)
m Meter • mm: Millimetre
• µm: Micrometer
Microplate 96 well container used for holding sample/
reagent mixtures for dilutions or analysis.
PCB Printed circuit Electronics board
board
Run Analytical session, consisting of all actions
related to the scheduling and analysis of a
group of samples, beginning with an operator-
initiated start and ending when the analyser
returns to ready state.
V Volt(s)
Well One of the 96 positions in a microplate.
X-direction - left Left/Right direction as seen from the operator
+ right standing in front of the instrument.
Y-direction - back Back/Front direction as seen from the opera-

+ front tor standing in front of the instrument.
Z-direction - up Up/Down direction as seen from the operator

+ down standing with his feet toward the earths centre
of mass.
Table 1-1: Definitions, acronyms and abbreviations

Intended Use Evolis
Definitions, Acronyms and Abbreviations

Evolis System
Safety and Hints
2 System
2.1 Safety and Hints
Follow all safety instructions before servicing the machine (see

chapter 1.2 on page 1-5) to avoid personal and material damage!
2.2 Mechanical Architecture
Figure 2-1: Mechanical architecture 1
The mechanical architecture for the system is functionally modular. Various - func-
tional modules for performing the plate processes will be contained in the system.
The system consists of two main areas. The area for pipetting fluid into the plate and
the module drawer ('function drawer').
The samples and reagents are to be stored in a rack mechanism. The disposable
tips, and dilution plates or tubes are to be located in an open drawer mechanism. A
XYZ-drive mechanism moves the pipettor around the working area of the system.
The pipettor is used for sample and reagent distribution into plates located in the
plate preparation area. The pipettor uses disposable tips. The pipettor uses a syringe
pump with a system fluid. The incubators are located below the pipetting area. Once
a plate is prepared, it can be moved by the plate transport system to the other func-
tional modules of the system located in the module drawer.

System Evolis
Mechanical Architecture
The photometer, washer and stacker are mounted in a module drawer mechanism
below the pipetting area. The washer unit is towards the front, then the stacker, and
lastly the photometer behind. The plate transport mechanism is attached to the side
that will be able to move the micro plates between the various modules and pipette
areas.
The following sketch shows the layout of the modules (shown with the module drawer
open for clarity).
Figure 2-2: Mechanical architecture 2
1 Pipettor
2 Dilution plates and dilution tubes
3 Tip racks
4 Patient sample and reagent unit
5 Pipettor station
6 Tip ejection station and pipettor wash station
7 Incubator
8 Wash buffer and internal waste bottles
9 Photometer
10 Stacker
11 Washer
12 Plate transport unit

Evolis System
Electronic Architecture
2.3 Electronic Architecture
Figure 2-3: Electronic architecture
An external PC, via a RS232 communications link, controls the instrument.

The instrument is divided into a number of functional modules. Each module has its
own processor to allow multitasking of various operations on the system (e.g. plate
reading and sample pipetting of another plate). The serial messages sent by the con-
trolling PC go to a communications processor system (COP). This module processes
the messages and instructs the appropriate module to perform the required tasks.
The modules are connected to the COP via a serial communication interface.
Power for the instrument will be provided by the local mains power supply. The mains
power voltage is converted to 24 V DC for distribution to the functional modules of
the system.
The functional modules connect to the COP via a single cable connection that must
house the necessary power, communications and control signals required.
The architecture allows automatic update of the firmware for the system to be per-
formed by the controlling PC.

System Evolis
The system is a fully automated system for EIA and LIA processing. With a capacity
of up to 4 plates as standard. However the PC software scheduler is able to schedule
more than 4 plates at the same time in the system. The system will automate the
steps required to process micro plate assays from sample distribution, dilution, incu-
bation, washing, reagent addition, and detection using absorbance technologies.
The product will be controlled by Microsoft Windows® software for all operations, in-
cluding assay creation and worklist generation, time scheduling, data reduction and
reporting of results. The software will also focus on in-process control, validation and
verification. The product is targeted for labs running between 20,000 and 100,000
tests per year.

Evolis Installation
Safety and Hints
3 Installation
Aim of this document is to give the main guidelines for a correct installation of the
analyser.

chapter 1.2 on page 1-5) to avoid personal injuries and material damage!
3.2 Environment
Don't position the equipment so that it is difficult to operate the discon-

necting device!
Place this product on an stable platform, cart, stand or table (see

chapter 18.4.2 on page 18-2)!
The entire Evolis system (analyser, computer, monitor and printer) requires a space
of approximate 200 cm x 85 cm x 120 cm (W x D x H). The total depth (with wall dis-
tance and completely opened drawer) is 176 cm. The workbench on which the Evo-
lis system is set up should have a size of at least 75 x 200 cm.
The ventilation slits on the rear panel of the analyser, the computer and the monitor
must not be covered and should be away from the wall at least 20 cm.
The room where the Evolis is should be evenly heated (summer and winter), since
most immuno assays are temperature sensitive. The operation temperature is be-
tween 15 °C and 25 °C (see chapter 18.1 on page 18-1). We recommend to set up the Ev-
olis in air-conditioned rooms.
3.3 Packaging
Save the packaging to allow for safe transportation back to the manufacturer in case
the instrument needs to be serviced.

Installation Evolis
Contents of the System
3.4 Contents of the System
3.4.1 Contents of Box A (Analyser)
The analyser box contains:

• Analyser
• 6 sample racks
• 3 reagent racks
• 4 plate carriers
• 4 washer bottles with level switch
• 2 washer waste bottles with level switch
• Evolis backup disk
3.4.2 Contents of Box C
The cover box contains:

• Side covers
• Instrument cover
• Waste container 10 litre
• System fluid container 10 litre
3.4.3 Contents of Box D
The box contains:

• RS232 cable
• Mains plug
• Evolis software CD
• Evolis firmware disk
• Washer cleaning kit
• Components of the washer (silicon tubing, wash head)
• Components of the pipettor system (disposable tip adapter, Z-axis rack, tub-
ing guidance)
• Components of the instrument cover (4 knurled head screws)
• Spare parts (2 fuses 4 A, 1 lamp)
• Set of Allen keys
• Final check procedure
• Waste bag holder
• Waste bag
• Sample rack label set

Evolis Installation
Installation of the System
3.5 Installation of the System
3.5.1 Setup of the System
1. Lift the carton and remove it.

2. Remove the foil from the analyser.
3. Remove the foam rubber parts 'A' to 'C' from the analyser.
Figure 3-1: Analyser with all foam rubber parts
4. Write down the serial number on the back side of the analyser for later use.
5. Put the analyser on the workbench (see chapter 18.1 on page 18-1 and chapter 3.2 on
page 3-1).
The analyser is heavy! Use lifting device or handle!
6. Remove the foam rubber part 'D' from the pipettor bridge.

Installation Evolis
Figure 3-2: Foam rubber part on pipettor bridge
7. Remove the foam rubber part 'E' from the rack system.
Figure 3-3: Foam rubber part on rack system
8. Open the instrument drawer.

9. Remove the cardboard covering 'F' from the drawer.

Evolis Installation
Figure 3-4: Instrument drawer
10. Remove the foam rubber part 'G' from the plate transport.
11. Remove the tip eject ramp '2-1' and put it aside for later use.
12. Remove the foam rubber part 'H' from the photometer.

Installation Evolis
Figure 3-5: Foam rubber part on photometer
13. Open the washer.

14. Remove the foam rubber part 'I' from the washer.
Figure 3-6: Foam rubber part on the washer module

Evolis Installation
3.5.2 Installation of the Wash Head
1. Take the wash head out of the accessories box.

2. Open the washer.
3. Connect the aspirate tube '1-2' to the wash head '1-1'.
Figure 3-7: Connect tubing to the wash head
4. Connect the dispense tube '1-3' to the wash head.

5. Take the two wash head fixing screws out of the accessories box.
6. Fix the wash head with the two screws '1-4'.

Installation Evolis
Figure 3-8: Wash head fixing
7. Close the washer.

Evolis Installation
3.5.3 Installation of Waste Bag System
1. Take the waste bag holder, the waste bag and the waste bag cover out of the
accessories box.
2. Put the waste bag holder '2-2' in the slot from the instrument drawer.
Figure 3-9: Waste bag holder
3. Place the waste bag '2-3' into the holder.
Figure 3-10: Waste bag

Installation Evolis
4. Lock the bag with the four black clips.

5. Put in the cover with the tip eject ramp '2-1'.
Figure 3-11: Tip eject ramp
6. Put the waste bag cover '2-4' to the waste bag.
Figure 3-12: Waste bag cover

Evolis Installation
3.5.4 Installation of the Pipetting System
1. Take the disposable tip adapter, the Z-guide and the tubing guide out of the
accessories box.
2. Check if the tubing guide '3-1' can easily be moved.
Figure 3-13: Dispense pump and pipettor tube
3. Pull the pipettor tube '3-2' to the front of the analyser.

4. Move the pipettor bridge to the front of the analyser.
5. Put the Z-axis rack '3-3' into the X-sledge.
Figure 3-14: Upper side of the X-sledge

Installation Evolis
Figure 3-15: Z-axis rack
6. Move the X-sledge over the eject pin.

7. Insert the pipettor tube '3-2' in the second tubing guide '3-4'.

Evolis Installation
Figure 3-16: Second tubing guide
8. Insert the second tubing guide and the pipettor tube in the Z-axis rack.
9. Insert the pipettor tube in the needle adapter '3-5'.
Figure 3-17: Pipettor tube and needle adapter

Installation Evolis
10. Insert the needle adapter into the Z-axis rack. The metal pin must be on the
back.
11. Tighten the needle adapter with the upper hexagon screw '3-6'.
Figure 3-18: Needle adapter
12. Check that the lower hexagon screw '3-7' is tighten.

13. Put the needle adapter sensor plug '3-8' in the socket on the lower side of the
X-sledge.
Figure 3-19: Needle adapter sensor plug and socket

Evolis Installation
3.5.5 Installation of the Side Covers
1. Take the side covers out of the cover box.

2. Open the drawer.
3. Hang the top of the side cover on the top of the analyser.
Figure 3-20: Installation of the side cover
4. Press the side cover on the side of the analyser.

5. Repeat step 3 and 4 for the other side cover.
6. Close the drawer.
3.5.6 Installation of the Top Cover
Locking Mecha- 1. Take the cover of the locking mechanism out of the accessories box.
nism of the 2. Open the screws '5-1'.
Hinged Cover 3. Put the cover on the locking mechanism.
4. Tighten the screws '5-1'.
Figure 3-21: Locking mechanism
Top Cover 1. Take the top cover out of the cover box.

Installation Evolis
2. Put the cover on the top of the analyser.

3. Open the hinged cover.
4. Tighten the four screws '5-2' on the left and right side.
Figure 3-22: Gas spring (left)
Figure 3-23: Analyser with covers and waste bag cover

Evolis Installation
3.5.7 Installation of System Fluid and Waste Containers
1. Take the system fluid container and the waste container out of the accesso-
ries box.
2. Put the system fluid tube in the CPC quick connection '6-1'.
Figure 3-24: Back of the analyser
3. Put the system fluid sensor plug in the socket '6-2'.

4. Put the thick waste container tube in the CPC quick connection '6-7'.
5. Put the thin waste container tube in the CPC quick connection '6-5'.
6. Put the waste container sensor plug in the socket '6-6'.
The waste container should be under the level of the analyser.

Installation Evolis
3.5.8 Installation of Computer and Cable Connections
1. Take the computer (with keyboard, mouse and cables), the monitor, the
printer and the all cables out of the accessories box.
2. Set up the computer near of the analyser.
3. Set up the monitor near of the computer or onto the computer housing.
4. Set up the printer near of the computer.
5. Set up the keyboard near of the computer.
6. Set up the mouse near of the computer.
7. Put the plugs in the correct sockets (see the following figure and table).
Figure 3-25: Back of a COMPAQ computer
Plug/Socket: Equipment:
7-1 RS232 to the analyser

7-2 Mouse
7-3 Keyboard
7-4 Printer
7-5 Monitor
7-6 Mains plug
7-7 Mains voltage selector
Table 3-1: Computer sockets
8. Put the second RS232 plug in the analyser socket '6-3' (see figure 3-24: on
page 3-17).
9. Put the second printer plug in the printer socket.
Check whether the correct computer voltage is selected on the mains

voltage selector switch '7-7'. If necessary select the correct voltage.
Use a 3-wire grounding type plug to connect all instrument and periph-
erals to mains voltage!

Evolis Installation
Preparations for the User Software
Grounding of the analyser, computer and its peripheral devices to the

same protective earth potential must be ensured.
Country-specific regulations regarding safe electrical operation of the

installed equipment have to be observed.
10. Put the mains plug in the monitor.

11. Put the mains plug in the printer.
12. Put the mains plug from computer, monitor and printer in the mains voltage.
13. Put the mains plug in the analyser '6-4' (see figure 3-24: on page 3-17).
14. Put the mains plug from the analyser in the mains voltage.
The analyser must be connected with a delivered connection cable to

dedicated socket. The use of a multi plug is not allowed!
3.6 Preparations for the User Software
Please have a look to Bio-Rad instructions for EVOLIS software, service

software, and protocols installation.
3.7 Check of the System
Prior to operation of the analyser and its peripherals the user must en-
sure correct and safe connection to the mains voltage.
3.7.1 Preparations for the Check
1. Fill in distilled water in the system fluid container.

2. Fill in distilled water in the four washer bottles.
3. Power on the computer and the monitor.
4. Power on the analyser.
5. Wait for the end of the analyser self test and the start up of Microsoft Win-
dows.
3.7.2 Check with Service Software
Please look up in the other chapters of the service manual for detailed infor-
mation.
1. Start the system (see chapter 3.7.1 on page 3-19).

2. Start the service software.
3. Enter the password.
4. Select the C O P driver.
5. Click on the L o a d M o d u l e d r i v e r . . . button.

Installation Evolis
Check of the System
6. Click on the S e l f t e s t button.

7. Wait for the message S e l f t e s t O K .
8. Click on the C l o s e button.
9. Repeat steps from step 4 for the following drivers:
• Incubator
• Rack
• Reader
• Washer
10. Select the P i p e t t o r driver.
12. Click on the A u t o m a t i c M o d u l e T e s t button (see chapter 11.9.7 on
page 11-77).
The automatic module test runs almost completely independently. Only at the
beginning tips and a rack must be placed. The different parts can be dese-
lected by removing the ticks in the check boxes except for the initialisations.
13. Click on the S t a r t button to start the test.
14. Place short tips at the shown position.
15. Click on the O K button.
16. Place long tips at the shown position.
18. Place a T-rack, filled with tubes (with and without liquid), on the first track.
The test runs itself with the selected parts. The result window for the level
detection is constantly updated. At the end a log file is created automatically.
21. The automatic module test dialogue shows the test results.
22. Click on the C a n c e l button.
23. Click on the C l o s e button.
24. Select the I n c u b a t o r driver.
26. Select O v e r r i d e for the four incubators.
27. Click on the S e t P a r a m e t e r s button.
28. Change to the service software application window.
29. Select the P l a t e T r a n s p o r t driver.
31. Click on the M o d u l e T e s t . . . button.
32. Enter your Name.
33. Select M a n u a l .
35. Click on the N o button for the firmware download.
36. Click on the N o button for the serial number test.
37. Click on the N o button for the parameters test.
38. Click on the N o button for the plate in sensor test.
39. Click on the N o button for the door test.
40. Click on the N o button for the LED test.
41. Click on the N o button for the stacker sensor test.
42. Click on the N o button for the X-motor test.
43. Click on the N o button for the Y-motor test.
44. Click on the N o button for the Z-motor test.
45. Click on the N o button for the Shake test.
46. Click on the Y e s button for the self test.
47. Click on the Y e s button for the position test.
48. Insert a plate carrier.

Evolis Installation
Check of the System
49. Click on the OK button.

50. Remove the plate carrier.
52. Click on the Clo se button.
53. Change to the I n c u b a t o r window.
54. Deselect Ov er ride for the four incubators.
55. Click on the S e t P a r a m e t e r s button.
56. Click on the Clo se button.
57. Click on the T e r m i n a t e P r o g r a m button.
58. Open the Windows Explorer.
59. Select the directory 'C:\Program Files\BioRad\Evolis Service\gSddmmyy'
(dd=day; mm=month; yy=year).
60. Open the file 'PLxxxxxx.txt'. (xxxxxx=Number).
The positions are correct, if all tests are passed.
3.7.3 Check of the Pipettor Positions with the Teacher
Please look up in (see chapter 11.7 on page 11-44) for detailed information about
the teaching software.
3.7.3.1 Protect the positions files

1. Start the Evolis system (see chapter 3.7.1 on page 3-19).
3. Select Drive (C:).
4. Select the directory E v o l i s .
5. Select the directory S y s t e m .
6. Select all files with the ending 'rac', 'dat' and 'mpc'.
7. Choose F i l e | P r o p e r t i e s from the Windows explorer menu.
8. Select Read-only
9. Click on the Ap p l y button.
If you modify positions with the teacher, then the teacher displays an error
message and doesn't execute the modification. For modifications you must
remove the write protection.
Figure 3-26: Teacher error message

Installation Evolis
Check of the System
3.7.3.2 Check
1. Start the teacher software.
2. Enter the password.
Reference Posi- 3. Click on the R e f . l e f t button.

tion 4. Click on the P r e v . Z button.
The correct reference position '7' is reached if the tip adapter (without a tip)
touches the reference point.
Figure 3-27: Reference position
5. Click on the C a n c e l button.

6. Click on the Y e s button.
Dilution Area 7. Click on the dilution area '1'.

8. Check all positions.
Disposable Tip 9. Remove all disposable tip racks.

Racks 10. Insert an empty disposable tip rack on position '2-1'.
11. Click on the first disposable tip rack '2-1'.
13. Repeat steps for the four other disposable tip racks.
Sample and Rea- 14. Insert the rack teaching tool in the far left position of the rack.
gent Positions 15. Click on the sample and rack position '3'.
16. Check position 1 and 2.
17. Remove the rack teaching tool.
18. Insert the rack teaching tool in the far right position of the rack.
19. Check position 3.
Pipette Positions 20. Insert the MTP teaching tool (placed in a plate carrier) on pipette position '4-
1'.
21. Click on the pipette position '4-1'.
23. Remove the MTP teaching tool (placed in a plate carrier).
24. Repeat steps for the pipette positions '4-2', '4-3' and '4-4'.

Evolis Installation
Check with User Software
Eject Position 25. Click on the eject position '5'.

Wash/Waste Posi- 27. Click on the wash/waste position '6'.

tion 28. Check all positions.
MTP Positions 29. Click on the MT P ' s button.

30. Select a MTP file.
31. Click on the Ed it button.
32. Insert the correct microplate on position '4-1'.
33. Click on the Teac h button.
36. Repeat steps for the other MTP files.
Rack Positions 38. Insert a small tip (300 µl) into position 1 of the disposable tip rack '2-1'.
39. Click on the Pi c k u p D button.
40. Click on the Ra ck s button.
41. Select a rack file.
42. Click on the Ed it button.
43. Insert the correct sample/bottle rack in the far left position of the rack.
44. Insert a bottle or tube into the first position of the sample/bottle rack.
45. Click on the Teac h button.
46. Check the position.
47. Click on the arrow button ^ for the next position.
48. Repeat steps for all positions.
50. Repeat steps for the other rack files.
51. Click the Q u i t button.
3.8 Check with User Software
Please have a look to Bio-Rad instructions for EVOLIS software, service

software, and protocols installation.
3.9 Save System Files
1. Insert a floppy disc into the floppy disc drive A.

2. Open the Windows explorer.
3. Select Drive (C:).
4. Select the directory 'Evolis'.
5. Select the directory 'System'.
6. Select all existing files with the ending 'rac', 'dat', 'glb', 'h86' and 'mpc'.
7. Choose E d i t | C o p y from the Windows explorer menu.
8. Select 3 Floppy (A:).
9. Choose E d i t | P a s t e from the Windows explorer menu.

Installation Evolis
Save System Files

Evolis Maintenance
Safety and Hints
4 Maintenance

The waste system could have had contact with dangerous material! Pay
attention to safety regards! Always wear gloves!
Never use bio-hazardous liquids when testing the washer!
Care must be taken when operating and testing this module as moving
parts may cause injury if obstructed by user!
Don't weight the complete opened drawer! The analyser is able to up-
set!
4.2 Overview about Maintenance Kits
Half-yearly Main- The half-yearly maintenance kit contains the tubing’s and accessories which have to
tenance Kit be changed every half year (see chapter 4.3 on page 4-2).
Yearly Mainte- The yearly maintenance kit contains the half-yearls maintenance kit, a syringe, and
nance Kit a valve which have to be changed every year (see chapter 4.3 on page 4-2).
Lubrication Kit The lubrication kit consists oil, grease and a monovette for cleaning and lubrication
(see chapter 4.4 on page 4-7).

Maintenance Evolis
Half-Yearly and Yearly Maintenance Kits
4.3 Half-Yearly and Yearly Maintenance Kits
The following figures and tables are showing the tubing’s and accessories of the half-
yearly and the yearly maintenance kits.
Figure 4-1: Tubing’s of the half-yearly and yearly maintenance kits
Figure 4-2: Tubing and accessories of the half-yearly and yearly mainte-
nance kits

Evolis Maintenance
Figure 4-3: Syringe and valve of the yearly maintenance kits
No.: Tubing or Accessories: Location:
1 Tubing (lenght 22 cm) • Wash head

• Water trap (input)
2 Tubing (lenght 25 cm) • Water trap (output)
• Internal waste bottle (red mark)
3 Tubing with fitting (lenght 25 cm) • Internal waste bottle (grey mark)
• Tubing cassette (input) of the washer
peristaltic pump
4 Tubing’s with fitting and Y-fitting • Tubing cassette (output) of the
washer peristaltic pump
• Waste pump (output)
• CPC quick connector (small one)
5 Tubing (length 160 cm) • Pipettor wash station
• Waste pump (input)
6 Tubing (lenght 200 cm; transpar- • CPC quick connector (small one)
ent) • Waste container
7 Tubing cassette • Washer peristaltic pump
8 Wash buffer filters • Washer dispense pumps
9 System liquid filter • System liquid container
10 Liquid level detection cable • Pipettor disposable tip adapter
11 Syringe • Pipettor dispense pump
12 Three way valve • Pipettor dispense pump
Table 4-1: Tubings and Accessories

Maintenance Evolis
4.3.1 Half-Yearly and Yearly Maintenance
Place a container or put a cloth under the end of the tubing which
should be removed, because (dangerous) liquid could be in the tub-
ing’s!
Preparations The preparations are only necessary if the waste pump on the back side of the in-
strument:
• Tubings 4: Cut the 44 cm long tubing to 25 cm.
• Tubing 5: Cut the tubing to 120 cm.
1. Switch off the system.

2. Disconnect main power from the system.
3. Open the system liquid container.
4. Remove the old system liquid filter ’9’.
Figure 4-4: System liquid filter
5. Put the new system liquid filter ’9’ on the suction tube.
6. Close the system liquid container.
The system liquid filter ’9’ should be in system liquid 30 minutes before a run
should be started. Otherwise air bubbles can reach the pipette tubing.
7. Open the functional drawer completely (open locking mechanism on left side
of the functional drawer).
8. Remove the four wash buffer bottles.
9. Remove the wash bottle tray.
10. Remove the front cover with the tip eject ramp.
11. Remove the old tubing ’5’ from the pipettor wash station.
12. Remove the old tubing ’5’ from the pipettor waste pump (input) see
chapter 11.5.12 on page 11-24 or chapter 11.5.13 on page 11-25).
13. Remove the old tubing ’5’ from the instrument.
14. Install the new tubing ’5’ in the instrument.
15. Put the new tubing ’5’ on the pipettor wash station.
16. Put the new tubing ’5’ on the pipettor waste pump (input).
17. Install the front cover with the tip eject ramp.
18. Remove the old tubing cassette ’7’ of the peristaltic pump (see chapter 7.6.5 on
page 7-13). It isn’t necessary to remove the washer.
Press the clips ’A’ at the top and the bottem at the same time and pull down
the tubing cassette .
It isn’t necessary to remove the tubing’s!

Evolis Maintenance
Figure 4-5: Waste pump cassette
19. Remove the old tubing ’4’ from the pipettor waste pump (output) see
chapter 11.5.12 on page 11-24 or chapter 11.5.13 on page 11-25).
20. Remove the old tubing ’4’ from the CPC quick connector (small one).
21. Put the new tubing ’4’ on the pipettor waste pump (output).
22. Put the new tubing ’4’ on the CPC quick connector (small one).
23. Remove the old tubing ’3’ from the internal waste bottle (grey mark) (see
chapter 7.6.14 on page 7-22).
24. Remove the old tubing ’3’, the old tubing ’4’, and the old tubing cassette ’7’
from the instrument.
25. Install the new tubing cassette ’7’ of the peristaltic pump.
26. Remove the guards from the new tubing cassette tubing’s.
27. Put the new tubing ’4’ on the tubing cassette ’7’ (output).
See arrows on the tubing cassette ’7’ to find the output.
28. Put the new tubing ’3’ on the tubing cassette ’7’ (input).
29. Put the new tubing ’3’ on the internal waste bottle (grey mark).
30. Remove the old tubing ’1’ from the wash head (see chapter 7.3 on page 7-2).
31. Remove the old tubing ’1’ from the water trap (input).
33. Put the new tubing ’1’ on the wash head.
34. Put the new tubing ’1’ on the water trap (input).
35. Remove the old tubing ’2’ from the water trap (output).
36. Remove the old tubing ’2’ from the internal waste bottle (red mark).
38. Put the new tubing ’2’ on the water trap (output).
39. Put the new tubing ’2’ on the internal waste bottle (red mark).
40. Remove the old tubing ’6’ from the CPC quick connector (small one).

Maintenance Evolis
41. Remove the old tubing ’6’ from the waste container.
43. Put the new tubing ’6’ on the waste container.
44. Put the new tubing ’6’ on the CPC quick connector (small one).
45. Remove the old filters ’8’ from the washer dispense pumps tubing’s (see
46. Remove the old filters ’8’ from the system.
47. Put the new filters ’8’ on the washer dispense pumps tubing’s
48. Install the wash bottle tray.
49. Install the four wash buffer bottles.
50. Close the functional drawer completely (close locking mechanism on left side
51. Disconnect the old liquid level detection cable ’10’ of the disposable tip
adapter from the X-sledge (see chapter 11.5.1 on page 11-9).
52. Open the cover of the disposable tip adapter.
53. Disconnect the old liquid level detection cable ’10’ from the disposable tip
adapter.
54. Remove the old liquid level detection cable ’10’ from the system.
55. Connect the new liquid level detection cable ’10’ to the disposable tip adapter.
56. Close the cover of the disposable tip adapter.
57. Connect the old liquid level detection cable ’10’ to the X-sledge.
58. If planned start with the yearly maintenance procedure (see chapter 4.3.2 on
page 4-6) or the lubricate procedure (see chapter 4.4 on page 4-7).
59. Check the pipettor reference position (see chapter 11.7.4 on page 11-48).
4.3.2 Yearly Maintenance
1. Start with the ’Half-Yearly and Yearly Maintenance’ (see chapter 4.3.1 on page 4-
4).
2. Remove the old syringe ’11’ from the pipettor dispense pump (see chapter 11.5.5
on page 11-15).
3. Remove the old syringe ’11’ from the system.
4. Remove the old three way valve ’12’ from the pipettor dispense pump (see
5. Remove the old three way valve ’12’ from the system.
6. Install the new three way valve ’12’ to the pipettor dispense pump (see
7. Install the new syringe ’11’ to the pipettor dispense pump (see chapter 11.5.5 on
page 11-15).

Evolis Maintenance
Lubrication Kit
4.4 Lubrication Kit
Figure 4-6: Lubrication kit
4.4.1 X-axis: Cleaning and Lubrication of X-Guiding

Mechanism

3. Remove all dirt from the X-guiding mechanism 'O-5', 'O-6' and 'O-7' with a
cleaning paper.
Figure 4-7: Cleaning and lubrication of X-rollers on X-axis
4. Use in a second step a cleaning paper with alcohol (standard disinfection flu-
ids of the laboratories).
5. Remove all dirt from all rollers 'O-1', 'O-2', 'O-3', 'O-4', 'O-8', 'O-9', 'O-10', 'O-
11', 'O-12' and 'O-13' with a cleaning paper on both sides of the bridge.
6. Lubricate all roller bearings with max. 0.25 ml oil each via the monovette '23'.
7. Remove oil from the X-guiding mechanism 'O-5', 'O-6' and 'O-7' with a clean-
ing paper.

Maintenance Evolis
Lubrication Kit
4.4.2 Y-axis: Cleaning and Lubrication of Y-Guiding

Mechanism
Figure 4-8: Cross-sectional picture of the pipettor bridge
Figure 4-9: Top view of the pipettor bridge


Evolis Maintenance
Lubrication Kit
3. Remove all dirt and old oil from the pipettor bridge (guiding mechanism) with
a cleaning paper.
5. Clean the rack completely especially also on the top.
6. Clean also the ends of the sledge in the area of the bearing to the guiding
mechanism.
7. For refilling the oil reservoirs of the sledge 'O-19' and 'O-20' use the
monovette '23'. Soak up a volume of 0.5 ml.
8. Move the sledge to the right side of the bridge. In the top of the bridge is a
small hole (see figure 4-9: on page 4-8). Via this hole the oil reservoirs of the
sledge can be accessed.
9. Move the sledge so the right bearing holder is symmetric to the access hole.
10. Place the pipette and find the reservoir hole 'O-19' in the sledge.
11. Place the oil into the reservoir slowly.
12. Move the sledge so the left bearing holder is symmetric to the access hole.
13. Place the pipette and find the reservoir hole 'O-20' in the sledge.
14. Place the oil into the reservoir slowly.
15. Lubricate the roller bearings 'O-14' and 'O-16' with max. 0.25 ml oil each via
the monovette.
16. Remove oil from the Y-guiding mechanism 'O-15' with a cleaning paper.
17. Put the oil on the guiding rod 'O-17'.
Do not place too much oil on the guiding rod! Dropping oil is absolutely not
allowed!
18. Move the sledge all across the Y-axis 10 times to build up a complete oiled
surface on the guiding mechanism.
4.4.3 Z-axis: Lubrication of Z-Rack

3. Remove all dirt and old oil from the Z-rack 'O-18' with a cleaning paper (see
figure 4-8: on page 4-8 and figure 4-9: on page 4-8).
5. Place with your finger tip oil on the Z-rack.
6. Put the oil on the complete surface of the Z-rack but not into the teeth of the
rack.
Do not place too much oil on the rack! Dropping oil is absolutely not allowed!
7. Move the Z-rack all across the Z-axis 10 times to build up a complete oiled
surface on the Z-rack.

Maintenance Evolis
Lubrication Kit
4.4.4 X-Axis of Plate Transport: Cleaning and Lubrication

of Guiding Rod
Figure 4-10: Plate transport

3. Open the functional drawer.
4. Remove all dirt and old oil from the guiding rod 'O-21' with a cleaning paper.
6. Place with your finger tip oil on the guiding rod.
7. Put the oil on the complete surface of the guiding rod.
Do not place too much oil on the guiding rod! Dropping oil is absolutely not
allowed! Do not oil other parts of the plate transport!
8. Move the plate transport across the whole length of the guiding rod 10 times
to build up a complete oiled surface on the guiding rod.

Evolis Maintenance
Lubrication Kit
4.4.5 Z-Spindle of Plate Transport: Cleaning and Grease of

Z-Spindle

4. Remove all dirt and old grease from the spindle 'G-1' with a cleaning paper
(see figure 4-10: on page 4-10).
5. Press the cleaning paper into the thread grounds of the spindle and turn the
spindle on top of the plate transport with a screw driver.
6. Pick up some grease out of the grease box '25' with a cleaning paper.
7. Place the grease on the spindle.
8. Wipe the grease with the paper into the spindle surface.
Do not place too much grease on the spindle! Do not grease other parts of
the plate transport!
9. Turn the spindle with the screw driver at least 5 times up and down to build up
a closed and homogeneous film of grease on the spindle.

Maintenance Evolis
Lubrication Kit

Evolis Service Software
Safety and Hints
5 Service Software

Care must be taken when operating and testing using this module as
moving parts may cause injury if obstructed by user!
Care must be taken when operating and testing the bar code scanners
as they use a laser class 2. Never look directly into the laser beam!
5.2 Installation of Service Software
The family of service software modules or dll's (dynamic linked library) required for
the system are accessed via the parent application gSERVICE.exe. gSERVICE.exe
also requires five other dll's and the serial client to communicate with the system. In-
stallation should be automatic from the original installation disks, simply follow the in-
structions. However, if any problems do occur, ensure the structure is as follows
within the main sub-directory containing the application gSERVICE.exe. There
should also be the following files:
gSERVICE.INI Global settings, this must be set up correctly.
Rs232s32.exe RS232 serial driver, required to communicate with system

Stclms.dll Library functions
Stmfcext.dll Library functions
Stth32dll.dll Library functions
Stth32link.dll Library functions
ServiceUtils.dll Library functions
Table 5-1: Files for the application gSERVICE.exe
5.2.1 Installation
To install, run the Setup application from whatever media the software was distribut-
ed. When you attempt to install and the installation program detects a previous instal-
lation, it will automatically uninstall it. This will require you to run the installation
program again.
1. First, you will be prompted to select a language.
2. Next, the welcome banner will appear. Exit all Windows programs before run-
ning the setup, as recommended.
3. You may select a different destination folder than the default.
4. Next, the type of installation can be selected, choose T y p i c a l .

Service Software Evolis
Installation of Service Software
5. Next, you may select a different folder name for the Windows start menu.
6. Last, if installation is successful, press on the Finish button.
5.2.2 Global Settings in gSERVICE.INI
This INI file contains the path names for all the installed modules as well as the def-
inition for the serial communications. It must have the correct path names for each
module, otherwise gSERVICE will not show the module. There are a number of di-
rectives within the INI file: A directive is enclosed within square brackets '[-]'.
DEVICE1 (number increments for each module) is the directive that informs gSERV-
ICE of a module. Below the DEVICE1 label are three attributes, DEVICENAME, DE-
VICEDRIVER and DEVICE_PHYSADDR. PORTMAP allows COM port 2 to be used.
[MAIN]
Contains the path for data, DATA_PATH=path
[DEVICE1]
DEVICENAME=Name that appears in gSERVICE module window
DEVICEDRIVER=pathname/filename. Path and dll name, example
C:\SERVICE\WASHER.DLL.
DEVICE_PHYSADDR=Physical address for module, example 68
For the washer, the entry in the INI file would be like, depends on device
number and installation path;
[DEVICE1]
DEVICENAME=Washer
DEVICEDRIVER=c:\...installation_path...\Washer\Washer.dll
DEVICE_PHYSADDR=68
For the reader, the entry in the INI file would be like, depends on device number
and installation path;
[DEVICE2]
DEVICENAME=Reader
DEVICEDRIVER=C:\...installation_path...\Reader\Reader.dll
DEVICE_PHYSADDR=67
For the incubator, the entry in the INI file would be like, depends on device
[DEVICE3]
DEVICENAME=Incubator
DEVICEDRIVER=C:\...installation_path...\Incubator\Incuba-
tor.dll
DEVICE_PHYSADDR=69
For the plate transport, the entry in the INI file would be like, depends on device
[DEVICE4]
DEVICENAME=Plate Transport
DEVICEDRIVER=C:\...installation_path...\PlateTx\PlateTx.dll
DEVICE_PHYSADDR=66
For the Rack module, the entry in the INI file would be like, depends on device
[DEVICE5]
DEVICENAME=Rack
DEVICEDRIVER=C:\...installation_path...\Rack\Rack.dll
DEVICE_PHYSADDR=0
For the COP module, the entry in the INI file would be like, depends on device
[DEVICE6]
DEVICENAME=COP
DEVICEDRIVER=C:\...installation_path...\COP\Cop.dll

Installation of Service Software
DEVICE_PHYSADDR=0
For the pipettor module, the entry in the INI file would be like, depends on de-
vice number and installation path;
[DEVICE7]
DEVICENAME=Pipettor
DEVICEDRIVER=C:\...installation_path...\Pipettor\PipDrv.dll
DEVICE_PHYSADDR=253
For the PCB utilities, the entry in the INI file would be like, depends on device
[DEVICE8]
DEVICENAME=PCB Utilities
DEVICEDRIVER=C:\...installation_path...\PCBUtils\PCBUtils.dll
DEVICE_PHYSADDR=0
For the cycle, the entry in the INI file would be like, depends on device number and
installation path;
[DEVICE9]
DEVICENAME=Cycle
DEVICEDRIVER=C:\...installation_path...\PCBUtils\Cycle.dll
DEVICE_PHYSADDR=0
Additionally the pipettor needs further information:
[Pipettor]
Machine=FPS
LongTips=4845
ShortTips=2440
TipsLeft=1
TipsRight=0
TipLenLeft=3
TipLenRight=3
Polar=0
Direct=0
CooFile=C:\BioRad\system\koordina.dat
Entry: Meaning:
Machine Machine: 4-Plate-System: FPS

LongTips Length of long tips in steps (4845)
ShortTips Length of short tips in steps (2440)
TipsLeft Number of needles on left arm: 0
TipsRight The same for the right arm
TipLenLeft 0
TipLenRight The same for the right arm
Polar 0
Direct 0
CooFile Path and name of the coordinates-file
Table 5-2: Meaning of further information for pipettor

Replacement of Service Software
5.2.3 COM Ports
The gSERVICE application only supports a limited set of COM ports. Within the
gSERVICE.INI file is the directive [PORTMAP], that informs gSERVICE if the default
COM port1 is not available and to use another.
[PORTMAP]
COM1=COM2
The above entry within the INI file will use COM port 2 to communicate to the system.
The default is to use COM1. To edit the file to make the above change, open with
notepad.
If COP port is changed, you must also change teacher by opening and editing
the 4pscoo.ini file ([COMPORT] PortNo=1).
5.3 Replacement of Service Software
To uninstall the software:

1. Select the C o n t r o l P a n e l , which you can access from the S T A R T but-
ton, S e t t i n g s . . .
2. Select the A d d / R e m o v e Programs icon.
3. Find in the list of software, which can be automatically removed, the entry for
the S e r v i c e software.
4. Select S e r v i c e .
5. Click the A d d / R e m o v e button.
The sub-directory is locked so it is likely you will be prompted during the proc-
ess that certain files can not be removed at this time, select the reboot button
if this occurs.
6. At the end of the process you may be requested to R e s t a r t your computer,

select this option.

Start of Service Software
5.4 Start of Service Software
The main application gSERVICE must be run to access any of the service modules.
The service modules will not run by themselves.
If the teaching software or the user software was running before, this pro-
grams has to be closed!
To start gSERVICE.EXE, double click the icon. Before the application starts you must
enter the service software password.
Figure 5-1: Service software log-on screen
The user name (if entered) will become the default value used in reports, but can be
overwritten. If a password is not entered, no EEPROM values can be changed.
Figure 5-2: Service software main window
The list of available drivers will vary depending on what you have installed and the
contents of the INI file. The window on the right hand side will show the communica-
tion log.

5.4.1 About Service Software
Displayed in the top left hand corner is the S e r v i c e S o f t w a r e icon, clicking on

the icon displays a drop down menu, with the standard M o v e and C l o s e (Alt + F4).
Below this is the menu item A b o u t S e r v i c e S o f t w a r e … . This displays an
about box, showing the versions of all components.
Figure 5-3: About service software dialogue
When reporting any problems with the software, please include this information.
5.4.2 Load Module Driver
Loads the selected driver and opens its main dialogue. If the driver is already loaded,
only the dialogue is shown.
5.4.3 Activate all Drivers
Loads all drivers in the list without displaying the dialogues.
5.4.4 Low Level Command
When the low level commands button is pressed, the following dialogue box is dis-
played to allow the user to select or enter a low level command.
Figure 5-4: Low level commands dialogue
Refer to module specifications for low level commands. Typing 44 41 04 49 and

clicking S e n d will send the A B O R T to the washer which will abort a current wash
or aspirate operation for instance.
The drop down list box displays the commands as described in the INI file, under the
[LOW_LEVEL] directive. Data in command box must be correctly formatted.Example
(gService.INI):
[LOW_LEVEL]

COMMAND1=FD CF FF FF 00 00 10 00
Send To Port allows for different COM port to be selected.
5.4.5 Write Global Parameters
Lets you select a new global data file (*.glb) and calls the WriteGlobalVar(CGlobFile
* pMyFile) function of each loaded driver. Forces all activated dll's to write any useful
parameters into a specified file. Uses Microsoft Windows S a v e A s dialogue
box.This will write a global file of all active dll's parameters. Within some loaded dll's,
it is possible to write their parameters only. When either the global file containing oth-
er module parameters or a module only parameter file is loaded by a module dll, only
that module parameters are overwritten.
5.4.6 View Global Parameters
Shows the content of a selected global data file. Each module parameter is identified
by its module ID number, the following shows typical parameters for a reader and
washer module:
Figure 5-5: Global parameters
5.4.7 Hex View
Invokes the H e x V i e w P a r a m e t e r dialogue.
Figure 5-6: Hex view parameter dialogue

Results of the Service Software
5.4.8 Port Status
Returns current status of communication port.
5.4.9 Terminate Program
Unloads all active drivers and exits the service program.
5.5 Results of the Service Software
All modules generate result files. The result files are in a special folder in the service
software folder. The name of the special folder is gSddmmyy (dd=day; mm=month;
yy=year). The following table shows the names of the result files:
Module: File:
COP CPxxxxxx.txt
Incubator INxxxxxx.txt
Plate Transport PLxxxxxx.txt
Rack RAxxxxxx.txt
Reader RDxxxxxx.txt
Washer WAxxxxxx.txt
Table 5-3: Result files (xxxxxx=Number)
Show a result file with the Microsoft Notepad:

2. Select the directory 'C:\Program Files\BioRad\Evolis Service\gSddmmyy'.
3. Open a result files.

Evolis Photometer
Safety and Hints
6 Photometer

Module uses halogen lamp, it will be hot even after short periods of use
and takes time to cool down. Handle with care!
set!
Take care not to touch any optic surfaces!
Every time the photometer module or plate transport is disturbed, the calibra-
tion of the positions used to insert and remove plate carriers must be re-
viewed and potentially re-calibrated. Please refer to the plate transport
section for detailed information (see chapter 8 on page 8-1).

Photometer Evolis
Overview
6.2 Overview
The absorbance photometer module has eight way optics with a ninth reference
channel. It uses up to 8 interference filters, between the range of 400 nm and
700 nm. A tungsten halogen lamp provides the light source.
Figure 6-1: Photometer module

Evolis Photometer
Figure 6-2: Photometer mechanical architecture

Photometer Evolis
Description of Connections
6.4 Description of Connections
Figure 6-3: Reader top view without cover schematic
Figure 6-4: Power and signal cable

Evolis Photometer
Maintenance
6.5 Maintenance
Routine maintenance to be carried out according to published schedules.
Every time the photometer module or plate transport is disturbed, the calibra-
6.5.1 Photometer Adjustment and Testing Tools
Figure 6-5: Absorbance reader adjustment and testing tools
1 Black plate
2 Alignment plate
3 Adjustment plate and two metal pins
4 Reader verification plate
6.5.1.1 Reader Verification Plate

For detailed information on the reader verification plate, refer to its manual. The read-
er verification plate has been designed to provide the following functions:
• Accuracy
To verify measurements are within the stated accuracy of the absorbance
photometer specification and the accuracy, uncertainty of the reference
standard used.

Photometer Evolis
Maintenance
• Linearity
To verify measurements are within the stated linearity of the absorbance pho-
tometer specification.
• Uniformity
To verify every optic channel measures the same value, within the stated
accuracy of the photometer specification.
• Alignment
To verify the measurements are taken at the optimum position within the
micro plate well.
• Dynamic Range
To verify the measurements can span the dynamic range as stated within the
absorbance photometer specification.
• Cross Talk
To verify cross talk is below limits that maintain the stated specifications.
• Filter
To verify the correct filter is installed and has no major defects.
• Long Term Drift
To verify the measurements remain constant within the accuracy limits over
time.
6.5.2 Replacement of the Photometer Module
Prior to replacing the photometer module, try to get a screen capture of the
current reader module driver for reference. If you do not follow these direc-
tions, the new photometer module could simulate an out of box failure.
Removal


Evolis Photometer
Maintenance
Figure 6-6: Unlocking safety lock of drawer
4. Remove the tip disposal ramp cover and the door for the sample rack area.
5. After the screw on the left side hinge has been removed, the rack door can be
removed.
Figure 6-7: Screw on left side hinge
6. Release the two retaining screws at the back of the photometer.

Photometer Evolis
Maintenance
Figure 6-8: Photometer retaining screws to function drawer
7. Remove the two screws on the plate transport bulkhead.
Figure 6-9: Photometer retaining screws to bulkhead
8. Hold the photometer module and disconnect the 15 pin cable connected to
the photometer top cover (see figure 6-4: on page 6-4).
9. Remove the module.
Installation 10. Insert the photometer module in the rear position.

11. Insert the two screws on the plate transport bulkhead, holding the front of the
photometer.
Do not tighten!
12. Start the two retaining screws holding the rear of the photometer to the func-
tion drawer (see figure 6-8: on page 6-8).
Do not tighten!
13. Tighten the two screws on the plate transport bulkhead and then the two rear
screws.
14. Connect the 15 pin cable to the photometer top cover (see figure 6-4: on page 6-
4).
15. Before the photometer can be verified, the interface to the plate transport will
need to be calibrated.

Evolis Photometer
Maintenance
6.5.3 Replacement of Lamp
Module uses halogen lamp, it will be hot even after short periods of use
and takes time to cool down. Handle with care!
In the event of a lamp failure, replace the lamp with the recommended part only. Use
of other lamps is not acceptable.
To replace the lamp:

3. Open the functional drawer completely.
4. Release the two retaining screws on the back of the photometer and pull out
the photometer back.
Figure 6-10: Photometer rear access
Figure 6-11: Open lamp and filter access door
5. Remove the lamp connector.

6. Lift the lamp retaining clip and remove the lamp.

Photometer Evolis
Maintenance
Figure 6-12: Lamp removal
7. Reverse the process after inserting new lamp.

8. To verify the new lamp, power up the system.
9. Run the verification plate process.
6.5.4 Replacement of Filter
Removal Always use the recommended filter part. Use of other filters is not acceptable.

4. Release the two retaining screws on the back of the photometer and pull out
the photometer back (shown in figure 6-10: on page 6-9 and figure 6-11: on page 6-9).
5. Exchange the filter.
Take care not to touch any optic surfaces!

Evolis Photometer
Maintenance
Figure 6-13: Filter replacement
Installation 6. Reverse the process after installing new filter.

7. Ensure filters are inserted correctly.
• Arrow on filter indicates the direction of light through the filter.
• Filters must be positioned starting from position 1.
• Filters must occupy every position in sequence, no omissions.
8. After a new filter with a different wavelength has been installed the settings
for the filters in the system setup of the user software has to be changed.
9. To verify new filter, power up the instrument.
10. Execute the verification plate process.
6.5.5 Replacement of Primary Optics (Lower Optic Block)
The lamp shines light through an interference filter onto the collection of 9 plastic fi-
bres directly behind the filter. Each fibre carries the light into the lower optic block. A
lens within the block focuses the light onto the photometer PCB directly above. The
depth each fibre end is inserted into the lower optic block is critical. Incorrect posi-
tioning will cause the light beam to scatter. The depth is set so that the image pro-
jected onto the photo diodes is a crisp, round circle, with no optic aberrations (like
light seals). One method of reviewing the beam is to shine white light (remove a filter)
through the optics and project onto a sheet of paper held where the photometer-
board would be. The circles should all be consistently the same, in line and clearly
defined. This is best viewed in a darkened room.
Removal 1. Remove the photometer module (see chapter 6.5.2 on page 6-6).
2. Remove the photometer cover.
3. Disconnect all cables at the photometer PCB and the plate in sensor fibre
(turn the cap of the connector and pull out the fibre) and remove the photom-
eter PCB.
4. Remove optic fibre bundle (see chapter 6.5.6 on page 6-13).
5. Turn the reader and pull gently the plate in sensor fibre and turn it out of the
lower optic block.

Photometer Evolis
Maintenance
Figure 6-14: Lower optic block
6. Remove the six optic block slit screws from top and take it out.
Installation 7. Before installing the new one, check the optic channels and clean if neces-
sary (use oil free compressed air or soft brushes only).
8. Set the optic block slit screws softly.
9. Put in the adjustment plate into the plate sledge (see chapter 6.5.1 on page 6-5).
10. Place it in top of the adjustment holes.
11. Set the metal pins through adjustment plate into the lower optic block.
12. Tighten the six screws.
13. Remove metal pins and adjustment tool.
14. Place the photometer PCB onto the fixing bolts set the metal pins through the
photometer PCB, upper optic block to the lower optic block and tighten the
photometer PCB screws.
15. Connect all cables (see chapter 6.4 on page 6-4).
16. Connect the plate in sensor fibre.
17. Turn the fibre into the lower optic block.
18. Lay the fibre on photometer PCB and push the fibre into the open connector
as deep as possible.
19. Pull back the fibre 1 mm and tighten it.
20. Check the plate home and plate in position sledge movement. The sledge init
metal at the belt must move through the light barrier.
21. Place the cover.
22. Install the absorbance reader into the instrument.
23. Connect main cable.
24. Check with the service software, alignment (see chapter 6.6.1 on page 6-17), and
other functions.

Evolis Photometer
Maintenance
6.5.6 Replacement of Fibre Optics
Don't pull at the single fibres!
Don't bend the fibres (min. radius 2,5 cm / 1 inch)!
Don't touch the end of fibres!
Removal 1. Remove the photometer module (see chapter 6.5.2 on page 6-6).
2. Pull out the lamp and filter drawer approx. 14 cm / 5,5 inch.
3. Unscrew the fibre tubing clamp near the filter motor and remove it.
4. Turn the absorbance reader on it’s top.
5. Pull out the lamp and filter drawer.
6. Remove single fibre clamp at the lower optic block (see figure 6-14: on page 6-12).
7. Lift the lower optic block and the single fibre tubing carefully without turning
out.
Figure 6-15: Lower optic block schematic
Installation 8. Mount the new fibre bundle in reverse steps.

9. Check assembly by testing with service software.

Photometer Evolis
Maintenance
6.5.7 Replacement of Photometer X-Movement Motor
Removal

4. Remove the photometer cover.
5. Loosen screws 1 and 2.
Figure 6-16: Plate transport motor schematic
6. Press the seal and tighten the screws.

7. Lift the belt out of the fixing slits and remove.
8. Disconnect the motor (photometer PCB ST3).
9. Remove screws 3 and 4.
10. Remove the motor.
Installation 11. Install the new motor.

12. Connect the motor to the photometer PCB.
13. Set the belt around the wheels into the belt fixing slits soft tension.
14. Loosen screws 1 and 2, so that the belt is tensioned by the seal.
15. Tighten the screws.
6.5.8 Cleaning of Fibre Optics
Don't pull at the single fibres!
Don't bend the fibres (min. radius 2,5 cm / 1 inch)!
Don't touch the end of fibres!
1. Remove the fibre optic (see chapter 6.5.6 on page 6-13).

Evolis Photometer
Maintenance
2. Place a soft fleece on a flat surface.

3. Press the end of the fibres tubing's straight to the fleece and move in a circu-
lar notion.
Figure 6-17: Cleaning of fibre optics
4. Rebuild the optic fibres bundle.
6.5.9 Filter Drive
The filter drive should not require any maintenance or calibration during the service
life of the photometer module. The two light barriers provide the feedback path for
the firmware to detect the home position and index to each filter.
Only replace light barriers with the appropriate part.
Figure 6-18: Filter drive
6.5.10 Replacement of Photometer PCB
There are no electronic adjustments to make on the photometer PCB. However, if a

new photometer PCB is installed, it must be fitted using the alignment tools to ensure
the lower optics are correctly aligned. Always observe static precautions when han-
dling any circuit boards.
Prior to replacing the PCB, try to get a screen capture of the current reader
module driver for reference. If you do not follow these directions, the new
photometer PCB could simulate an out of box failure.

Photometer Evolis
Maintenance
Removal 1. Remove the photometer from the system (see chapter 6.5.2 on page 6-6).
2. Remove the top cover of the photometer and disconnect the COM cable.
3. Remove the cables and fibre optic.
4. Remove the photometer PCB.
Installation 5. Take the black cover from bottom of old photometer PCB and put on new
photometer PCB.
6. Load the Adjustment plate (see chapter 6.5.1 on page 6-5).
7. Place the new photometer PCB on the standoffs and stick the metal align-
ment pins (see chapter 6.5.1 on page 6-5) through the photometer PCB to the
lower optic block.
8. Tighten the four-photometer PCB screws (see figure 6-21: on page 6-18).
9. Connect the cables and the plate in sensor fibre.
10. Put the cover on and connect the cable.
11. Reconnect the reader to the instrument.
12. Reconnect main power and switch on the instrument.
13. Start service software.
14. Load the reader module driver (DO NOT perform self test!).
15. Upgrade reader firmware (see chapter 6.8.1 on page 6-25).
The values that are displayed after the firmware upgrade need to be
changed!
16. Input wet test filter configuration, test filter 405 nm and ref. filter 690 nm.
17. Input read plate filter settings, test 405 nm and ref. 690 nm.
18. Input filter configuration with filter 1 at 405 nm, filter 2 at 450 nm, filter 3 at
492 nm, filter 4 at 620 nm, filter 5 at 650 nm, filter 6 at 690 nm, filter 7 and fil-
ter 8 at 0 nm.
19. Press on the W r i t e F i l t e r s button to store the information to the EEP-
ROM.
20. Press on the Y e s button to confirm.
21. Enter in the field S e r i a l the serial number of the reader.
22. Press on the S e t S e r i a l N u m b e r button.
23. Press on the Y e s button to confirm.
24. The A/D values should initially be set to 0.
25. Perform the filter drive auto align (approx. 5 min.).
26. Place the alignment plate with holes in a plate carrier.
27. Press on the A u t o A l i g n m e n t button.
28. Insert the plate carrier with the alignment plate into the reader.
Either directly into the reader or via the plate transport.
29. Complete the verification process by running the reader verification plate.
6.5.11 Glass Fibre for Plate Detection
The Plate-in signal is derived from using a Siemens SFH450 V LED device and a
photo-transistor mounted on the PCB. A fibre carries the light from the Siemens de-
vice into the lower optic block. The beam is directed onto a photo-transistor directly
above. When a plate carrier obscures the light beam, the firmware assumes the car-
rier is in position.
If this is not functioning correctly, first check the optical alignment for any obstruction
in the light path.
Otherwise, replace the fibre optic assembly (see chapter 6.5.6 on page 6-13).

Evolis Photometer
Adjustment and Calibration
6.6 Adjustment and Calibration
6.6.1 Adjustment of Optical Axis

4. Open the photometer cover.
5. Loose slit screws at the lower optic block.
Figure 6-19: The slit screws at the lower optic block
6. Place the adjustment plate above the lower optic block (see chapter 6.5.1 on
page 6-5).
7. Stick the metal pins through the lower optic block into the adjustment holes of
the optic block.
8. Tighten all slit screws of the lower optic block.
Figure 6-20: Use of the adjustment plate
9. Place the photometer PCB to the bolts and stick the metal pins through the
photometer PCB to the lower optic block.

Photometer Evolis
10. Tighten the four photometer PCB screws.
Figure 6-21: The photometer PCB
11. Connect the cables and the plate in sensor fibre.

12. Replace the cover.
13. Connect the absorbance reader with the PC.
14. Switch on the system.
16. Load the reader module.
17. Perform a self test.
18. Place the alignment plate (with 96 holes) into the sledge.
19. Start the auto alignment test.
20. Complete verification of the photometer can be carried or by executing the
verification plate process.

Evolis Photometer
Service Software
6.7 Service Software
When the photometer (reader) is invoked, the application attempts to communicate

to the system and photometer module When successful the following dialogue will
be displayed with the Version and serial number displayed. Defaults such as instru-
ment offsets, will be read from the module EEPROM. If no module is detected, the
version # will be left blank.
Figure 6-22: Photometer service software main window
6.7.1 Functions of the Photometer Service Software
6.7.1.1 Instrument
Field or Button: Meaning:
Version Shows the firmware version number, if connection is

established with the module.
Serial Shows the serial number, if connection is established
with the module. The edit allows to change the serial
number.
Set Serial Number Programs serial number. User is warned before any
changes made.
Table 6-1: Fields and buttons of the I n s t r u m e n t area

Photometer Evolis
Service Software
6.7.1.2 Lamp
Lamp on Turns the lamp ON.

Lamp off Turns the lamp OFF.
Check Lamp Checks lamp status.
Table 6-2: Fields and buttons of the L a m p area
6.7.1.3 Select Filter
Filter No Enter the required filter number in the edit box.

Goto Filter Moves to the selected filter.
Table 6-3: Fields and buttons of the S e l e c t F i l t e r area
6.7.1.4 Plate Sensor
Status Displays the status of the plate sensor. 'No' repre-

sents no plate, 'Yes' represents plate carrier
detected.
Get Status Updates the plate sensor S t a t u s field.
Table 6-4: Fields and buttons of the P l a t e S e n s o r area
6.7.1.5 Filter Configuration

Allows user to read or set the filter wavelengths.
F i l t e r s 1 to F i l t e r s 8 Shows the filter values or when edited allow the val-

ues to be updated (see chapter 6.5.10 on page 6-15).
Read Filter Reads the current filter wavelengths and displays
them in the edit boxes.
Write Filter Writes filter wavelengths from the contents of the edit
boxes.
Table 6-5: Fields and buttons of the F i l t e r C o n f i g u r a t i o n area

Evolis Photometer
Service Software
6.7.1.6 Plate Alignment
Home to Col.1 The plate alignment values for H o m e t o C o l 1

offset will be different for each instrument, it is used
to adjust for the position of well A1 and the drive
home position. It should be checked if the PCB has
been moved - use the alignment test to do this.
Inter col. offset Define the plate dimensions and should be the same
on all readers.
Inter-well offset Define the plate dimensions and should be the same
on all readers.
Read Alignment Reads and displays alignment parameters in H o m e
t o C o l . 1 , I n t e r c o l . o f f s e t , and I n t e r - w e l l
offset.
Set Alignment Writes values to EEPROM for alignment.
Table 6-6: Fields and buttons of the P l a t e A l i g n m e n t area
6.7.1.7 Read Plate

Allows user to read plate using specified measurement wavelength, reference wave-
length, and number of readings.
Test Allows to enter the measurement wavelength.

Ref. Allows to enter the reference wavelength. To read in
single mode, leave reference wavelength blank.
Number of readings Allows to enter the number of readings.
Read Plate Performs plate read, using parameters defined in the
fields T e s t , R e f . and N u m b e r o f r e a d i n g s .
Statistics Displays multiple readings and statistics. When the
number of reads is set below 5, a minimum of 5
reads is used anyway.
Table 6-7: Fields and buttons of the R e a d P l a t e area

Photometer Evolis
Service Software
6.7.1.8 Shake
Drives the plate drive in shake mode using the parameters shown in amplitude,
speed, and time edit boxes.
Amp. Allows to enter the shaking amplitude. Amplitude will

only accept integers between 5 and 22.
Freq. Allows to enter the shaking frequency.
Time Allows to enter the shaking time.
Shake Shakes for the duration of time, at amplitude and fre-
quency supplied. If amplitude and frequency exceed
the drives capability, a motor error will occur.
Table 6-8: Fields and buttons of the S h a k e area
6.7.1.9 Reader Test

Allows user to test reader module using parameters defined in wet tests, test filter,
and reference filter.
Test filter Allows to enter the measurement wavelength.

Ref. filter Allows to enter the reference wavelength.
Module Test (see chapter 6.7.2 on page 6-24)
Board Test (see chapter 6.7.3 on page 6-24)
Table 6-9: Fields and buttons of the R e a d e r T e s t area

Evolis Photometer
Service Software
6.7.1.10 High Level Commands
Selftest (see chapter 6.7.4 on page 6-25)

Init Axis Initialises filter and plate drive.
View Raw Data Displays selftest results.
A u t o A li g n m e n t Executes the auto alignment routine. Requires oper-
ator to have alignment tool.
Verification Plate Executes the verification plate tests. Requires opera-
tor to have a verification plate and valid certificate file
for verification plate.
Load Displays a warning message before allowing the
user to select a file containing module parameters.
Save Allows the module parameters to be saved to a file.
Upgrade Firmware (see chapter 6.8.1 on page 6-25)
Table 6-10: Fields and buttons of the H i g h L e v e l C o m m a n d s area
6.7.1.11 Filter Drive Parameter

Allows operator to set filter drive offset
Filter Drive Offset Set filter drive offset.

Set Offset Writes offset to EEPROM.
Show Moves the filter wheel to position 1 using the current
offset. Set offset must be pressed to change offset.
A u t o A li g n Runs auto align software to determine offset. After
completion the user is prompted to confirm new off-
set, filter wheel will be at position 1 with the new off-
set. The user must visually check offset is correct
before acceptance.
Table 6-11: Fields and buttons of the F i l t e r D r i v e P a r a m e t e r area
6.7.1.12 General
Close Closes application

Command Line Dis- The line at the bottom of the screen displays the
play devices reply.
Table 6-12: General fields and buttons

Photometer Evolis
Service Software
6.7.2 Test Procedure for Module Test
Runs the sequence of tests that verify correct operation of the reader module. When
the M o d u l e T e s t button is pressed, the module test dialogue appears.
The user must update the U s e r field. This data is stored in the results file. Test
modes allow for automatic sequencing through all the tests or allows the user to se-
lect and skip tests manually.
1. Unique identifications
The data report produced will display the User ID, input from the above dia-
logue, as well as the test software version.
2. Firmware download
Allows new firmware to be installed.
3. Serial number
Allows the serial number to be written to the module EEPROM.
4. Parameter test
Verifies current values stored in EEPROM.
5. Filter test
Verifies filter drive.
6. Drive test
Verifies plate drive
7. Plate sensor test
Checks plate in sensor.
8. Selftest
Performs self test.
9. Plate alignment test
Checks X and Y alignment using a series of offset holes.
10. No plate test
Reads with no plate inserted, testing for 0.000 OD.
11. Black plate
Reads opaque plate, testing for OVER or greater than 3.000 OD.
12. Verification plate test
Reads using the reader verification plate.
13. Wet test plate
Reads plate with reagent and compares multiple readings. Nominal value
1.000 OD.
14. Wet test reference read
Reads plate with reference filter only; low OD expected, typically 0.050 OD.
15. Turn plate test
Reads wet plate, turns plate 180 degrees, reads again to test values are sim-
ilar.
6.7.3 Test Procedure for Board Test
Runs the sequence of tests that verify correct board operation. When the B o a r d
t e s t button is pressed, the board test dialogue appears. The user must update the
U s e r field. This data is stored in the results file.
Test modes allow for automatic sequencing through all the tests or allows the user to
select and skip tests manually.
The data report produced will display the user ID, input from the above dia-

Evolis Photometer
Firmware Upgrade
3. Serial number
4. Parameter test
Verifies current values stored in EEPROM.
5. Filter test
Verifies filter drive
6. Drive test
Verifies plate drive
7. Plate sensor test
Verifies plate in sensor.
8. Selftest
Executes the self test routine.
6.7.4 Self Test
When S e l f t e s t button clicked, selftest command is processed. Performs the fol-

lowing tests in sequence:
• Tests the EEPROM checksum
• Move X-axis home
• Move Y-axis to each position 1 to 8, then check that it goes back to home at
position 1.
• Measure reference voltages of front end
• Measure photo diode dark background signals
• Test lamp signals
• Test each filter for gain and noise
• Measure optic channel transmissions
If an error occurs during any test, the appropriate error response is given and the test
stops (see chapter 17.2.5 on page 17-16).
Otherwise command responds with O K , successful command execution.
6.8 Firmware Upgrade
6.8.1 Firmware Upgrade with Service Software
Invokes the Firmware Upgrade dialogue box. It is assumed the new firmware file
*.h86 resides within the reader sub-directory, as described within the INI file.
Figure 6-23: Firmware upgrade dialogue

Photometer Evolis
Firmware Upgrade
If direct connection has been selected, you must place the module in Bootstrap
mode. The following message box will prompt you to do so.
Figure 6-24: Module bootstrap mode prompt
If power is applied to the board, turn ON Pin 1 of the 4-way DIP switch SW1, and tog-
gle Pin 2. This puts the device into Bootstrap mode. If the module power is off, turn
ON Pin 1 and turn ON the module.
Press O K; the download should then start. If the progress indicator does not
change, cancel, cycle the power and repeat the process.
Once the download is complete, you must turn OFF Pin 1, otherwise the device
remains in bootstrap mode and will not operate.
6.8.2 Firmware Upgrade with User Software
To upgrade the firmware:

1. Open the user software.
2. Select U t i l i t i e s | S y s t e m S e t u p . . . from the main menu bar.
3. Click on the C o l o r i m e t e r tab.
4. Click on the U p g r a d e F i r mw a r e button.
The file (READ.H86) used to update the firmware must be stored in the PC
software directory (e. g. C:\BioRad\System).
5. Follow the instructions.

6. When complete, click the O K button.
If failure during firmware update, please change photometer PCB!

Evolis Washer
Safety and Hints
7 Washer

The wash head could have had contact with dangerous material! Pay at-
tention to safety regards! Always wear gloves!
set!
Every time the washer module or plate transport is disturbed, the calibration
of the positions used to insert and remove plate carriers must be reviewed
and potentially re-calibrated. Please refer to the plate transport section for de-
tailed information (see chapter 8 on page 8-1).

Washer Evolis
Overview
7.2 Overview
The washer module is an 8 way washer with 8 dispense and 8 aspirate tubes. It has
4 reagent bottles, each with their own low level float switch. There is an internal waste
bottle with full alarm and froth trap bottle. A vacuum sensor verifies aspiration air flow.
Figure 7-1: Washer module
Figure 7-2: Pattern of washer module
1 Washer PCB
2 Aspirate pump, air compressor, vacuum pump

Evolis Washer
Fluid Architecture
3 Peristaltic pump, waste pump

4 Z- motor, washer lift
5 X- motor, plate transport motor with incremental encoder
6 Dispense pump
7 Dispense manifold
8 Wash buffer fitting
9 Wash buffer alarm
10 Dispense fitting
11 Water trap
12 Wash head axle
13 Wash head arm
14 Dispense valve, solenoid valve
15 Wash head
16 Vacuum sensor
17 Purge station
18 Plate in sensor fibre
19 Plate sledge
20 X-init light barrier
21 Tooth belt
22 Washer fixing screws
23 Wash head init light barrier
24 Filter
7.4 Fluid Architecture
7.4.1 Wash Buffer Tubing
Figure 7-3: Wash buffer tubing

Washer Evolis
Fluid Architecture
No Start tube (flow to) End tube Medium
1 Wash buffer bottle 1, 2, 3, 4 CPC quick connector Liquid

2a Manifold out 1/16-1/8 Tube connector Liquid
2b 1/16-1/8 Tube connector Wash head valve in Liquid
3 Wash head valve out Wash comb Liquid
5a CPC quick connector out Tube filter in Liquid
5a Tube filter in Buffer pump in Liquid
Table 7-1: Wash buffer tubing
7.4.2 Instrument Waste Tubing
Figure 7-4: Instrument waste tubing

Evolis Washer
Fluid Architecture
No Start tube (flow to) End tube Medium
4 Waste bottle Waste pump in Liquid

6 Waste pump cassette - Liquid
7 Waste bottle Foam bottle Air vacuum
8a Aspirate pump out With fitting connect to tube Air blow
12
8b Foam bottle Aspirate pump in Air vacuum
9a Wash head Vacuum snorkel Liquid
9b Vacuum snorkel junction Vacuum switch Air vacuum
9c Vacuum snorkel Waste bottle input Liquid
10a Waste pump out Y-fitting Liquid
10b Waste pump wash station Y-fitting Liquid
out
10c Y-fitting CPC quick connector (small Liquid
one)
11 Wash station Waste pump wash station in Liquid
12 Aspirate out 8a CPC quick connector (big Air blow
one)
13 CPC quick connector (big Waste container Air blow
outside)
14 CPC quick connection (small Waste container Liquid
outside)
Table 7-2: Instrument waste tubing

Washer Evolis
Figure 7-5: Washer PCB
Connections
Meaning:
LD1 Plate in sensor (fibre)

ST1 Plate drive - NPN photo transistor
ST2 Head drive - home sensor
ST3 Plate drive - home sensor
ST4 Sensors - dispense level sensors
ST5 Sensors - dispense level sensors
ST7 Pump drives 0, 1 (pump connector 1 and 2.
ST8 Pump drives 2, 3 (pump connector 3 and 4.
ST9 Sensors - ASP flow sensors
ST10 Sensors - DSIP flow sensors
ST12 Sensors - internal waste full
ST15 Pump drives - aspirate
ST16 Pump drives - waste
ST17 Plate drive - stepper motor drive
ST18 Head drive - stepper motor drive (Z-motor)
ST19 Pump drives - pinch (sole) valve drive
ST21 Wash verification interface
ST22 Plate drive - encoder
ST24 Power
ST25 RS232 - COP
Table 7-3: Meaning of washer PCB connections

Evolis Washer
Maintenance
7.6 Maintenance
Routine maintenance is to be carried out according to published schedules.
7.6.1 Washer Adjustment and Testing Tools
7.6.1.1 Washer Adjustment Tool
Figure 7-6: Washer alignment plate
The alignment plate is used to set the parallelism of the wash head and the X-drive
offset. It has 2 mm holes in place of the first and last column of wells.

Washer Evolis
Maintenance
7.6.1.2 Washer Calibration Tool
Figure 7-7: Washer calibration tool with plate carrier
With the washer calibration tool it can be tested whether the wash head dispenses
uniformity.
7.6.2 Replacement of Washer Module
Removal

4. Disconnect and remove all the bottles and waste tubing.
5. Remove the bottle tray.
6. Release the two retaining screws at the back of the washer.
Figure 7-8: Module retaining screw next to waste pump

Evolis Washer
Maintenance
Figure 7-9: Module retaining screw next to tubing filter
7. Remove the two screws on the plate transport bulkhead holding the washer
module.
Figure 7-10: Bulkhead retaining screws
8. Move the module out to gain access to the cables.

9. Disconnect the power cable and the serial cable from the washer PCB.
10. Remove the module.
Installation 11. Insert the washer module in the front position.

12. Connect the power cable and the serial cable to the washer PCB.
13. Insert the two screws on the plate transport bulkhead holding the front of the
washer.
Do not tighten!
14. Start the two retaining screws holding the rear of the washer to the function
drawer.
Do not tighten!
15. Tighten the two screws on the plate transport bulkhead.
16. Tighten the two rear screws.

Washer Evolis
Maintenance
7.6.3 Replacement of Vacuum Switch
Removal 1. Remove the washer module (see chapter 7.6.2 on page 7-8).
2. Remove screws at position 'A'.
Figure 7-11: Washer vacuum switch
3. Take the vacuum switch 'D' out of the washer housing.

4. Disconnect cable and tubing 'B' from the vacuum switch.
Installation 5. Install the new vacuum switch.

6. Connect the cables and tubing's as shown. The tubing's must be air tight at
the vacuum switch.
7. Check that the internal waste bottles are air tighten.
8. Set the vacuum switch into the washer housing, position 'C' behind position
'A'.
9. Set the screws and tighten.
10. Have a look at tubing 'B' and the cable. They must not touch the moving parts
of the plate transport.
The vacuum switch will have to be adjusted in any case! Test the switching
point when connecting all tubing's and wash comb only. The tubing system
must be wet. See chapter 7.8 on page 7-26 for general instructions.
11. After the installation power on the system.

Evolis Washer
Maintenance

13. Open the module washer.
14. Press the S e l f t e s t button in the menu H i g h L e v e l C o m m a n d s and
wait until the initialisation routine is finished.
15. Press the A s p i r a t e o n button in the menu A s p i r a t e .
16. Press the C o n t i n u o u s button in the menu A s p i r a t e .
17. For the vacuum switch adjustment you will need a small screw-driver. Stick
through hole 'F' into the adjustment screw 'E'.
Figure 7-12: Vacuum switch adjustment
18. If the Aspirate Flow value is 0, then turn the adjustment screw to the right until
it changes to 1.
19. If the Aspirate Flow value is 1, then turn the adjustment screw to the left until
it changes to 0.
20. Turn the adjustment screw half rotation left. The Aspirate Flow value must
remain on 0.
21. Performance control: The Aspirate Flow value changes to 1 when:
• the waste bottles are not closed tightly or
• the tubing behind the sensor is disconnected.

Washer Evolis
Maintenance
7.6.4 Replacement and Cleaning of Wash Head
For actions at the wash head it's not necessary to remove the washer.
Removal

4. Remove dispense and aspirate tubing from the back side.
5. Remove knurled screws 'A'.
6. Remove the wash head.
Figure 7-13: Wash head
Cleaning 7. Remove the four screws 'B'.

8. Insert through the 16 washer needles 'D' a stainless steel wire style (the
longer ones are aspirate, the shorter are dispense needles).
9. Wash the drilling across the wash head under running water.
10. Install a new O-seal ´C´ to bolt 'B' if necessary.
11. Close the drillings.
Tighten screws 'B' so they don't squeeze the O-seal 'C' plus 90° up to 180°
degrees.

Evolis Washer
Maintenance
Figure 7-14: Wash head (chart)
Installation 12. Insert the wash head and tighten knurled screws 'A'.
13. Check by hand free swinging.
Normally it's not necessary to align the wash head.
7.6.5 Replacement of Peristaltic Pump Motor and Tubing

Cassette
3. To remove the pump motor: Remove the washer module (see chapter 7.6.2 on
page 7-8).
4. Remove the tubing cassette 'A' by pressing the clips 'C' at top and bottom of
the cassette and pulling down the tubing cassette.
Figure 7-15: Peristaltic pump (washer bottom view)
5. To remove the pump motor: Disconnect cable 'F'.

6. To remove the pump motor: Remove the four screws 'B'.
7. To remove the pump motor: Remove the pump motor.
Installation 8. To install the pump motor: Install a new pump motor.

Washer Evolis
Maintenance
9. To install the pump motor: Tighten the four screws ’B’.

10. To install the pump motor: Connect cable ’F’ (+ brown; - green).
Figure 7-16: Cable connections of the peristaltic pump motor
11. Push the cassette onto the motor axle until the clips snap in.
7.6.6 Replacement of Plate Transport Belt
2. Loosen both screws at position 'D'.
Figure 7-17: Plate transport belt
3. Push the roller to loosen the belt tension.

4. Tighten the screws ’D’ in this pushed position again.
5. Place the plate sledge 'C' into the very right position.
6. Lift the belt 'A' out of the slits 'B'.
7. Remove the belt.
Installation 8. Install the new belt.

9. Lay it around the rollers.
10. Attach end of belt in the slits 'B’.
Figure 7-18: Plate transport belt (chart)

Evolis Washer
Maintenance
11. Release both screws at position 'D'.

The belt is tensioned automatically.
12. Tighten the screws ’D’.
7.6.7 Replacement of Aspiration Pump
2. Remove screws 'C'.
Figure 7-19: Aspiration pump (washer bottom view)
3. Pull off tubing's 'A' after removing clamp.

4. Disconnect cable 'B'.
5. Remove the aspiration pump.
Installation 6. Insert the new aspiration pump.

7. Tighten screws, reconnect tubings, and set the clamps.
8. Connect the cable (- brown; + green).
Figure 7-20: Cable connection aspiration pump (chart)

Washer Evolis
Maintenance
7.6.8 Replacement of Dispense Pump
The four dispense pumps are fitted to the rear of the module.
There are no serviceable parts. When it is faulty then replace it.
2. Disconnect the pump plugs inside of the washer case.
3. Pull down all 4 tubing's 'B' from pumps 'A.0 - A.3'.
Figure 7-21: Dispense pumps
4. Remove both screws at position 'E' and take away the bracket 'F'.
5. Pull the pumps out of the manifold 'C'.
6. Remove 4 screws 'D'.
7. Take away the sheet metal and remove the O-seals inside the manifold.

Evolis Washer
Maintenance
Figure 7-22: Dispense pump (chart)
Installation 8. Insert new O-seals inside the manifold.

9. Insert new dispense pumps and reassemble.
Pay attention for direction of liquid flow of pump.
Connecting correct plug. See name at the washer PCB "pump0,1; pump 2,3".
10. The liquid flow of replaced pumps must be adjusted by service software (see
chapter 7.8 on page 7-26).
7.6.9 Replacement of Dispense Valve
To replace the dispense valve or tubing's it's not necessary to remove the
washer.
Removal

4. Pull down the silicon tubings 'A' and 'B' from valve head.
Note the correct silicon tubing connection.

Washer Evolis
Maintenance
Figure 7-23: Dispense valve
5. Remove both fixing screws 'C'.

6. Release plug screw 'D' and remove plug.
7. Remove the valve.
Installation 8. Install the new valve.

9. Install the plug.
10. Tighten the plug screw ’D’.
11. Install the silicon tubings 'A' and 'B' from valve head.

Evolis Washer
Maintenance
7.6.10 Replacement of Z-motor (Wash Head up and down

Motor)
2. Remove screws 'C'.
Figure 7-24: Installed Z-motor
3. Push the motor 'A' inside the case 'B'.

4. Disconnect motor plug 'E' from washer PCB.
Figure 7-25: Z-motor
Installation 5. Set the silicon rubber seal 'D' on to the new Z-motor.
6. Install the new parts from the bottom into the washer case.
7. Tighten screws.
8. Connect Z-motor to washer PCB.

Washer Evolis
Maintenance
Figure 7-26: Z-motor (chart)
7.6.11 Replacement of Washer Light Barriers
First check the optical alignment and ensure that the light barrier is not dirty
or has fluid on it.
1. Remove the washer module (see chapter 7.6.2 on page 7-8).
Figure 7-27: Washer light barriers
Replace Plate 2. Remove metal bridge 'A'.

Transport Init and 3. Disconnect cable from washer PCB (see chapter 7.5 on page 7-6).
Plate in Light Bar- 4. Pull cable to the top of the washer.
rier 5. Replace the light barrier.
6. After reassembling the washer check the movement of sledge.
7. The metal flag 'D' must break the light barrier 'F' in init position.
8. The height can be adjusted with two screws 'E'.

Evolis Washer
Maintenance
Replace Wash 9. Disconnect cable from washer PCB.

Head Init Light 10. Pull cable to the top of the washer.
Barrier 11. Replace the light barrier 'G'.
7.6.12 Plate in Fibre
The Plate-in signal is derived from using an IR LED device and a photo-transistor
mounted above the plate drive. A fibre carries the light from the LED device into a
bolt mounted underneath the main chassis. The beam is directed onto a photo-tran-
sistor directly above. When a plate carrier obscures the light beam, the firmware as-
sumes the carrier is in position (see also chapter 7.3 on page 7-2 and chapter 7.5 on page 7-6).
Figure 7-28: Plate in sensor
7.6.13 Replacement of Washer PCB
There are no settings on the circuit board.
2. Remove all the connectors.
3. Release the PCB from its 4 retaining bolts.
Installation 4. Install the new PCB.

5. Set all DIP switches "off".
6. Install all the connectors.
7. Install the washer module (see chapter 7.6.2 on page 7-8).
8. After the PCB is replaced, the calibration procedure will need to be executed.

Washer Evolis
Maintenance
7.6.14 Internal Waste Bottle and internal Froth Trap Bottle
Waste bottle and froth trap must be air tight. Ensure O-seals are used to provide
good air seal.
Figure 7-29: Internal froth trap bottle (left) and internal waste bottle (right)
No.: Description:
1 Internal waste bottle

2 Internal froth bottle
3 Tubing between internal waste bottle (red mark) and water trap (out-
put)
4 Tubing between internal waste bottle (grey mark) and peristaltic
pump (input)
5 Liquid level detection sensor cable
6 Tubing between internal waste bottle (yellow mark) and internal froth
trap bottle (yellow mark) and
7 Tubing between internal froth trap bottle (black mark) and aspirate
pump (input)
Table 7-4: Description

Evolis Washer
7.7.1 Alignment of Wash Head

4. Put the alignment plate into the plate sledge.
5. Loosen the two fixing screws 'A' of the wash head.
Figure 7-30: Wash head fixing screws
6. Put the aspirate needles (see figure 7-14: on page 7-13) into the drillings of the
alignment plate.
7. Tighten the two fixing screws 'A' of the wash head.
For rough alignment:
• Loosen the two fixing screws 'B' of the wash head arm.

Washer Evolis
Figure 7-31: Fixing screws of the wash head arm
8. Tighten the two fixing screws 'B' of the wash head arm after rough alingn-
ment.
9. Check the alignment with service software (see chapter 7.8.3 on page 7-33).
10. Check default heights of the dispensing needle during washing with the user
software system setup.
7.7.2 Adjustable of Washer Bottles Float Switches
The orientation of the float on the float switch sets the switch action, normally opened
or normally closed.
Figure 7-32: Adjustable float switch
Adjustment float switch length on 1 or 2 litre washer bottles:

1. Open the screw.
2. Adjust the float switch has to length value.
• 1 litre bottles: Length = 168 +/- 1 mm
• 2 litre bottles: Length = 183 +/- 1 mm

Evolis Washer
Figure 7-33: Float switch length
3. Tighten the screw.
7.7.3 Volume Calibration of the Washer
1. Start the service software and the washer driver module.

2. Press on the C a l i b r a t e button.
The message "Do you want to perform a gravimetric calibrate using labora-
tory scales?" will appear.
• If you select Y e s, please follow the known calibration procedure using
a scale.
• If you select N o , please select the C h a n n e l and follow the following
procedure:
3. Load the washer calibration tool (see chapter 7.6.1 on page 7-7) into the washer
(opening is equal to strip 1).
4. Press on the O K button to confirm the message "Please load the Volume
Calibration plate in the Washer".
5. At the end of the calibration step remove the washer calibration tool.
6. Move the washer calibration tool into vertical position.
7. Add all eight values and divide through eight.
8. Insert the value into the V o l u m e ( µl ) field.
9. Press on the O K button.
10. Empty the washer calibration tool.
11. Place the washer calibration tool back into the washer.
13. Repeat this for all four channels.

Washer Evolis
Washer Service Software
7.8 Washer Service Software
When the washer is invoked, the application attempts to communicate to the system
and washer module. When successful, the following dialogue will be displayed with
the version and serial number displayed. Defaults, such as instrument offsets will be
read from the module EEPROM and shown. If no module is detected,??? will be
shown for the version.
Figure 7-34: Washer main window

Evolis Washer
7.8.1 Functions of the Washer Service Software
7.8.1.1 Instrument
X Offset X-offset of the wash head. Automatically set by the

alignment function (see page 7-32)
Z Offset Z-offset of the wash head. Automatically set by the
alignment function (see page 7-32).
Set offsets X-offset and Z-offset edit boxes provided; Pressing
set offsets sends offsets to module.
number.
Set Serial number Sends contents of S e r i a l N u m b e r edit box to
washer. It will only accept up to 10 alphanumeric
characters. Warning displayed when request to
update.
7.8.1.2 Plate Sensor
Status Displays the status of the plate sensor. 'No' repre-

sents no plate, 'Yes' represents plate carrier
detected.
Get Status Updates the plate sensor S t a t u s field.
Table 7-6: Fields and buttons of the P l a t e S e n s o r area
7.8.1.3 X-Motor
Allows user to control the X-motor (plate drive).
Home Moves to the home position.

Move to Enter coordinate in edit box provided.
Energise Energises coils of motor, locks motor.
De-energise De-energises coils of motor, allows motor to free run.
Table 7-7: Fields and buttons of the X - M o t o r area
7.8.1.4 Z-Motor
Refer to X-motor. Allows user to control the Z-motor (wash head drive).

Washer Evolis

The values assigned to the parameters within this section are used for other se-
quences and command buttons. It is important they are set correctly when running
the calibration, accuracy, repeatability, and residual tests within the module test as
the tests will fail otherwise.

Evolis Washer

Reagent Numbers 0 to 3.
• 0 = RED channel
• 1 = BLUE channel
• 2 = YELLOW channel
• 3 = BLACK channel
First Strip First strip number defaults to 1
Last Strip Last strip number defaults to 12, therefore default is
for whole plate.
Wash Cycles Number of cycles to wash defaults to 1, range 0 to
100.
Top Wash Top wash duration defaults to 1000 ms.
Disp. Speed Dispense speed, 255 is equivalent to 100 %. (See
note)
Top Height Defaults to 20.
Min. Cycle Time Sets the minimum cycle time defaults to 0, no delay.
Aspirate Height Defaults to 170.
Aspirate Mode Always ensure the correct sweep mode is selected
for the plate used: No sweep for U plates, Sweep for
flat and C type plates.
Purge Speed Default is 255. Purging is most effective at the fastest
speed.
Time Purge time defaults to 2000 ms.
Purge Purges reagent channel. Edit boxes for purge speed
and time (ms) provided. Purging is most effective
when the highest speed (255) is used.
Dispense as head If this item is selected, the wash heads dispenses
rises wash fluid already while moving upward.
Bottom Cycles Number of bottom cycles defaults to 0, range 0 to
100.
Bottom Wash Duration of bottom wash defaults to 500 ms.
Bottom Height Height of head during bottom wash operation
defaults to 100.
Wash Washes plate using the parameters assigned.
Partial Mode Defaults to ASAP, other option Constant. (See note)
Aspirate Aspirates plate using the parameters assigned.
If you pause the wash process, do not immediately click on A b o r t or C o n -

t i n u e , wait until the washer has paused, before selecting either Ab o r t or

Washer Evolis
C o n t i n u e . If you press abort too early, flooding may occur! Pressing S e l f t -

e s t will reset the module.
Dispense speed ranges from 0 to 255. This equates to a frequency drive to

the dispense pump. 255 is equivalent to 50hz and 0 is equivalent to 10hz.
However, the 100% used in the user software can be adjusted by the rate 100
parameter (in the registry of the application software) to lower frequencies
than 50hz. Typically this parameter is 75%, i.e. 191.
Partial mode is used to alter the method of washing when less than 12 strips
are being washed. Asap means the plate will be washed as soon as possible.
Constant means that the wash time will be the same as for a full plate.
If you pause the aspirate process, do not immediately click on A b o r t or

C o n t i n u e , wait until the washer has paused, before selecting either A b o r t
or Co n t i n u e . If you press abort too early, the aspiration cycle will not move
home correctly. Pressing S e l f t e s t will reset the module.
7.8.1.6 Dispense
Allows user control of dispense pumps.
Running the pump with full reagent bottles connected will result in flooding.

Evolis Washer
Pump Allows to enter the pump number (0 - 3)

Speed Dispense speed.
Pump on Turns on the pump selected from list, pump #, pump
speed determined by contents of edit box for speed.
Pump off Turns pump off.
Fire valve for Edit box to enter time in ms, pressing 'Fire Valve for'
button will activate the valve for the period of time
given.
Sensors Displays sensor float status for pumps reagent, the
first position is reagent 0. 0 = reagent present, 1 =
empty. Example 0101 would indicate reagent 0 & 2
present, reagent 1 & 3 empty.
Get s t at us Updates the sensor float status of the S e n s o r s
field.
Table 7-9: Fields and buttons of the D i s p e n s e area
7.8.1.7 Aspirate
Aspirate On Turns on the aspirate pump.

Aspirate Off Turns off the aspirate pump.
Waste On Turns on the waste pump (peristaltic pump).
Waste Off Turns off the waste pump.
Internal Sensor Displays internal float switch (full) sensor status. 0 =
Okay, 1 = Fluid Low or low vacuum.
Aspirate Flow Displays aspirate flow sensor. 0 = Okay, 1 = Fluid
Low or low vacuum.
Get Sens or Stat us Updates the sensor float status of the I n t e r n a l
S e n s o r and A s p i r a t e F l o w fields.
Continuous Continuous aspirate sensor check that updates dia-
logue until A b o r t pressed.
Table 7-10: Fields and buttons of the A s p i r a t e area
The external float switch connection is not used. The system waste sensor is
connected to the cop (see chapter 15.4.1 on page 15-6).

Washer Evolis
7.8.1.8 Cycle
X Drive Enable the X-drive for cycle test.

Z drive Enable the Z-drive for cycle test (12 movements to
simulate a full plate per cycle).
Aspirate/Waste Enable aspirate/waste function for cycle test.
Dispense Enable dispense function for cycle test.
Cycle Starts the cycle test.
Table 7-11: Fields and buttons of the C y c l e area
7.8.1.9 Miscellaneous
Alignment (see chapter 7.8.3 on page 7-33)

Calibrate Runs the calibration process. Follow the instructions
in each dialogue box. Requires empty plates and
precision scales.
Read Plate... Allows a plate dispensed from the washer using a
dyed solution to be read in the reader module. This
allows the C.V. across the plate to be calculated from
each OD reading.
Load... Loads the module alignment parameters from a file.
Module Test... (see chapter 7.8.4 on page 7-34)
Board Test... (see chapter 7.8.5 on page 7-36)
Save Saves the current module alignment parameters to
file. It uses the standard file dialogue.
Upgrade Firmware (see chapter 7.9.1 on page 7-37)
Table 7-12: Fields and buttons of the M i s c e l l a n e o u s area
7.8.1.10 General
Close Closes application.

play devices reply.

Evolis Washer
7.8.2 Self Test
When S e l f t e s t button clicked, selftest command processed. Performs the follow-

ing tests in sequence:
• X-axis encoder test.
• Move Z-axis home.
• Check the aspirate pump operates.
• Check the dispense pump operates.
7.8.3 Alignment
The "Z-Offset Alignment" is required to guarantee the same wash height parameters
for each individual instrument defined in the assay protocol and in the washer system
set up.
The alignment procedure in the service software calculates a "Z-Offset" which works
like a "Reference point" (point 0), which varies from instrument to instrument due to
mechanical tolerances.
All the defined wash height parameters are based on the reference point.
This means that all wash heights like "Aspirate height", "Top wash height" and "Travel
height" are based on the reference position.
Different Wash Head positions:
• Home position (detected by home sensor).
• Travel height (movement from strip to strip) is equal the reference point (point
0).
• Top wash height: programmed height is added to the reference point.
• Aspirate height: programmed height is added to the reference point.
Alignment proc-
ess
Follow the instructions in each dialogue box!
Requires the washer alignment plate.

2. Select the washer module.
3. Press on the S e l f t e s t button.
4. Press on the A l i g n m e n t button to start the procedure.
5. After performing the X-alignment the Z-alignment dialogue box will be dis-
played.

Washer Evolis
Figure 7-35: Z-alignment dialogue
6. Use the Up and Down keys to move the wash head up and down.
The aspirate pins of the wash head have to touch the flat surface of the align-
ment plate.
7. Confirm by pressing the O K button.
A dialogue box with the offset parameters is displayed.
Figure 7-36: Drive offsets dialogue
8. Confirm the dialogue box by pressing the Yes button to store the offset-
value.
Runs the sequence of tests that verify correct operation of the washer module. When
the M o d u l e T e s t . . . button is pressed, the following sequence is performed. The
User must update the u s e r field. This data is stored in the results file.
The data report produced will display the user ID input from the above dia-
logue as well as the test software version.
3. Serial number
4. Volatile parameters
Verifies default values stored within the EEPROM.

Evolis Washer
5. Plate drive
Verifies the Plate drive. Requires a plate drive motor to be attached to the
PCB and the home sensor.
6. Plate in sensor
Verifies the plate in sensor.
7. Z-drive
Verifies the Z-drive.
8. Pump control
Verifies the pumps.
The dispense pumps will function in this test. If reagent bottles are connect-
ed, reagent will be dispensed!
9. Level sensors
Verifies the level sensors by detecting a change on each input.
10. Selftest
Performs the self test.
11. Alignment
Verifies correct alignment of wash head. Requires washer alignment tool.
12. Calibration
Calibrates each dispense channel. Requires scales, empty micro plates and
reagent.
13. Dispense Accuracy
Verifies dispense accuracy. Requires scales, empty micro plates and reagent.
One channel should contain reagent that has an OD of approximately 1.000
O.D. at 300 µl using the 405 nm filter. The plate dispensed with the colour
dye is required for the repeatability test, next.
Channel should use colour reagent. Keep plate for repeatability. The last 'ze-
ro' plate should also be kept for the 'aspirate' test.
14. Repeatability
Verifies washer consistency in dispensing, by using the absorbance reader to
read every well. The plate used from the above 'Dispense Accuracy' test,
using a reagent of known O.D. (water with colour dye) is required. The User
must place the plate into the absorbance reader before selecting O k . The
C.V. of the plate will be determined, default number of reads is set to 10.
Requires full micro plate of coloured dye from previous test and reader.
15. Aspirate
Verifies the residual volume after aspiration. The 'empty' plate is weighed to
determine the residual volume. Requires scales and 'full' micro plate from dis-
pense test. The last plate of the dispense test should have its empty weight
stored on the scales, therefore use this plate to aspirate from.

Washer Evolis
Runs the sequence of tests that verify correct board operation. When the B o a r d
T e s t . . . button is pressed, the following sequence is performed. The user must up-
date the u s e r field. This data is stored in the results file.
The data report produced will display the user ID input from the above dia-
logue as well as the test software version.
3. Serial number
4. Volatile parameters
5. Plate drive
Verifies the plate drive. Requires a plate drive motor to be attached to the
PCB and the home sensor.
6. Plate in sensor
Verifies the plate in sensor.
7. Z-drive
Verifies the Z-drive.
8. Pump control
Verifies the pumps.
The dispense pumps will function in this test. If reagent bottles are connect-
ed, reagent will be dispensed!
9. Level Sensors
Verifies the level sensors by detecting a change on each input.
10. Selftest
Performs the self test.

Evolis Washer
Firmware Upgrade
Invokes the firmware upgrade dialogue box. It is assumed the new firmware file *.h86
resides within the washer sub-directory, as described within the INI file. Otherwise
you may browse all available drives.
Direct connection allows upgrade using a RS232 cable directly connected to a PC.
If direct connection has been selected, you must place the module in bootstrap
mode, the following message will prompt you to do so.
gle Pin 2. This puts the device into Bootstrap mode. If the module power is off, turn
ON Pin 1 and turn ON the module.
Press O K ; the download should then start. If the progress indicator does not
change, Ca n c e l , cycle the power and repeat the process.

3. Click on the W a s h e r tab.
4. Click on the Up g r a d e F i r m w a r e button.

Washer Evolis
Firmware Upgrade
The file (WASHER.H86) used to update the firmware must be stored in the
PC software directory (e. g. C:\BioRad\System).


Evolis Plate Transport
Safety and Hints
8 Plate Transport

set!
If you have done service actions on the plate transport, it's necessary to do
new calibration (see chapter 8.7 on page 8-23 and chapter 8.8 on page 8-27)!
If you have done service actions at washer, incubator, photometer, pipetting

station or stacker, it's necessary to check all positions and if necessary to do
new calibration (see chapter 8.7 on page 8-23 and chapter 8.8 on page 8-27)!

Plate Transport Evolis
Figure 8-1: Mechanical architecture of the plate transport (chart)
1 Small cogwheel
2 Big cogwheel
3 Z-motor PCB
4a/b Plate transport Z-high flex cable
5 Z-motor
6 Z-incremental encoder
7 Z-spindle
8 Y-cog belt fixing
9 Y-axle slide bearing

10 X-incremental encoder
11 X-motor
12 X-transport belt
13 Roller
14 X-motor PCB
15 X-guide rail
16 Z-spindle nut
17 Z-guide block
18 Plate carrier detect light barrier
19 Plate carrier moving sheet
20 X-light barrier (init position)
21 Z-guide ball bearing
22 Z-guide rail
23 Z-light barrier (init position)

8.3 Electronic Architecture
Figure 8-2: Electronic architecture of the plate transport
4 Plate transport high-flex cable

24 Plate transport PCB
25 Y-motor with encoder
26 Y-init position light barrier

Figure 8-3: Plate transport PCB
Number: Connection:
ST1 X-motor (high-flex cable)

ST2 Z-motor (high-flex cable)
ST3 Y-encoder
ST4 Stacker light barrier 1
ST5 Y-init position light barrier
ST6 Washer LED
ST7 Door sensor
ST8 Power supply (+ 24V)
ST9 RS232
ST10 Y-motor
Table 8-1: Connections of the plate transport PCB

Figure 8-4: X- and Z-motor PCB (two boards)
Number: Connection:
X-motor PCB: Z-motor PCB:
ST1 X-motor Z-motor

ST2 X-motor incremental encoder Z-spindle incremental encoder
ST3 Plate carrier detect light barrier N.C
ST4 X-init position light barrier Z-init position light barrier
ST5 Plate transport PCB (high-flex Plate transport PCB (high-flex
cable) cable)
Table 8-2: Connections of the X- and Z-motor PCB

Maintenance
8.5 Maintenance
8.5.1 Plate Transport Alignment Tools
8.5.1.1 Shaft X-Drive Alignment Tool

Tool to align the X-guide rails (see chapter 8.6.2 on page 8-20).
8.5.1.2 X-Gantry Alignment Plate

Tool to align the plate carrier moving sheet and the plate carrier guides (see
8.5.2 Replacement of Plate Transport
Removal

Figure 8-5: Plate transport inside drawer
4. Loosen Y-belt fixing screws 'B'.

Maintenance
Figure 8-6: Y-belt fixing
5. Compress the spring.

6. Tighten Y-belt fixing screws 'B'.
7. Take out the Y-belt on both sides.
8. Open screw 'C' by holding the screw and turning Y-guiding rod '2'.
Do not damage the Y-guide rail surface!
Figure 8-7: Guiding rod fixing
9. Pull the Y-guiding rod ’2’ to the back of the instrument out of the Y-axle slide
bearings.
10. Disconnect the high flex cable from X-motor PCB (see chapter 8.4 on page 8-5).
11. Disconnect the high flex cable from Z-motor PCB.
12. Lift the plate transport out of the drawer.

Maintenance
Installation 13. Insert the new plate transport.

14. Connect the high flex cable to the Z-motor PCB.
15. Connect the high flex cable to the X-motor PCB.
16. Insert the Y-guiding rod ’2’.
17. Tighten screw 'C' by holding the screw and turning Y-guiding rod.
18. Insert the Y-belt on both sides.
19. Loosen Y-belt fixing screws 'B'.
20. Tighten Y-belt fixing screws 'B'.
21. It's necessary to do new calibration (see chapter 8.7 on page 8-23 and chapter 8.8 on
page 8-27).
8.5.3 Replacement of Plate Transport PCB
Removal

4. Remove screws 'A'.
Figure 8-8: Plate transport PCB cover
5. Remove the plate transport PCB cover '1'.

6. Disconnect cables from plate transport PCB (see chapter 8.4 on page 8-5).

Maintenance
Figure 8-9: Plate transport PCB
7. Remove screws 'B'.

8. Remove screws 'C' from the electronic components.
9. Remove the plate transport PCB '2'.
Installation 10. Install the plate transport PCB '2'.

11. Tighten screws 'C' from the electronic components.
12. Tighten screws 'B'.
13. Connect cables to the plate transport PCB.
14. Install the plate transport PCB cover '1'.
15. Tighten screws 'A'.

Maintenance
8.5.4 Replacement of High Flex Cable
To replace the high flex cable use a folded spare part only!
Removal 1. Open the plate transport PCB cover (see chapter 8.5.3 on page 8-9).
2. Disconnect high flex cable from plate transport PCB (see chapter 8.4 on page 8-5).
3. Disconnect high flex cable from X-motor PCB.
4. Disconnect high flex cable from Z-motor PCB.
5. Remove the faulty high flex cable.
Installation 6. Install new high flex cable.
Figure 8-10: High flex cable
7. Push the high flex cable through the slit in left side of the washer, to plate
transport PCB.

Maintenance
Figure 8-11: High flex cable fixing 1
8. Connect high flex cable to plate transport PCB.

9. Connect high flex cable to X-motor PCB.
10. Connect high flex cable to Z-motor PCB. Set fold ’A’ like in figure 8-11:.
11. Place the high flex cable in the middle of the fixing points at the bottom of the
drawer.
12. Cover the high flex cable with the protector foil.
13. Fix the high flex cable with rubbers.
Figure 8-12: High flex cable fixing 2

Maintenance
8.5.5 Replacement of Y-Transport Belt
Removal

4. In the back of Y-guide rail the belt is be around the roller.
Loose screws 'A'
Figure 8-13: Belt tension adjust
5. Press spring at roller and tighten screws ’A’.

The belt is slack now.
6. Loose nuts at transport unit '1'.
Figure 8-14: Y-transport belt fixing
7. Lift up the slit sheet metal 'B'.

8. Pull out the faulty bel.t
Installation
The new Y-transport belt must have a length of 1200 mm +/- 2 mm.
9. Install the new belt around the Y-motor and belt tension roller.
10. Attach it at the Y-transport.
11. Loose screws 'A' to stretch belt.
12. Tighten screws again.

Maintenance
8.5.6 Replacement of X-Transport Belt
Stretch belt every 12 month!
Removal

4. Loose screws 'A'.
Figure 8-15: Plate transport lift (top view)
5. Press roller 'B' with a screw driver.

6. Tighten screws. The belt is slack now.
7. Remove faulty X-transport belt.
Installation 8. Install new X-transport belt.

9. Put the belt 'C' around the Y-Motor and belt tension roller.
10. Attach the belt at the X-transport.
11. Loose screws 'A' to stretch belt.
12. Tighten screws again.

Maintenance
8.5.7 Replacement of X-Motor
Removal 1. Loose X-transport belt tension (see chapter 8.5.6 on page 8-14).
2. Disconnect cables from X-motor PCB (see chapter 8.4 on page 8-5).
3. Remove screws 'A'.
Figure 8-16: Plate transport lift
4. Remove the faulty X-motor.
Installation 5. Install the new X-motor.

6. Put the X-transport belt around the motor wheel.
7. Set the screws 'A'.
8. Connect the cables.
9. Tighten X-transport belt (see chapter 8.5.6 on page 8-14).

Maintenance
8.5.8 Replacement of Z-Motor
Removal 1. Remove the plate transport (see chapter 8.5.2 on page 8-7).
2. Disconnect connector ST1 from Z-motor PCB (see chapter 8.4 on page 8-5).
3. Push out the pin 'A' inside the shaft of the cogwheel '2'.
Figure 8-17: Z-motor and cogwheels
4. Pull down the cogwheel '2'.

5. Remove screws and cable fixings.
6. Replace the faulty Z-motor.
Installation 7. Install the new Z-motor.

8. Tighten screws and cable fixings.
9. Install the cogwheel '2'.
10. Insert the pin 'A' into the shaft of the cogwheel '2'.
11. Connect connector ST1 to Z-motor PCB.
12. Install the plate transport (see chapter 8.5.2 on page 8-7).
8.5.9 Replacement of X-light barrier (Init Position)
After replacement the light barrier, the position must be taught!
Removal

4. Disconnect connector ST4 from X-motor PCB (see chapter 8.4 on page 8-5).
5. Remove cable fixings.
6. Remove the X-light barrier ’20’ (see figure 8.2 on page 8-2).
Installation 7. Install the new X-light barrier.

8. Install cable fixings.
9. Connect connector ST4 to X-motor PCB (see chapter 8.4 on page 8-5).

Maintenance
8.5.10 Replacement of Carrier Detect Light Barrier
Removal

4. Disconnect connector ST3 from X-motor PCB (see chapter 8.4 on page 8-5).
6. Remove the carrier detect light barrier ’18’ (see figure 8.2 on page 8-2).
Installation 7. Install the new carrier detect light barrier.

9. Connect connector ST3 to X-motor PCB (see chapter 8.4 on page 8-5).
8.5.11 Replacement of Z-light barrier (Init Position)
Removal

4. Disconnect connector ST4 from Z-motor PCB (see chapter 8.4 on page 8-5).
6. Remove the Z-light barrier ’23’ (see figure 8.2 on page 8-2).
Installation 7. Install the new Z-light barrier.

9. Connect connector ST4 to Z-motor PCB (see chapter 8.4 on page 8-5).

8.6.1 Alignment of Plate Transport

4. Open the screws 'A'.
Figure 8-18: Plate transport rollers screws
5. Align the plate transport.
The plate transport must be vertical! The distance between plate transport
and housing must be wide enough!

Figure 8-19: Distance between plate transport and housing
6. Tighten the screws 'A'.

7. Open the screws 'B'.
Figure 8-20: Plate transport – top view (chart)
8. Align the X-drive.
The X-drive must be horizontal!

Figure 8-21: X-drive alignment
9. Tighten the screws 'B'.
8.6.2 Use of the Shaft X-Drive Alignment Tool
In field do not disassemble the complete plate transport!
1. Insert parts.
2. Place X-transport belt ’12’ around the rollers.
3. Fix the parts with screws.
Don’t tighten the screws!
Figure 8-22: Opened X-drive
4. Insert the "Shaft X-Drive Alignment Tool" ’A’ as shown in the following figure.
The shafts must fit into the tool to guarantee the correct position.

Figure 8-23: Use of the "Shaft X-Drive Alignment Tool"
5. Tighten the screws and protect with Loctide.
8.6.3 Use of the X-Gantry Alignment Plate
In field do not disassemble the complete plate transport!
1. Insert the plate carrier moving sheet ’19’.
Figure 8-24: Plate carrier moving sheet
2. Fix screws ’B’ and Loctide 222.

3. Insert 4 pins of the "X-Gantry Alignment Plate" ’C’ in the slots of the metal
carrier and tighten the screws of the plate carrier guides ’D’.

Figure 8-25: X-Gantry Alignment Plate: alignment of the plate carrier guides
4. Insert 2 pins of the "X-Gantry Alignment Plate" ’C’ in the slots of the plate car-
rier moving sheet and move it into the correct position.
Figure 8-26: X-Gantry Alignment Plate: alignment of the plate carrier moving
sheet
5. Tighten the screws ’B’.

Teaching
8.7 Teaching
Before leaving the manufacturer the pipettor and the plate transport of the system are
adjusted exactly. Nevertheless, it is recommended to check the settings before start-
ing the system for the first time. This procedure has to be repeated when parts for
maintenance reasons have been changed.
8.7.1 Start Teaching
See service software for general instructions (see chapter 8.8 on page 8-27).
Password Protec- A window will come up to enter the password to have access to the service software.
tion 2. For editing, the 'High Level Password' must be entered. For checking, the
'Low Level Password' can be used.
3. Before you start to teach in different positions from the plate transport, the fol-
lowing modules must be initialised:
• Reader
• Washer
• Incubator
Reader 4. Load the reader module and press on the S e l f t e s t button.

The reader is checked and initialised and has to came back with the message
S e l f t e s t O K in the status line.
Washer 5. Load the washer module and press on the S e l f t e s t button.

The washer is checked and initialised and has to came back with the mes-
sage S e l f t e s t O K in the status line.
Incubator 6. Load the incubator module and press on the S e l f t e s t button.

The incubator is checked and initialised and has to came back with the mes-
sage S e l f t e s t O K in the status line.
7. Enable the O v e r r i d e box for incubator 1 to 4 in the S h a k e c o n t r o l
field.
8. Press on the S e t P a r a m e t e r s button.
The magnets in all incubator chambers are switched on to have a defined
condition for load/unload position for the plate carriers.
8.7.2 Continue Teaching the Plate Transport
1. Load the plate transport module.

2. Press on the S e l f t e s t button.
The plate transport is checked and initialised and has to come back with the
message S e l f t e s t O K in the status line. Also the plate transport move to
the home position.

Teaching
There are 20 positions stored within the module. Each position must be
taught.
3. Press on the E d i t P o s i t i o n button.

The adjust positions window gives access to all positions to teach in.
4. Place a plate carrier on to the plate transport.
Washer Positions 5. Select in the P o s i t i o n area W a s h e r .

The current stored coordinates are displayed in the X Y Z fields.
6. Press on the M o v e T o . . . button.
The plate transport is moving to the current X- and Y-positions.
7. Press on the D e - e n e r g i s e X Y Z button.
The X-, Y- and Z-motors are switched off.
8. Move the plate transport by hand to the correct Y-position.
9. Use a screwdriver and move the plate transport by turning the lead screw to
the correct Z-position.
10. Move the plate carrier per hand into the module to get the correct X-position.
11. Press on the G e t X Y Z P o s i t i o n button.
In the window below the transfer button the actual positions of XYZ are dis-
played.
X-axis Use the T r a n s f e r button to update the position.

Y-axis Use the T r a n s f e r button to update the position.
Z-axis pick-up Use the T r a n s f e r button to update the position.
Z-axis open Value(open) = Value(pick-up) + 6 mm
Z-axis closed Value(closed) = Value(pick-up)
Door mechanism Door fitted disabled / 0 mm
12. Press on the U p d a t e P o s i t i o n button to store the new coordinates into

the database
13. With the P u t and G e t buttons to check again if the positions are correct
and the plate carrier moves into the module smoothly.
14. Also, check if the plate carrier moves in completely to the end position.
Reader Positions 15. Repeat washer position steps for the reader positions.
Incubator Posi- Before starting the teaching procedure for the incubator the magnets for the shake
tions mechanism have to be switched on as described in chapter 8.7.1 on page 8-23.
16. Repeat washer position steps for incubator 1 to 4, accept:
X-axis Use the T r a n s f e r button to update the position.

Y-axis Use the T r a n s f e r button to update the position.
Z-axis pick-up Use the T r a n s f e r button to update the position.
Z-axis open Value(open) = Value(pick-up) + 6 mm
Z-axis closed Value(closed) = 18 mm
Door mechanism Door fitted disabled / 16 mm

Teaching
Pipette Positions 17. Repeat washer position steps for pipette position 1 to 4.
Stacker Positions 18. Repeat washer position steps for stacker position 1 to 4.
Bar Code Start 19. Enter the bar code start positions manually:
Positions
X-axis 3
Y-axis 150
Z-axis (all) Visual check: The laser beam must be in the centre
of the bar code (e. g. value 92.5).
20. Press on the U p d a t e Position button.
Bar Code End Po- 21. Enter the bar code end positions manually:
sitions
X-axis 3
Y-axis 10
Z-axis (all) Visual check: The laser beam must be in the centre
of the bar code (e. g. value 92.5).
22. Press on the U p d a t e Position button.
8.7.3 Save Plate Transport Coordinates
If all positions are taught, the coordinates must be stored on a disk for backup (disk
is included in the instrument).
Do not overwrite the file with the "manufacturer values".
1. To store coordinates press on the S a v e button.

The S a v e dialogue will come up to enter a file name.
2. Select the file name.
It is recommended to add the date to the default name 'PlateTx' to prevent
overwritting of existing files.
3. Press on the S a v e button.
8.7.4 Load Plate Transport Coordinates
The coordinates will be loaded into the P o s i t i o n I n f o r m a t i o n area of the

service software. The old coordinates will be lost!
1. Press on the L o a d button to load plate transport teaching parameters.

2. Press on the Y e s button to confirm the warning message.
3. Select the file name in the L o a d dialogue.
4. Press on the L o a d button.
The parameters will be transferred into the P o s i t i o n I n f o r m a t i o n area of
the service software.

Teaching
8.7.5 Store Plate Transport Coordinates
The coordinates, shown in the P o s i t i o n I n f o r m a t i o n area, will be stored

into the EEPROM of the plate transport.
1. Press on the S e t P o s i t i o n s button.

2. Press on the Y e s button to confirm the warning message.
The coordinates will be stored into the EEPROM of the plate transport.

Service Software
When the Plate transport is invoked, the application attempts to communicate to the
system and plate transport module. When successful, the following dialogue will be
displayed with the firmware version number, and serial number displayed. Defaults
such as instrument offsets will be read from the module EEPROM and shown. If no
module is detected,??? will be shown.
Figure 8-27: Plate transport service software main window
8.8.1 Functions of the Plate Transport Service Software
8.8.1.1 Instrument

number.
plate transport. It will only accept up to 10 alphanu-
meric characters. Warning displayed when request to
update.

Service Software
8.8.1.2 Plate Carrier Sensors
X Axis Displays status of the plate in sensor on the X-axis of

the plate transport. No displayed if empty. Yes if plate
carrier detected.
#1 - #4 Displays status of the plate in sensor of the ambient
stacker chambers 1 to 4. No displayed if empty. Yes
if plate carrier detected.
Get status Updates the plate carrier sensors.
Table 8-4: Fields and buttons of the P l a t e C a r r i e r S e n s o r s area
8.8.1.3 Position Information

There are several positions stored within the module. Each position must be taught.
Double clicking the display will automatically show the edit position dialogue box (see
Load... Reads positions stored in a global parameter file.

Save... Writes positions to a global parameter file.
Edit Positions (see chapter 8.8.2 on page 8-31)
Set Positions The coordinates will be stored into the EEPROM of
the plate transport (see chapter 8.7.5 on page 8-26).
Table 8-5: Fields and buttons of the P o s i t i o n I n f o r m a t i o n area
8.8.1.4 X-Motor, Y-Motor and Z-Motor

Same for all drives. Each axis can be individually controlled.
Home Moves to drive's home position.

Move to Moves to the position in the edit box. Position set in
tenths of mm, i.e. 10 will move the drive 1.0 mm
away from home.
Energise Leaves coils of motor energised, therefore locking
the motor.
De-energise Leaves coils of motor de-energised, therefore
unlocking the motor.
Table 8-6: Fields and buttons of the X - M o t o r , Y - M o t o r , a n d Z -

M o t o r areas

Service Software
8.8.1.5 Door
Door Override The access door for the plates has a sensor to detect
its open or closed state. Normally if the door is
detected to be open, no movement of the plate trans-
port will occur. However for service it is possible to
override this safety feature. To disable, check the
door override.
Set Override Sends door override when check box enabled.
Get Status Returns status of door override.
Table 8-7: Fields and buttons of the D o o r area

Get... Using the position displayed in the drop down list
box, pressing this button will get a plate carrier using
the current coordinates.
Put... Using the position displayed in the drop down list
box, pressing this button will put a plate carrier using
the current coordinates.
Move To... Using the position displayed in the drop down list
box, pressing this button will move to that position
using the current coordinates.
This area contains the buttons that control sequences of commands.

XZ Test... (see chapter 8.8.6 on page 8-36)
Upgrade (see chapter 8.9.1 on page 8-37)
Firmware...
8.8.1.8 Cycle
The user is not prompted to load a plate carrier.

Service Software
It is unwise to run X- and P-cycles together.
X , Y , Z , and P Each axis, X, Y, Z and P can be enabled for continu-

ous cycling. P is for a position cycle.
Go Continuously cycles enable axis.
Table 8-10: Fields and buttons of the C y c l e area
8.8.1.9 LEDs
Washer Provides a white LED to illuminate the wash area. To

turn on the check box must be enabled.
Spare Not used.
Set LEDs Drives LED outputs according to the status of the
check boxes.
Table 8-11: Fields and buttons of the L E D s area
8.8.1.10 General

play devices reply.

Service Software
8.8.2 Adjust Positions
Allows the user to edit and test every position. Pressing the E d i t P o s i t i o n button
invokes the adjust positions dialogue.
Figure 8-28: Adjust positions dialogue
8.8.2.1 Position
Update Position Transfers the data in the X, Y, Z, and door mecha-

nism edit boxes to the data table and stores them in
the EEPROM.
Put... Puts plate carrier into position displayed in drop
down list box using the current values in the data
table.
Get... Gets plate carrier from position displayed in drop
down list box.
Move To... Moves to position displayed in drop down list box.
Cycle... Repeats the put and get function again and again.
The cycle function can be stopped manually.
Table 8-13: Fields and buttons of the P o s i t i o n area

Service Software
8.8.2.2 X-Axis and Y-Axis

The first field displays the current coordinate for the position. New coordinates can
be written into this field.
T r ans f er Transfer button will update the window above the

button with the contents of the gray background win-
dow.
Out Moves out by the value in the spin box. The value is
the number of steps moved relative from the current
position. The new position is shown in the gray box.
In Moves in by the value in the spin box. The value is
De-energise De-energises or unlocks the motor. Allows the mech-
anism to be moved by hand.
Home Moves to the drive's home position.
Table 8-14: Fields and buttons of the X - A x i s a n d Y - A x i s areas

Service Software
8.8.2.3 Z-Axis
Operates the same as X and Y, but there are 3 heights.
Open The O p e n height is the height required to open a

door if present. It is the height that allows the X axis
to enter a module with its prongs below the carrier.
The heights are in millimetres, with zero at the top.
Increasing numbers moves the Z-drive lower.
Pick-up P i c k - u p is the height used to pull in or out a plate
on the prongs. It is a smaller number than the O p e n
height. Typically, the Z open is exactly 6 mm greater
than the Z pick-up.
Closed C l o s e d is the height the drive approaches a door or
module. It should be just above (approx. 2 mm) the
door stops. The size value is used to make a square
obstacle that the drive will avoid (the value added to
the left and right and 2x the value in the Z below the
C l o s e d coordinate).
Transfer Transfer button will update the widow above the but-
ton with the contents of the gray background window.
Up Moves up by the value in the spin box. The value is
Down Moves down by the value in the spin box. The value
is the number of steps moved relative from the cur-
rent position. The new position is shown in the gray
box.
De-energise De-energises or unlocks the drive. Allows the Z-axis
to be moved manually. A screwdriver can be used to
turn the lead screw.
Home Moves to the drive's home position.
Table 8-15: Fields and buttons of the Z - A x i s area
8.8.2.4 Door Mechanism
Door fitted Door fitted flag indicates the presence of a door.
Table 8-16: Fields and buttons of the D o o r M e c h a n i s m area
The edit box allows for a size parameter to be entered that is used to calculate an
obstacle that the drive avoids. This allows the drive not to crash into the door stops.
The value represents a square shape in millimetres. The size value is used to make
a square obstacle that the drive will avoid (the value added to the left and right and
2x the value in the Z below the C l o s e d coordinate).

Service Software
8.8.2.5 Motors
Get XYZ Position Reports the current encoder values in the gray
boxes.
Home XYZ Drives home all axises.
De-energise XYZ De-energises all the drives.
Table 8-17: Fields and buttons of the M o t o r s area
Overrides On Incubator shaking solenoids will be deactivated.

Overrides Off Incubator shaking will stop and solenoids will be acti-
vated to allow load/unload of plates by plate trans-
port mechanism.
Lock Draw Locks the drawer.
Unlock Draw Unlocks the drawer.
8.8.2.7 General
Close Closes window and returns to main plate transport

window.
8.8.3 Self Test
When S e l f t e s t button clicked, self test command is processed. Performs the fol-
lowing tests in sequence:
• Move Y-axis home
• Move Z-axis home.
• Plate carrier detection

Service Software
8.8.4 Test Procedure for Module Tests
Runs the sequence of tests that verify correct operation of the plate transport mod-
ule. When the M o d u l e t e s t . . . button is pressed, the following sequence is per-
formed. The user must update the user field. This data is stored in the results file.
logue box, as well as the test software version.
3. Serial number
4. Parameters
5. Plate in sensor
Verifies the plate in sensor. Pass, if set and clear states detected.
6. Door
Verifies door sensor. Pass, if open and closed states detected.
7. LED
Allows user to verify LED drive. Pass, if the user confirms the washer LED
went on and off.
8. Stacker position
Verifies stacker plate in sensors. Pass, if set and clear states detected.
9. X-motor
Pass, if 5 cycles completed without error.
10. Y-motor
11. Z-motor
12. Shake
Shakes plate carrier drive. Pass, if shake completed without error.
13. Selftest
Performs Selftest. Pass, if selftest completes without error.
14. Position test
Cycles the mechanism to all the positions. Positions are: Load/Unload,
Washer, Reader, Incubator 1, Incubator 2, Incubator 3, Incubator 4, Pipette 1,
Pipette 2, Pipette 3, Pipette 4, Stacker 1, Stacker 2, Stacker 3, Stacker 4, Bar-
code Start, Barcode End.
Pass if 5 cycles completed without error.
Runs the sequence of tests that verify correct board operation. When the Bo a r d
Test. . . button is pressed, the following sequence is performed. The user must up-
date the user field. This data is stored in the results file.

Service Software
3. Serial number
4. Parameters
5. Plate in sensor
6. Door
Verifies door sensor. Pass, if open and closed states detected.
7. LED
Allows user to verify LED drive. Pass, if the user confirms the washer LED
went on and off.
8. Stacker position
Verifies stacker plate in sensors. Pass, if set and clear states detected.
9. X-motor
10. Y-motor
11. Z-motor
12. Shake
13. Selftest
8.8.6 XZ-Test
Runs the sequence of tests that verify correct operation of the X and Z drives of the
plate transport module. When the X Z T e s t . . . button is pressed, the following se-
quence is performed. The user must update the user field, this data is stored in the
results file.
3. Serial number
4. Parameters
5. Plate in sensor
6. X-motor
7. Z-motor
8. Shake

Firmware Upgrade
Invokes the Firmware Upgrade dialogue box. It is assumed the new firmware file
*.h86 resides within the reader sub-directory, as described within the INI file.
If Direct connection has been selected, you must place the module in bootstrap
mode, the following message will prompt you to do so.
gle Pin 2. This puts the device into bootstrap mode. If the module power is off, turn
ON Pin 1, and turn ON the module.
change, Ca n c e l , cycle the power, and repeat the process.
Once the download is complete, you must turn OFF Pin 1. Otherwise, the de-
vice remains in bootstrap mode and will not operate.

3. Click on the Pl a t e T r a n s p o r t tab.
The file (PLATETX.H86) used to update the firmware must be stored in the

Firmware Upgrade

Evolis Plate Bar Code Scanner
Safety and Hints
9 Plate Bar Code Scanner

Do not touch the lenses in front of the scanner!
Figure 9-1: Plate bar code scanner
1 Plate bar code scanner

Plate Bar Code Scanner Evolis
Maintenance
2 Wash station (bottom view)

A Fixing screws
9.3 Maintenance
9.3.1 Replacement of Plate Bar Code Scanner
Do not touch the lenses in front of the scanner!
Removal

3. Open the tip ramp cover door.
4. Open stainless steel cover ’1’ (see chapter 11.2 on page 11-2).
5. Remove the rack system (see chapter 14.4.1 on page 14-4).
6. Disconnect SRP100 (ST14) at COP PCB (see chapter 15.2 on page 15-1).
7. Remove the screws 'A' (see figure 9-1: on page 9-1).
8. Remove the plate bar code scanner '1'.
Installation 9. Install the plate bar code scanner '1'.

10. Tighten the screws 'A'.
11. Connect SRP100 (ST14) at COP PCB.
12. Install the rack system link.
13. Close COP stainless steel cover link.
14. Close the tip ramp cover.
No mechanical adjustment is required!

Evolis Incubator
Safety and Hints
10 Incubator

Care must be taken when operating and testing this module as heaters
can be at elevated temperatures and may cause injury if touched by us-
er!
set!
For all actions it's necessary to remove the incubator out of the instrument,
otherwise noted.
If you have done service actions on the incubator, it's necessary to do new
calibration (see chapter 10.6 on page 10-17)!
Every time the incubator module or plate transport is disturbed, the calibra-
10.2 Overview
The incubator module has four chambers only heating and shaking incubator. The
temperatures and shake frequencies are software adjustable. The temperature
range is min. 21oC or ambient +5oC to max. 55oC. The frequency of shake is adjust-
able from 5 Hz to 20 Hz. The amplitude of shaking is fixed 0.5 mm +/- 0.1 mm and
will be adjusted by the service software.

Incubator Evolis
Figure 10-1: Mechanical architecture (chart)
1 Shake PCB
2 Position sensor PCB, sensor
3 Shake solenoid
4 Solenoid fixing plate
5 Anchor plate
6 Plate in light barrier
7 Plate shake sledge
8 Incubator foam flaps (front side)
9 Upper and lower heating plate with temperature sensor
10 Incubator box insulation
11 Door spring
12 Incubator fan with foam fixing
13 Stacker fan
14 Incubator main PCB
15 Solenoid fixing plate

Evolis Incubator
Incubator Posi- • Incubator position 1: Front side of the instrument

tions • Incubator position 4: Back side of the instrument
Incubator PCB
Figure 10-2: Incubator PCB connectors
Number: Connection:
ST1 Incubator box 4 (shake PCB)

ST2 Incubator and stacker fan
ST4 Power supply (+24V)
ST7 RS232
ST8 Ambient temperature sensor
SW1 DIP switch (normally OFF)

Incubator Evolis
Shake PCB
Figure 10-3: Shake PCB connectors
Number: Connection:
ST1 Lower heating foil

ST2 Lower temperature sensor
ST3 Incubator PCB
ST4 Upper heating foil
ST5 Upper temperature sensor
ST6 Shaking solenoid
ST7 Position sensor

Evolis Incubator
Maintenance
10.5 Maintenance
Every time the incubator module or plate transport is disturbed, the calibra-
10.5.1 Replacement of Incubator Module
Removal

4. Loosen screws 'A' and turn two times only.
Don’t remove the screws!
Figure 10-4: Plate transport cover fixing screws
5. Pull the plate transport cover '1' to the left and remove it.
Figure 10-5: Incubator fixing screws

Incubator Evolis
Maintenance
7. Loosen screws 'C' from bottom and turn two times only.
Don’t remove the screws!
8. Pull out the incubator carefully into the plate transport area.
9. Disconnect the RS232, the power supply, and the ambient temperature sen-
sor plugs from the PCB in the back of the instrument.
Installation 10. Connect the RS232, the power supply, and the ambient temperature sensor
plugs from the PCB in the back of the instrument.
11. Put the incubator carefully under the pipetting area.
12. Loose tighten screws 'B' and 'C'.
Figure 10-6: Alignment of incubator module
13. Align the incubator module.
The incubator module must be parallel to the plate transport housing, with a
tolerance of +/- 0.5 mm!
14. Tighten screws 'B' and 'C'.

15. Install the plate transport cover '1'.
16. Close the drawer.
17. Teach the plate transport positions for the incubator (see chapter 8.7 on page 8-
23).

Evolis Incubator
Maintenance
10.5.2 Replacement of Incubator PCB
There are no serviceable parts on the circuit board. If it is faulty then replace
it.
Removal 1. Remove the incubator module (see chapter 10.5.1 on page 10-5).
2. Disconnect all connectors.
3. Remove the four PCB retaining screws.
4. Remove the incubator PCB.
Installation 5. Install the incubator PCB.

6. Tighten the four PCB retaining screws.
7. Connect all connectors.
8. Install the incubator module.
9. Calibrate the incubator module (see chapter 10.6 on page 10-17).
10.5.3 Open Incubator Housing
2. Remove the six screws at the bottom first.
3. Remove the bottom sheet metal '3' with stacker fan.
Figure 10-7: Open incubator housing
4. Remove the 14 screws ’D’ as shown.

5. Remove the front sheet metal '1'.
6. Remove the top sheet metal '2'.
Installation 7. Install the top sheet metal '2'.

8. Install the front sheet metal '1'.
9. Tighten the 14 screws ’D’ as shown.
10. Install the bottom sheet metal '3' with stacker fan.

Incubator Evolis
Maintenance
10.5.4 Replacement of Incubator Box
Removal There are four incubator boxes:

1. Open the incubator housing (see chapter 10.5.3 on page 10-7).
2. Disconnect upper heating foil of the selected incubator box.
3. Disconnect temperature sensor of the selected incubator box.
4. Remove the 4 nuts at the bottom.
5. Take the box at the metal and pull carefully (cable move through slits).
Installation 6. Take the box at the metal and push carefully (cable move through slits).
7. Install the 4 nuts at the bottom.
8. Connect temperature sensor of the selected incubator box.
9. Connect upper heating foil of the selected incubator box.
10. Close the incubator housing.
10.5.5 Replacement of Shake PCB
There are no serviceable parts on the circuit board. If it is faulty, replace it.
Removal There are four shake PCBs:

1. Remove the incubator box (see chapter 10.5.4 on page 10-8).
2. Remove two screws at the bottom.

Evolis Incubator
Maintenance
Figure 10-8: Incubator box bottom view
3. Remove two screws at the left and right side of the stainless steel box.
4. Remove two screws M4x5 from plate carrier sledge inside the incubator
chamber.
5. Pull at the solenoid fixing plate carefully and remove it (including anchor plate
and sensor PCB.
6. Remove three PCB screws.
7. Move the shake PCB sideways to heat foil cable and lift out.
Between metal case and PCB mounted on 3 mm spacer.

Incubator Evolis
Maintenance
Figure 10-9: Replacement of shake PCB
Installation 8. Install the new shake PCB.

Between metal case and PCB are mounted 3 mm spacer.
9. Tighten three PCB screws.
10. Push the solenoid fixing plate careful and install it inclusive anchor plate and
sensor PCB.
11. Tighten two screws M4x5 from plate carrier sledge inside the incubator cham-
ber.
12. Tighten two screws at the left and right side of the stainless steel box.
13. Tighten two screws at the bottom.
14. Install the incubator box.
10.5.6 Replacement of Sensor PCB
After all service actions on the position sensor, programming hall sensor and
calibrate the incubator are necessary!
In field do not change anything!
There are four shake PCBs:
Removal 1. Remove the incubator box (see chapter 10.5.4 on page 10-8).
2. Disconnect ST7 on shake PCB (see chapter 10.4 on page 10-3).
3. Remove screw at sensor PCB.

Evolis Incubator
Maintenance
Figure 10-10: Sensor PCB at the solenoid fixing plate
4. Lift sensor PCB out of centre bore.
Figure 10-11: Sensor PCB
5. Remove Sensor PCB.
Installation 6. Install the new sensor PCB.

Incubator Evolis
Maintenance
Figure 10-12: Sensor PCB and position magnet
7. Tighten the screw at sensor PCB.

8. Connect ST7 on shake PCB.
A software calibration is necessary after reassembling the incubator. Use the

service software to start the calibration.
10.5.7 Replacement of Shaking Solenoid
2. Disconnect shaking solenoid at shake PCB (see chapter 10.4 on page 10-3).
3. Loosen screw inside the solenoid fixing plate in top of the solenoid.
Figure 10-13: Part top view to shaking solenoid
4. Pull out the solenoid to the back.

5. Carry the cable through the drilling at the bottom of the fixing plate.

Evolis Incubator
Maintenance
Installation 6. Set the silicon washer onto the position magnet at the anchor plate (see
figure 10-12: on page 10-12).
7. Carry the cable through the drilling at the bottom of the fixing plate.
8. Push the solenoid into the fixing plate.
9. The distance between solenoid and anchor plate is set to 2.0 mm +/- 0.1.
10. Tighten screw inside the solenoid fixing plate in top of the solenoid.
11. Connect shaking solenoid at shake PCB.
A software calibration is necessary after reassembling the incubator. Use the

service software to start the calibration.
10.5.8 Replacement of upper Heater
2. Disconnect cables of the upper heater and the temperature sensor ST4 and
ST5 at shake PCB (see chapter 10.4 on page 10-3)
3. Lift the upper insulation.
4. Lift up the upper heater 2-3 mm from insulation.
5. Press down and pull out all four rivets.
Figure 10-14: Upper heater (view twisted)
6. Remove the heater.
Installation 7. Install the heater.

8. Install the four rivets.
9. Connect cables of the upper heater and the temperature sensor ST4 and ST5
at shake PCB.
10. Use foam rubber to insulate the grommet.

Incubator Evolis
Maintenance
10.5.9 Replacement of lower Heater
Removal 1. Remove the shake PCB (see chapter 10.5.5 on page 10-8).
2. Disconnect cables of the lower heater and the temperature sensor ST1 and
ST2 at shake PCB (see chapter 10.4 on page 10-3)
3. Remove screws sideways of the metal housing.
Figure 10-15: Opened incubator box with lower heater
1 Locking ring
2 Washer metal
3 Washer plastic
4 Bushing
5 Standoff
6 Stainless steel housing
7 Screw M3x4 mm
8 Standoff
4. Lift out plate carrier sledge.

5. Lift up 2-3 mm the heating plate from insulation.
6. Press down and pull out all four rivets.
7. Remove the heater.
Installation 8. Install the heater.

9. Install the four rivets.
10. Install the plate carrier sledge.
11. Tighten the screws side wards of the metal housing.
12. Connect cables of the lower heater and the temperature sensor ST1 and ST2
at shake PCB.
13. Use foam rubber to insulate the grommet.
14. Install the shake PCB.
In front of the lower box insulation must be inserted iron blocks.

Evolis Incubator
Maintenance
10.5.10 Replacement of Foam Flap or Flap Spring
2. Remove the ten incubator front screws (see figure 10.5.3 on page 10-7).
3. Remove the foam flap and/or the flap spring.
Figure 10-16: Incubator without front sheet
1 Locking ring
2 Washer metal
3 Washer plastic
4 Standoff
5 Stainless steel housing
Installation 4. Install the foam flap and/or the flap spring.

5. Tighten the ten incubator front screws.
10.5.11 Replacement of Incubator and Stacker Fan
2. The incubator fan is only fixed inside the foam body at the right side of the
incubator.
Pull incubator fan out.
3. Disconnect connector ST2 at the incubator PCB (see chapter 10.4 on page 10-3).
4. Remove the six screws at the bottom (see figure 10-7: on page 10-7).
5. Remove the bottom sheet metal with stacker fan.
6. Remove the four retaining screws of the stacker fan.
7. Remove both fans.
Installation 8. Install the stacker fan.

Incubator Evolis
Maintenance
Figure 10-17: Incubator and stacker fan
9. Tighten the four retaining screws of the stacker fan.

10. Install the bottom sheet metal with stacker fan.
11. Tighten the six screws at the bottom.
12. Connect connector ST2 at the incubator PCB.
13. Install incubator fan out.

Evolis Incubator
10.6.1 Calibration of the Shake Function
See see chapter 10.7 on page 10-19 for general instructions.
1. Power on the system.

3. Open the module incubator.
4. Press on the S e l f t e s t button in the H i g h L e v e l C o m m a n d s area and
wait until the initialisation routine is finished.
5. Press on the G e t S t a t u s button in the S h a k e c o n t r o l area.
6. Press on the C a l i b r a t i o n S h a k e button in the H i g h L e v e l C o m -
m a n d s area.
7. Load incubator 1 with a full micro plate (250 µl water each well).
8. Press on the O K button to calibrate incubator 1 for 20 Hz.
9. Press on the U p d a t e button several times.
The current position will be changed.
Figure 10-18: Shake amplitude calibration dialogue
10. View the average value of the C u r r e n t P o s i t i o n values.

11. Compare average value with I d e a l P o s i t i o n values. The average value
must be:
Ideal Position >= current position <= Ideal Position + 2%
Example: Ideal Position 121%: Current Position 121 - 123%
12. If the average value isn't correct, then change the value in the A m p l i t u d e
C a l i b r a t i o n % field and press on the S e t C a l i b r a t i o n button.
13. Repeat steps 9 to 12 until the average value is correct.
14. Control visual the shake function in the incubator 1 (approx. 1 mm +/-
0.15 mm).

Incubator Evolis
15. If the average value is correct, press the O K button.

16. The same dialogue box will appear.
Repeat steps 9 to 15 to calibrate the incubator 1 for 5 Hz.
17. The micro plate loading dialogue box will appear.
Repeat steps 7 to 16 to calibrate all other incubators.

Evolis Incubator
Service Software
When the incubator is invoked, the application attempts to communicate to the sys-
tem and incubator module. When successful, the following dialogue will be displayed
with the firmware version number, and serial number. Defaults such as instrument
offsets will be read from the module EEPROM and shown. If no module is detect-
ed,??? will be shown for the firmware version number.
Figure 10-19: Incubator service software main window

Incubator Evolis
Service Software
10.7.1 Functions of the Incubator Service Software
10.7.1.1 Instrument
No. of Incubators Allows to enter the numbers of incubators (incubator

positions). Value from 1 - 4.
Set No. of Incuba- Used to pass parameter in N o . o f i n c u b a t o r edit
tors box.
number.
incubator. It will only accept up to 10 alphanumeric
update.
10.7.1.2 Temperature Control

Allows the user to set and control the heaters.
Column: Meaning:
Set point Set point edit boxes for Incubator 1 to Incubator 4 are used to
input set point temperatures. These will only accept integers
between 21 and 55.
Enable Enable check box to enable heaters. When the S e t P a r a m e -
t e r s button is pressed, all set points and enables are sent to the
module.
Lower Displays lower heater temperature. Only updated when Get
temp T e m p e r a t u r e s button is pressed.
Upper Displays upper heater temperature. Only updated when Get
temp T e m p e r a t u r e s button is pressed.
Status Displays 0 if heaters connected, 1 if an error is detected. Only
updated when the G e t S t a t u s button is pressed.
Ambient Displays temperature of ambient sensor. Only update when Get
Temperature pressed. If the sensor is unplugged 0 is displayed.
Table 10-2: Temperature control

Evolis Incubator
Service Software
Set Temperatures Sends all enabled temperature values (field S e t -

P o i n t s and checkbox E n a b l e) to the incubator.
Get Temperatures Retrieves current temperatures.
Get Status Retrieves current status.
O f f se t s. . . (see chapter 10.7.4 on page 10-26)
Get actual temper- Retrieves current temperatures automatically.
atures
Table 10-3: Fields and buttons of the T e m p e r a t u r e C o n t r o l area
• Set Parameters
Sends set points and enable settings to the module.
10.7.1.3 Shake Control

Allows user to verify shake mechanism.
Column: Meaning:
Frequency Frequency edit boxes for Incubator 1 to Incubator 4 are used to

input the chamber shake frequencies; these will only accept inte-
gers between 5 and 22.
Enable Enable check box must be set to shake. These settings are only
updated when the S e t P a r a m e t e r s button is pressed.
Ov err i de Override check box, if set, shaking will stop and solenoids will be
activated to allow load/unload of plates by plate transport mecha-
nism. These are only updated when the S e t P a r a m e t e r s
button is pressed.
Calibra- (see chapter 10.7.2 on page 10-24)
tion Min
Calibra- (see chapter 10.7.2 on page 10-24)
tion Max
Status Displays the shake status for the incubator. A 0 indicates that the
shake is good; a 1 indicates the shake is outside acceptable toler-
ances. The status is updated when the G e t S t a t u s button is
pressed. Once the status has been read the incubator automati-
cally clears the value and sets it to read good (0). The status that
is reported by the firmware is updated every 5 seconds. This
allows for the mechanism to start shaking before an invalid status
is flagged. Whenever new incubator shake parameters are sent
(using the S e t P a r a m e t e r s button), the status is also reset
to good (0) by the incubator firmware.
Table 10-4: Shake control

Incubator Evolis
Service Software
Set Parameters Sends frequency, enable, and override settings to

the module.
Set Calibrations (see chapter 10.7.2 on page 10-24)
Get Status Updates the S t a t u s fields and the S h a k e S t a -
t u s D e t a i l s dialogue values.
... (see chapter 10.7.3 on page 10-24)
Table 10-5: Fields and buttons of the S h a k e C o n t r o l area
For firmware version 2.10 and above the hardware generates a frequency
signal that can be measured by the microprocessor to determine the position
or the shaking mechanism. Details of these additional parameters can be ob-
tained using the '...' buttons alongside the status results; a dialogue box will
be displayed.
10.7.1.4 Plate Carrier Sensors
Inc 1 - Inc 2 Displays status for each chamber of the plate in sta-
tus. N o displayed if empty, Y e s if plate carrier
detected.
Get Status Updates the plate in sensor status.

Evolis Incubator
Service Software

Calibrate Shake... (see chapter 10.6.1 on page 10-17)
Log Shake... Starts the shaking process and logs the results in a
file.
Accuracy Test... Allows the user to verify the accuracy of each incuba-
tor chamber. Turns ON the heaters and waits up to
12 minutes for all temperatures to reach a 37.0oC set
point. A dialogue box with D e v i c e B u s y - T e s t -
i n g T e m p e r a t u r e A c c u r a c y is displayed while
heating. When the set point is reached, a dialogue
box is shown requesting the user to enter an inde-
pendent temperature measurement. The test passes
if temperature entered is within 0.8oC of set point.
(36.2oC <=T<=37.8oC).
A suitable calibrated temperature measurement
device must be used to obtain the independent tem-
perature measurement. The temperature device may
need to be left within the incubation chamber for a
period of time to reach the appropriate temperature.
L o a d P a r a m e t e r s . . . Displays a warning message before the user can
select a file containing module parameters.
Save Parameters Saves module parameters to a file.
Firmware...
10.7.1.6 General

play devices reply.

Incubator Evolis
Service Software
10.7.2 Calibrations
The calibration values are used to adjust the shake amplitude at various shake fre-
quencies.
The 'Min' calibration value is used to adjust the shake amplitude at low frequencies.
This is set for the 5 Hz shake. The 'Max' calibration value (only for firmware 2.10 and
above) is used to adjust the shake amplitude at high frequencies. This is set during
for 20 Hz shake (firmware version 2.10 or above) or 22 Hz shake for previous ver-
sions.
The values can be manually adjusted and updated using the S e t C a l i b r a t i o n
button. Note that these parameters are stored in the EEPROM of the module.Use the
C a l i b r a t e S h a k e button to set these calibration values.
10.7.3 Shake Status Details
Figure 10-20: Shake status details

Evolis Incubator
Service Software
Calibrated 0 if the shake self-test calibration has not been performed, 1 if

it has.
Self-test This is the shake calibration factor obtained during a self-test
Calibration calibration.
Override Off This is the position frequency obtained during a self-test cali-
Frequency bration when the shake override is off.
Override On This is the position frequency obtained during a self-test cali-
Frequency bration when the shake override is on.
Lower Shake This will display the lower shake test limit. If the measured
Limit position frequency is below this value, the status of the incuba-
tor will be marked as bad.
Upper Shake This will display the upper shake test limit. If the measured
Limit position frequency is above this value, the status of the incuba-
tor will be marked as bad.
Last Error This displays the last position frequency that was measured
Frequency that caused a bad status to be reported.
Current This is the measured position frequency.
Position
Shake Con- Shows all adjustment steps since the last calibration of the
trol shake mechanism. 15 steps are allowed.
OK Closes the dialogue.
Update This will update the current position frequency and last error
frequency (if the chamber status has gone bad since the previ-
ous status was read).
Table 10-9: Fields and buttons of the shake status details dialogue

Incubator Evolis
Service Software
10.7.4 Temperature Offsets
Figure 10-21: Temperature offsets dialogue
Column: Meaning:
Accuracy Offset to adjust individual incubator chambers.

Global General offset (e. g. value 2 and assay definition 35oC mean incu-
setpoint
bator temperature 37oC).
Upper Difference between upper and lower heating plate (e. g. value 8
plate means the temperature of the upper heating plate is 8oC higher
than the lower heating plate).
Enable Enables the temperature offset.
Table 10-10: Temperature offsets
10.7.4.1 General
OK Takes all parameters and closes window and returns

to main incubator window.
Cancel Drops all parameters, closes window and returns to
main incubator window.
10.7.5 Self Test
When the S e l f t e s t button is clicked, the incubator selftest command is processed.

It will performs the following tests in sequence:
• Tests the EEPROM checksum.
• Perform the shake self test.
This is for firmware 2.10 and above.
• Check the temperature sensors are reading within a valid range.
• heck the heater drives are not open circuit.

Evolis Incubator
Service Software
Runs the sequence of tests that verify correct operation of the incubator module.
When the M o d u l e t e s t . . . button is pressed, the following sequence is per-
formed. The user must update the user field. This data is stored in the results file.
3. Serial number
4. Parameters
5. Plate in sensor
6. Temperature sensors
Verifies temperature sensors.
7. Ambient sensor
Verifies ambient sensor. Passed, if temperature between 5.0oC and 35.0oC
inclusive.
8. Selftest
Performs self test. Pass, if self test completes without error.
9. Heaters
Verifies heater circuits.
10. Shake mechanisms
Verifies shake circuits.
Runs the sequence of tests that verify correct board operation. When the Bo a r d
t e s t . . . button is pressed, the following sequence is performed. The user must up-
date the user field. This data is stored in the results file.
3. Serial number
4. Parameters
5. Plate in sensor

Incubator Evolis
Service Software
6. Temperature sensors
Verifies temperature sensors.
7. Ambient sensor
Verifies ambient sensor. Passed, if temperature between 5.0oC and 35.0oC
inclusive.
8. Selftest
9. Heaters
Verifies heater circuits.
10. Shake mechanisms
Verifies shake circuits.

Evolis Incubator
Firmware Upgrade
Invokes the F i r m w a r e U p g r a d e dialogue box. It is assumed the new firmware

file *.h86 resides within the reader sub-directory, as described within the INI file.
If direct connection has been selected, you must place the module in bootstrap
mode. The following message will prompt you to do so.
gle Pin 2. This puts the device into bootstrap mode. If the module power is off, turn
ON Pin 1, and turn ON the module.
change, Ca n c e l , cycle the power, and repeat the process.

3. Click on the I n c u b a t o r tab.

Incubator Evolis
Firmware Upgrade
The file (INCUBATE.H86) used to update the firmware must be stored in the


Evolis Pipettor
Safety and Hints
11 Pipettor

The wash and waste position, and the waste tubing’s could have had di-
rect contact with dangerous material! Pay attention to safety regards!
Always wear gloves!
set!
Fill liquid into valve and syringe before starting operation, otherwise the seal-
ing surfaces will damage!
If you have done service actions on the pipettor, it's necessary to do new cal-
ibration (see chapter 11.9 on page 11-63)
The technical X- and Y-coordinates of the pipettor are exchanged with the
displayed messages! I. e., the displayed x-coordinate means the technical y-
coordinate and the displayed Y-coordinate means the technical X-coordinate.

Pipettor Evolis
Pipettor
Figure 11-1: Pipettor
1 Pipettor PCB and belt tension cover

2 Pump unit
3 Y-motor cover
4 Pipettor bridge
5 Disposable tip adapter
6 Switch instrument flap

Evolis Pipettor
Figure 11-2: Pipettor top view (chart)
4 Pipettor bridge
7 Y-init light barrier
8 System liquid sensor
9 CPC system liquid
10 Instrument cover switch
11 Y-belt tension spring
12 Pipettor PCB
13 Pipettor wash pump
14 Pipettor dispense pump
15 Wash pump PCB
16 Y-motor (DC)
17 High flex cable bridge
18 Y-belt
20 Z-motor
21 X-Z PCB

Pipettor Evolis
22 Belt bridge connection left

23 X-motor
24 X-cog rail
25 Belt bridge connection right
X-Sledge
Figure 11-3: X-sledge

20 Z-motor
21 X/Z PCB
23 X-motor
D X-cog wheel
E Z-cog rail break
F X-cog rail bearing
G Z-cog rail bearing

Evolis Pipettor
Disposable Tip
Adapter
Figure 11-4: Parts of the disposal tip adapter
A Liquid Level detection cable

B Fixing screw Z-rail
C Teflon tubing link
D Clamp screw pick up
E Z-init pin
F Tip dropping pin
G Tip discarding device
H Metal pick up

Pipettor Evolis
Fluid Architecture
11.3 Fluid Architecture
Figure 11-5: Pipettor tubing
5 Disposable tip adapter

9 CPC system liquid
A Stainless steel tube guide
T1 PVC tubing 1000 mm
T2 PVC tubing 150 mm
T3 Teflon tubing 1710 mm

Evolis Pipettor
Figure 11-6: Pipettor PCB
Meaning:
ST1 Power supply (+24V)

ST2 RS232
ST3 Modular pump (dispense pump)
ST4 Pipettor bridge
ST5 Y-init light barrier
ST6 Y-encoder
ST7 Y-motor
ST8 Diluter pump (wash pump)
ST9 Waste pump
ST10 Power out (not used)
ST11 Power out (not used)
ST12 Digital in/out Reserve 1
ST16 Monitor
Table 11-1: Connections of the pipettor PCB

Pipettor Evolis
Meaning:
F1 3.15L/250V
Table 11-2: Fuses of the pipettor PCB
Switch Meaning: Default:
1 D4 bootstrap OFF
2 Reset OFF
3 P5.14 OFF
4 P5.15 OFF
Table 11-3: DIP switches of the pipettor PCB
Meaning: Colour:
LED 1 Disposal Tip yellow

LED 2 LLD yellow
LED 3 Init red
LED 4 +5 V white
LED 5 +24 V white
Table 11-4: LEDs of the pipettor PCB

Evolis Pipettor
Maintenance
11.5 Maintenance
11.5.1 Replacement of Disposable Tip Adapter
Removal

3. Disconnect liquid level detection cable 'A'.
Figure 11-7: Y-sledge bottom view
4. Remove hexagon screw 'B' at disposable tip adapter '5'.

Pipettor Evolis
Maintenance
Figure 11-8: Disposable tip adapter
5. Hold the stainless steel Z-guide and pull down the tip adapter '5'.
6. Pull down the teflon tubing from adapter needle 'C'.
Installation 7. Insert the teflon tubing onto the adapter needle ’C’ of the new needle adapter.
8. Insert the needle adapter into the Z-axis rack.
The metal pin must be on the back.
9. Tighten the needle adapter with the upper hexagon screw 'B'.
10. Check that the lower hexagon screw 'D' is tighten.
11. Put the needle adapter sensor plug 'A' in the socket on the lower side of the
X-sledge.
12. Check the function of the disposable tip adapter (see chapter 11.8.1 on page 11-
62).
13. Check the reference position (see chapter 11.7.4 on page 11-48).
11.5.2 Replacement of Pipettor Tubing
Removal 1. Remove the disposable tip adapter (see chapter 11.5.1 on page 11-9).
2. Remove pump unit and tubing fitting at the dispense pump valve.
3. Pull the tubing back.
Installation
Use only original tubing!
4. Insert the new tubing, beginning at the dispense pump.

5. Insert the teflon tubing onto the tubing fitting.

Evolis Pipettor
Maintenance
Figure 11-9: Dispense pump valve fitting
6. Install the pump unit and tubing fitting at the dispense pump valve.
Figure 11-10: Pump unit back side
7. Install the disposable tip adapter (see chapter 11.5.1 on page 11-9).
8. Check sealing after replacement of the tubing.

Pipettor Evolis
Maintenance
11.5.3 Replacement of Wash Pump
Removal

3. Remove the cover with wash and dispense pump (see chapter 11.2 on page 11-2).
4. Disconnect the cable.
Figure 11-11: Wash pump (back side of pump unit '2')
5. Disconnect all tubing's
Pay attention to the system liquid in the tubing’s!
6. Remove the two retaining screws 'I'.

7. Remove the wash pump ’13’.
Installation 8. Install the new wash pump.

9. Tighten the two retaining screws 'I'.
10. Install the tubing’s.
Pay attention to the flow direction (see arrows on the pump!
11. Connect the cable.

12. Install the cover with wash and dispense pump

Evolis Pipettor
Maintenance
11.5.4 Replacement of Dispense Pump
Removal

3. Remove the cover with wash and dispense pump (see chapter 11.2 on page 11-2).
4. Disconnect connector ’G’.
Figure 11-12: Pump unit '2' (back view)

A Piston fixing screw
B Syringe drive
C Cylinder fixing screw
D Two way valve
E Sensor plug (not used)
F DIP switch
G Main connector (15 pin Sub D)
H Address switch
I Fixing screws 2pcs.
J Fixing screws 8pcs.

Pipettor Evolis
Maintenance
5. Disconnect all tubing's.
Pay attention to the system liquid in the tubing’s!
6. Remove the four retaining screws 'J' at the back side.

7. Remove the four retaining screws 'J' at the front side.
Figure 11-13: Dispense pump (pump unit '2')
8. Remove the wash pump ’14’.

9. Remove the syringe (see chapter 11.5.5 on page 11-15).
10. Remove the two way valve (see chapter 11.5.6 on page 11-16).
Installation 11. Set the arrowhead of the address switch ’H’ to address 0.
12. Set the DIP switches ’F’:
• 1 to 5: OFF
• 6: not used
• 7 and 8: ON
13. Install the two way valve (see chapter 11.5.6 on page 11-16) on the new dispense
pump.
14. Install the syringe (see chapter 11.5.5 on page 11-15) on the new dispense pump.
15. Install the new dispense pump.
16. Tighten the four retaining screws 'J' at the front side.
17. Tighten the four retaining screws 'J' at the back side.

Evolis Pipettor
Maintenance
Fill liquid into valve and syringe before start operation otherwise the sealing
surfaces will damage!
18. Connect all tubing's.

19. Connect connector ’G’
20. Install the cover with wash and dispense pump.
11.5.5 Replacement of Syringe
Removal

3. Open syringe fixing screw 'A'.
Figure 11-14: Syringe (pump unit '2')
4. Pull down pump drive 'B'.

5. Turn out the syringe nut at 'C'.
Installation
Fill liquid into syringe before start operation otherwise the sealing surfaces
will damage!
6. Fill liquid into the syringe.

7. Set the cylinder to 'C' tighten nut.
8. Push pump drive 'B' to piston rod.
9. Tighten fixing screw 'A'.

Pipettor Evolis
Maintenance
11.5.6 Replacement of three way Valve
Preparation To prevent deformation of valve body and valve inlet during storage, the inlet is not
completely pressed into the valve body. The inlet has to be pressed into the valve
before attaching to the dispense pump. Finally check, if the valve insert hole is posi-
tioned in the centre of the valve body hole.
Figure 11-15: Delivered condition (left) and assembled condition (right)
Removal 1. Remove the dispense pump (see chapter 11.5.4 on page 11-13).
2. Screw out both tubing fittings 'E'.
Pay attention to the system liquid in the tubings!
3. Remove the syringe (see chapter 11.5.5 on page 11-15).

4. Remove the three screws 'A' in front of the valve.
Figure 11-16: Two way valve (Pump unit '2')
5. Pull down the valve.
Installation 6. Turn valve inlet 'B' to position as shown.

7. Set valve motor 'C' to position as shown.

Evolis Pipettor
Maintenance
8. Set valve into coupling.

9. Drive in the three screws 'A'.
10. Insert the valve alignment tool (see chapter 11.7.1 on page 11-44) into the valve.
Figure 11-17: Use of the valve alignment tool
11. Tighten the syringe fixing screw.

12. Tighten the three screws 'A'.
13. Remove the valve alignment tool.
14. Install the syringe (see chapter 11.5.5 on page 11-15).
Fill liquid into valve before start operation otherwise the sealing surfaces will
damage!
15. Fill liquid into the valve.

16. Screw in both tubing fittings 'E' into valve.
17. Install the dispense pump (see chapter 11.5.4 on page 11-13).

Pipettor Evolis
Maintenance
11.5.7 Replacement of Pipettor Bridge
Removal

3. Remove the top cover of the instrument.
4. Remove left and right side cover of the instrument.
5. Remove pipettor cover left '1' (see chapter 11.2 on page 11-2).
6. Remove clamp and ferrite 'D'.
Figure 11-18: High flex cable connection on pipettor PCB
7. Pull the cable through the frame.

8. Remove disposable tip adapter '5' (see chapter 11.5.2 on page 11-10).
9. Pull down the pipettor tubing.
10. Remove Z-cog guide.
11. Remove belt bridge connection screws 'A' (see also chapter 11.2 on page 11-2 posi-
tion '22' and '25').
Figure 11-19: Pipettor bridge fixing

Evolis Pipettor
Maintenance
Do not loosen bridge adjustment screws 'b' at belt to bridge fixing right side!
Figure 11-20: Pipettor bridge to belt fixing side (left/right)
12. Pull the left and right belt to bridge fixing plate out of the positioning pins 'C'.
13. Pull the bridge gently to the front out of the guides.
Installation 14. Push the bridge gently to the back into the guides.
15. Press the left and right belt to bridge fixing plate into the positioning pins 'C'.
16. Tighten belt bridge connection screws 'A'.
17. Install the Z-cog guide.
18. Install the pipettor tubing and the disposable tip adapter '5' (see chapter 11.5.2 on
page 11-10).
19. Install the high flex cable.
20. Connect the high flex cable connection on pipettor PCB.
21. Install clamp and ferrite 'D'.
22. Install pipettor cover left '1'.
23. Install left and right side cover of the instrument.
24. Install the top cover of the instrument.
11.5.8 Replacement of X-Sledge
Removal 1. Remove the pipettor bridge (see chapter 11.5.7 on page 11-18).
2. Remove the four screws 'A'.
Figure 11-21: Bridge guide

Pipettor Evolis
Maintenance
3. Pull out the bridge guide 'B'.

4. Remove the X-sledge (see chapter 11.2 on page 11-2).
Installation 5. Insert the X-sledge.

6. Pull in the bridge guide 'B'.
7. Tighten the four screws 'A'.
8. Install the pipettor bridge.
11.5.9 Replacement of Bridge High Flex Cable
Removal 1. Remove the pipettor bridge (see chapter 11.5.7 on page 11-18).
2. Remove the screws 'C' (see figure 11-21: on page 11-19).
3. Remove the X-sledge (see chapter 11.5.8 on page 11-19).
4. Remove high flex cable fixing clip ’A’.
Figure 11-22: High flex cable fixing clip
5. Disconnect the high flex cable from pipettor PCB (see chapter 11.4 on page 11-7).
6. Disconnect the high flex cable from the X-sledge.
7. Remove the high flex cable.
Installation 8. Install the high flex cable.
Figure 11-23: Bridge high flex cable
9. Connect the high flex cable to the X-sledge.

10. Connect the high flex cable to the pipettor PCB.
11. Push the high flex cable fixing clip ’A’ onto the flex cable holder between the
plunger pins.
12. Install the X-sledge (see chapter 11.5.8 on page 11-19).
13. Tighten the screws 'C' (see figure 11-21: on page 11-19).

Evolis Pipettor
Maintenance
14. Install the pipettor bridge (see chapter 11.5.7 on page 11-18).
11.5.10 Replacement of Y-Belt
Removal

3. Open pipettor metal sheets '1' and '3' (see chapter 11.2 on page 11-2).
4. Loosen screws 'D'.
Figure 11-24: Y-belt tension mechanism (behind metal sheet ’1’)
5. Push the roller to the right side against the spring.

6. Tighten the screws 'D'. The belt is slack now.
7. Open screws 'B'.
Figure 11-25: Pipettor bridge and belt fixing (side left/right)
8. Take away the slit sheet metal where the cog belt is fixed.
9. Pull out the belt.
Installation 10. Insert the new belt.

11. Fix the belt at the slit sheet metal.
12. Set the screws 'B'.
13. Tighten the belt.
14. Adjust the distance Y1 to the front rollers of the right bridge to belt fixing. It
must be the same as left.

Pipettor Evolis
Maintenance
Figure 11-26: Left/right distance Y1

16. Adjust the timing of the Y-belt tension (see chapter 11.6.4 on page 11-35).
17. Install pipettor metal sheets '1' and '3'.
All pipettor positions must be taught new!
18. Teach the pipettor (see chapter 11.7 on page 11-44).
11.5.11 Replacement of Y-Motor/Encoder
Removal

3. Open pipettor metal sheets '1' and '3' (see chapter 11.2 on page 11-2).
4. Loosen screws 'D’ (loosen belt tension figure 11-24: on page 11-21).
5. Press the roller to the right side against the spring.
7. Disconnect encoder cable 'A'.

Evolis Pipettor
Maintenance
Figure 11-27: Y-motor with encoder
8. Disconnect Y-motor cable at pipettor PCB (see chapter 11.4 on page 11-7).
10. Lift out the Y-motor '16'.
Installation 11. Insert the new Y-motor '16'.
Pay attention to the belt guide!
Figure 11-28: Y-belt guiding mechanism

Pipettor Evolis
Maintenance

13. Connect Y-motor cable at pipettor PCB.
14. Connect encoder cable 'A'.
15. Adjust the timing of the Y-belt tension (see chapter 11.6.4 on page 11-35).
16. Install pipettor metal sheets '1' and '3'.
11.5.12 Replacement of Waste Pump (on the back Side)
The waste pump, and the waste tubing’s could have had direct contact
with potentially infectious material! Pay attention to safety regards! Al-
ways wear gloves!
Removal

of the functional drawer see chapter 6.5.2 on page 6-6).
4. Pull out the waste pump ’A’.
Figure 11-29: Waste pump (on the back side)
5. Disconnect connector ’B’.

6. Lay a cloth or a bowl under the waste pump to absorb the residual liquid.
7. Disconnect tubing ’C’.
8. Disconnect tubing ’D’.
9. Remove the waste pump.
Installation 10. Install the new waste pump.

11. Connect tubing ’D’ (from the wash/waste position).
Pay attention to the flow direction!

Evolis Pipettor
Maintenance
12. Connect tubing ’C’.

13. Remove the cloth or bowl.
14. Connect connector ’B’.
15. Push in the waste pump ’A’.
of the functional drawer.)
11.5.13 Replacement of Waste Pump (on the left Side)
The waste pump, and the waste tubing’s could have had direct contact
with potentially infectious material! Pay attention to safety regards! Al-
ways wear gloves!
Removal

of the functional drawer see chapter 6.5.2 on page 6-6).
4. Disconnect connector ’B’ (black).
Figure 11-30: Waste pump (on the left side)
5. Disconnect connector ’C’ (brown).

6. Open the two retaining screws ’D’.
7. Lay a cloth or a bowl under the waste pump to absorb the residual liquid.
8. Disconnect tubing ’F’.
9. Disconnect tubing ’E’.
10. Remove the waste pump.
Installation 11. Install the new waste pump.

12. Connect tubing ’F’.
Pay attention to the flow direction!
13. Connect tubing ’E’ (from the wash/waste position).

14. Tighten the two retaining screws ’D’.

Pipettor Evolis
Maintenance
15. Remove the cloth or bowl.

16. Connect connector ’C’ (brown).
17. Connect connector ’B’ (black).
of the functional drawer.)

Evolis Pipettor
11.6.1 Adjustment of the X- and Z-Axis
A metric steel ruler with 0.5 increments length 500 mm or a standard metric
ruler are recommended.
1. Start the service software (see figure 11.9 on page 11-63).

2. Start the pipettor sub-routine.
3. The following entries must be marked:
• Arm type: Left arm Needle
• Type left: One Needle
• Cartesian Coordinates
5. In the next window, press on the P i p e t t o r button.
6. Initialise the pipettor by pressing the L e f t A r m button in the I n i t i a l i z e
area.
The pipettor is now moving to left back corner!
7. If initialising is ready the coordinate window will appear automatically.

Now you must load the following coordinates.
8. In the r a c k box, you must choose the rack type T . Load it to Track-No. 1 and
12 by pressing the A d d button after each input.
9. In the m i c r o p l a t e s box, choose the default plate type 8 x 1 2 and load it to
position 03 and 08.
The coordinates will be sent to the pipettor. If sending is completed, the dis-
play will return the pipettor dialogue box.
11. Set the specified position numbers in the absolute movement box and if nec-
essary, the step value for the Z-axis in the relative movement box.
12. Press the M o v e button after each input.
13. Activate the Z-axis by setting the button Z .
Test position: Position-No.: Z-steps:
1 2692 0
2 2403 -1500
3 1559 -3000
4 1251 -5000
Table 11-5: Values
14. Now each position must be reached by using the values shown in the table.
15. Check the gear space now and if necessary adjusted by using a ruler as
shown in the picture below. Before adjusting the mechanical space, check
each position.

Pipettor Evolis
16. After these mechanical adjustments, all positions must be checked again.
11.6.1.1 Mechanical Adjustment

17. The ruler must be aligned to a fixed point on the arm.
If no such a ruler is available, it must be fixed by another way.
Figure 11-31: Check the X-positions
18. Now the gear space is to be checked by moving the X-sledge manually in X
direction.
Do not use too much force!
19. The back lash must be between min. 0.1 mm/0.2 mm to max. 0.5 mm.
20. If the space is to big or to small it has to be adjusted.
First loosen the motor screw 'A' by using a hex screwdriver of 3 mm.
Figure 11-32: X-motor adjustment screw
21. Adjust by moving the motor.

22. After adjusting tighten screw again.

Evolis Pipettor
11.6.1.2 Checking Play of Z-Drive

23. Put the ruler on the top of the X-sledge.
Figure 11-33: Checking play of Z-axis
24. Try to move the gear rod manually up and down.
Use no force!
25. The back lash must between min. 0.1 mm/0.2 mm to 0.5 mm.
26. If the space is not within those limits, the Z-motor space must be adjusted.
First loosen the two screws 'B' on the Z-motor slightly by using a 2.5mm hex
screw-driver.

Pipettor Evolis
Figure 11-34: Z-motor adjustment screws
27. Now set the Z-motor in the correct position while checking the movement
space as described above.
28. Tighten screws after alignment.
11.6.2 Adjustment of the X-Axis Roller
In some cases the adjustment of the rollers on the sledge are too close to the sheet
metal guiding. The following instructions shows how to check the correct adjustment
and how to correct in case of a wrong adjustment.


Evolis Pipettor
11.6.2.1 How to Check the Correct Adjustment

3. Fix the sledge with the right hand to ensure the sledge can not move. Then
try with a finger to turn the lower roller (roller with O-ring).
Figure 11-35: Check X-axis roller
Checkup:
• In case the roller is turnable without any friction to the sheet metal guiding
there is too much air.
The roller must be adjusted closer to the sheet metal guiding.
• In case the roller is only turnable with high friction to the sheet metal guiding
there is too much friction by the deformation of the O-ring which can cause a
blockage of the sledge.
The roller must be adjusted away from the sheet metal guiding.
• In case the roller is easy turnable with a low friction to the sheet metal guiding
the adjustment is in the correct level.
No readjustment is necessary.
11.6.2.2 How to Adjust the X-Axis Roller

4. Open the lower hex-screw with a 7 mm wrench.
Figure 11-36: Lower hex-screw

Pipettor Evolis
5. Turn the eccentric roller screw via the slots in the back of the bridge in clock
or counter clock direction.
Figure 11-37: Turn the eccentric roller screw (back of the bridge)
6. Tighten the hex screw again.

7. Check the correct adjustment again.
11.6.3 Adjustment of the Y-Axis Roller
The pipettor bridge is guided at the left side against up and down and at the right side
against up down and left right movement. This is done by two rollers per direction.
These rollers must be adjusted correctly for smooth running and long life. If you ad-
just the rollers, check the teach positions afterwards.

3. Remove the left and right instrument cover.

Evolis Pipettor
11.6.3.1 How to Check the Correct Adjustment

4. Fix the bridge with the right hand to ensure the bridge can not move. Then try
with a finger to turn the lower roller (roller with O-ring).
Figure 11-38: Check lower Y-axis front roller
Figure 11-39: Check lower Y-axis back roller
Checkup:
• In case the roller is turnable without any friction to the sheet metal guiding
there is too much air.
The roller must be adjusted closer to the sheet metal guiding.
• Is case the roller is only turnable with high friction to the sheet metal guiding
there is too much friction by the deformation of the O-ring which can force a
blockage of the bridge.
The roller must be adjusted away from the sheet metal guiding.

Pipettor Evolis
• Is case the roller is easy turnable with a low friction to the sheet metal guiding
the adjustment is in the correct level.
No readjustment is necessary.
11.6.3.2 How to Adjust the Y-Axis Roller.

5. Open the lower screw '1' on the inside of the bridge holder in the bridge or on
the back of the bridge '2'.
There is easy access to the eccentric roller screw via a hole '3' on the pipettor
side panels (therefore remove outer covers). Turn the eccentric roller screw
in clock or counter clock direction to adjust via the eccentrically design of the
roller screw the distance between roller and guiding.
Figure 11-40: Bottom view inside the bridge
Figure 11-41: Rear side of bridge holders

Evolis Pipettor
Figure 11-42: Side view from outside on pipettor side panel
6. Tighten the inner screws again.
Never press the o-seal!
7. Check the correct adjustment again.
11.6.4 Adjustment of Timing Y-Belt Tension
Important Back- • A too high adjusted timing belt tension can cause higher friction and so prob-
ground Informa- lems in the positioning of the bridge.
tion • A too low adjusted timing belt tension can cause a jumping of the timing belt
on the timing belt pulley. This is causing fault positioning of the system which
can not be recognized by the control software. So a too low adjusted timing
belt tension is dangerous!

3. Remove pipettor cover left '1' (see chapter 11.2 on page 11-2).
11.6.4.1 How to Check the Timing Y-Belt Tension
You will need a spring gauge (range min. 20 N) to check the tension.
4. Place the spring gauge as close as possible on the left of the pump unit.
5. Place the hook of the spring gauge around the timing belt in the back.

Pipettor Evolis
Figure 11-43: Check the tension
6. Pull the timing belt from the back to the position of the timing belt to the front.
7. Read the necessary force of the spring gauge.
Values of 17-20 Newton are valid. In other cases the tension must be
adjusted.
11.6.4.2 How to Adjust the Timing Y-Belt Tension

8. Loosen screws 'D' (see figure 11-24: on page 11-21).
9. Press the roller to the right side against the spring.
11. Loosen screws 'D' to stretch the belt by the spring '11' (see figure 11-24: on
page 11-21).
12. Tighten screws 'D' again.
13. Check the correct belt tension again.

Evolis Pipettor
11.6.5 Free Movement of the Bridge on the Guiding

Mechanism

3. Move the bridge by hand.
4. Take a look on the right roller plate.
5. Check the air between the roller plate and the edge of the sheet metal guid-
ing.
There must be air at least of about 1 mm all across the movement area of the
bridge.
Figure 11-44: Air between the roller plate and the edge of the sheet metal
guiding

7. Take a look on the left roller plate.
8. Check the air between the roller plate and the edge of the sheet metal guid-
ing.
There must be air at least of about 1 mm all across the movement area of the
bridge.
10. Take a look on the lower roller plate on the right side.
11. Check regarding any collisions in this area all across the movement area of
the bridge.

Pipettor Evolis
Figure 11-45: Lower roller plate
12. In case of a problem in the upper three areas the bridge must be removed
from the system.
• Remove the bridge (see chapter 11.5.7 on page 11-18).
• Then adjust via the 2 rollers (see figure 11-45: on page 11-38) to the needed
direction (left or right) to fix the collision problem.
• Reassemble the bridge again.
• Check the free movement.
14. Take a look on the foil cable holder plate on the left side.
15. Check regarding any collisions in this area all across the movement area of
the bridge.
16. In case there is a collision with the high flex cable holder or the O-ring fix the
problem by bending the sheet metal part.
11.6.6 Free Movement of the Upper Rollers on Guiding

Mechanism
See also chapter 11.6.7 on page 11-39 regarding missing washer for wear protec-
tion.

3. Place a mark on both white rollers (left and right) for better judgment regard-
ing correct function.

Evolis Pipettor
Figure 11-46: Mark on a white roller

5. Take a look on all 4 rollers and check for a correct turning along the sheet
metal guiding.
In case:
• A roller is not turning. Check the roller regarding correct adjustment towards
the guiding. In case there is too much air adjust the roller according to other
rollers.
• The adjustment is ok but doesn't turn. Remove the roller, clean the bearing or
change the roller against a new part.
11.6.7 Wear of the Roller Bearings on the Bridge Holder
On several Evolis systems (serial number < 50) the following described wear on the
roller bearings can occur. In bad conditions (depending on force directions etc.) a
change of the left and right roller plate against new parts is necessary.
On newer systems (serial number > 50) there is a wear protective washer between
the roller bearing and the aluminium roller plate mounted. This washer protects the
bearing of getting polluted by material of the roller plate.

3. Check all rollers.

Pipettor Evolis
Figure 11-47: Detail view into gap between roller and bridge holder
• In case a thin washer is placed between the roller and the plate the following
wear condition can not occur.
• In case of non mounted washers and massive black particles visible between
the roller and the bridge holder must be at least cleaned and lubricated again.
• In case this doesn't help a change of the complete roller plate with the imple-
mented washer is necessary.
11.6.8 Alignment of Z-Drive

3. Replace the disposable tip adaptor (see chapter 11.5.1 on page 11-9).
4. Push in the Z-alignment tool into the rack teaching tool. The nose of the Z-
alignment tool shows to the left side (see chapter 11.7.1 on page 11-44).
5. Insert the Z-alignment tool with rack teaching tool into the left positions of the
rack system.

Evolis Pipettor
Figure 11-48: Z-alignment tool with rack teaching tool in the left positions of
the rack system
6. Loosen both screws ’1’ of upper Z-axis bearing.
Figure 11-49: Upper Z-axis bearing
7. Loosen both screws ’2’ of lower Z-axis bearing.

Pipettor Evolis
Figure 11-50: X-sledge (bottom view)
8. Loosen both screws '3' which fix the Z-motor to X-sledge.

After that the Z-axis gear rack should be moveable up and down without
resistance.
9. Guide the Z-axis gear rack into Z-adjustment tool until it’s completely
inserted.

Evolis Pipettor
Figure 11-51: Z-axis gear rack in the Z-alignment tool
10. Tighten both screws ’1’ of upper Z-axis bearing.

11. Tighten both screws ’2’ of lower Z-axis bearing.
12. Push the Z-motor to the right side to define the backlash.
13. Try to move the Z-axis gear rack up and down.
The Z-bar has to move easily without scratching.
14. After right adjustment is reached tighten both motor holding screws '3'.
15. Install the disposable tip adaptor (see chapter 11.5.1 on page 11-9).
16. Adjust Z-bar break after installing disposable tip adapter.
To adjust the right brake force screw in both screws ’4’ until Z-bar doesn`t
move down, on it`s own.

Pipettor Evolis
Teaching
11.7 Teaching
Before leaving the manufacturer, the pipettor and the plate transport of the system
are adjusted exactly. Nevertheless, it is recommended to check the settings before
starting the system for the first time. This procedure has to be repeated also when
parts for maintenance reasons have been changed.
11.7.1 Teaching Tools
11.7.1.1 MTP Teaching Tool

Teaching of dilution and pipette position coordinates.
Figure 11-52: MTP teaching tool
11.7.1.2 Rack Teaching Tool

Teaching of sample and reagent rack coordinates.
Figure 11-53: Rack teaching tool
11.7.1.3 Z-Alignment Tool

Tool to align the Z-drive.

Evolis Pipettor
Teaching
Figure 11-54: Z-alignment tool with rack teaching tool
11.7.1.4 Position Alignment Tool

Teaching of Z-coordinates.
Figure 11-55: Position alignment tool
11.7.1.5 Valve Alignment Tool

Alignment of the tree way valve.
Figure 11-56: Valve alignment tool
11.7.2 Start of Teacher Software
The icon T e ac h er on the desktop gives you access to the coordinate teaching
program 4 p s c o o . e x e .
If the service software or the user software was running before, this programs
has to be closed!

Pipettor Evolis
Teaching
Password Protec- By starting the teacher program two password levels are available.
tion • With the high level Password there is access to all parts of the teacher soft-
ware.
• With the low level Password there is just access to the reference position.
The pipettor is initialised and a graphical representation of the working area with the
different working positions appears.
Figure 11-57: Teacher main window
1 Reagent bottles and dilution plates

2 Disposable tip rack 1-5
3 Patient and reagent racks
4 Pipette positions 1-4
5 Eject position
6 Wash/waste position
7 Reference position
8 Tip type determination position
The positions of the pipetting stations are reversed in the teacher software
(e. g. pipetting station 1 = teach position 4) (see chapter 12.2 on page 12-2)!
Moving the mouse arrow to a specific position of the graphical display and clicking
with the left mouse button allows modification of the coordinates at the different po-
sitions. The pipettor moves to the currently set X- and Y-coordinates and a window
like following appears:

Evolis Pipettor
Teaching
Figure 11-58: Adjust position dialogue
In order to avoid damage of the disposable tip adapter, the Z-axis does not move au-
tomatically. The following keys of the keyboard can be used for adjusting the pipettor
to the correct position:
Key: Action:
Cursor left Moves the pipettor to the left (X-axis - changes steps of Y on
screen).
Cursor right Moves the pipettor to the right (X-axis - changes steps of Y on
screen).
Cursor down Moves the pipettor to the front (Y-axis - changes steps of X on
screen).
Cursor up Moves the pipettor to the rear (Y-axis - changes steps of X on
screen).
Page up Moves the pipettor up (Z-axis).
Page down Moves the pipettor down (Z-axis).
Shift Moves the pipettor down the Z-axis in five steps to 1/2, 3/4 and
6
/8 of the previous set Z-position.
+ Increases the step size.
- Decreases the step size.
Table 11-6: Keys
Generally the step size of the movements can be adjusted by the step size bar (see
figure 11-58: on page 11-47). If the bar is adjusted to the bottom, the pipettor can be
moved with minimum steps. The P r e v . Z button moves the pipettor to the Z-posi-
tion which was stored before.
This button should only be used if it is sure that the needle might not hit the
bottom! To reach the final position in X/Y/Z, small step sizes must be used!
Except for the eject and the waste position, all positions have three alignment points
which are marked in red and must be taught. For the teaching of the dilution posi-
tions, pipette positions, and sample/reagent rack positions teaching tools (see
chapter 11.7.1 on page 11-44) have to be used. The correct position is reached, if the tip
adapter is in the centre of the alignment holes of the tools (X,Y-position) and the po-
sition alignment tool fits between teach tool and tip adapter (Z-position).

Pipettor Evolis
Teaching
When checking the coordinates, be careful of the technical error of the axis
in X-,Y- and Z-direction; a tolerance of 3 steps (minimal step size) can be ac-
cepted!
Z-Alignment Firstly adjust the X,Y-position. Then adjust the Z-position, that the thin part of the po-
sition alignment tool fits between teach tool and tip adapter. The thick part has to
touch against the tip adapter.
Figure 11-59: Z-alignment with position alignment tool
Pick-up Disposal Put a 300 µl disposal tip into the disposal tip rack 1 position 1 and press the P i c k u p
Tip D button. The pipettor picks-up the disposal tip.
Figure 11-60: Disposal tip position
11.7.3 Mechanical Z-Alignment
Before starting to teach different positions, the Z-drive must be adjusted. This is done
with the Z-alignment tool (see chapter 11.7.1 on page 11-44).
11.7.4 Teaching Reference Position
There is no need to use a tip to teach in the following positions. The only po-
sitions where you need a tip are the individual reagent/sample racks and the
reagent bottle tray in the dilution area which will be described later.
Due to the fact that the setting of dilution positions, disposable racks, etc. are all re-
lated to the reference positions in the most cases, it is enough to teach the reference
position. Therefore, it is also important to teach the reference position before all other
positions.
By clicking on the R e f . l e f t button, the pipettor moves to the last taught reference
position (except the Z-axis).

Evolis Pipettor
Teaching
Figure 11-61: Reference position
The correct reference position is reached if the tip adapter (without a tip) touches the
reference point. If this position has been adjusted, it can be stored by pressing the
OK button.
If the positions are only checked (not changed in any direction), the teaching
of this position (before saving the last position) must be finished by pressing
the C a n c e l . This has to be done by all different positions in the teacher!
If the pipettor crashes (Z-motor deenergized) while teaching any position, the
teacher program must be closed by pressing the Ca n c e l button.

Pipettor Evolis
Teaching
11.7.5 Teaching Tip Type Determination Position
As tip type determination position '8', the metal surface of the sample and reagent
rack (right side) has to be used. The position shall be near the reference position '7'.
By clicking on the T i p ? button the pipettor moves to the last taught position (except
the Z-axis).
Figure 11-62: Tip type determination position
The correct position is reached if the tip adaptor (without a tip) touches the surface
of the sample and reagent rack.
If this position has been adjusted it can be stored by pressing the O K button.
11.7.6 Teaching Disposable Tip Racks
All five tip areas have to be taught beginning with the first tip rack (rear of the instru-
ment area - see chapter 11.7.2 on page 11-45). A empty tip rack has to be positioned on
the 1st tip area. By clicking on this tip rack icon on the screen the pipettor moves to
the stored X, Y coordinates of position 1.
Figure 11-63: Positions
A dialogue to adjust the first position appears (see figure 11-58: on page 11-47).
The pipettor has to be moved in the tip pick up position. It should be centred in the
middle of the opening. The black cover of the tip adapter must just touch the upper
area of the empty tip rack. When the pipettor is positioned correctly, the O K button
must be clicked.
This procedure must be repeated for all positions. The last height which has to be
taught is Z-start. To adjust Z-start, move down 400 digits from the current position (Z-
travel).

Evolis Pipettor
Teaching
Figure 11-64: Adjust Z-start
This is the way the positions of all other tip racks have to be adjusted.
11.7.7 Teaching Dilution Area
The dilution area consists of a reagent bottle area with four reagent bottle positions
and a dilution plate area with three plate holders.
Figure 11-65: Select dilution area
11.7.7.1 Reagent Bottles Area

The reagent bottle area includes 4 positions for reagent bottles.
There is a need to use a 300 µl tip to teach in the reagent bottle area posi-
tions.
Place reagent bottles in all positions.
The reagent bottle positions have to be taught beginning with position 1 of the rea-
gent bottle area.
By clicking on the reagent bottle area on the screen the pipettor moves to the stored
X and Y position of reagent bottle position 1.
The pipettor must be adjusted in a way that the tip is centred in the reagent bottle.
The Z-max position is adjusted in the following way:
• Move Z down until you touch the bottom of the bottle.
• Move 5 steps (minimum step size) back up.
• Confirm with the O K button.

Pipettor Evolis
Teaching
Adjust Z-start about 3 mm above the bottle.

Continue with the other reagent positions in the same way as described above.
11.7.7.2 Dilution Plate Area

All dilution plate positions have to be taught beginning with the first in the rear of the
dilution plate area. The MTP teaching tool (see chapter 11.7.1 on page 11-44) has to be po-
sitioned on the specific dilution position. By clicking on the dilution plate position on
the screen the pipettor moves to the stored X and Y position 1 of this dilution plate
position.
For adjustment, the pipettor can be moved as described. The pipettor must be ad-
justed so that the tip is positioned in the centre of the MTP teach tool holes (X-,Y-
position). For the Z-position use the position alignment tool. After position 1 is adjust-
ed by pressing the O K button, the pipettor moves to position 2 which can be taught
in the same way as described for position 1. When the 3 positions are taught, all po-
sitions are stored and you can begin teaching the other dilution plate positions.
11.7.8 Teaching Pipette Positions
All four pipette positions have to be taught beginning with the first in the rear of the
working area. The MTP teaching tool is placed in a plate carrier and has to be posi-
tioned on the specific pipetting position. By clicking on the first pipette position on the
screen the pipettor moves to the stored X- and Y-coordinates of position 1).
The teaching for this position is correct, if the tip adapter is in the same plane as the
specific drill hole of the alignment tool. All three points have to be taught. This proce-
dure has to be repeated for the other three pipette positions as well.
The teaching for this position is correct, if the tip adapter is in the centre of the MTP
teach tool holes (X-,Y-position). For the Z-position use the position alignment tool. All
three points have to be taught. This procedure has to be repeated for the other three
pipette positions as well.
11.7.9 Teaching Eject Position
After the eject position is clicked on the screen a dialogue to adjust the eject position
appears (see figure 11-58: on page 11-47).
If the button for tip release (on the bottom of the tip ejector) is pressed by the tip eject
pin the correct height of the eject point is set. After you have confirmed this height by
pressing the O K button on the screen you are asked for the Z-start height.
This should be reached by teaching 2800 digits below Z-travel.

Evolis Pipettor
Teaching
Figure 11-66: Teaching eject position
Please check that the tip will not get in contact with the housing during eject,
otherwise it will not drop correctly (distance between tip adapter and housing
> 1 mm).
11.7.10 Teaching Wash/Waste Position
The adjustment of the correct wash/waste position is done as described for the other
positions. By clicking on the wash position on the screen the adjust left wash position
window appears. Now the set point for the wash position can be adjusted. The end
of the tip on the tip adapter should be in the centre of the wash station and 700 digits
below Z-travel as shown in the following figure.
Figure 11-67: Z-travel of wash/waste position
After you have confirmed this height by pressing the O K button on the screen, you
are asked for teaching the waste position on the adjust left waste position window.
Since you use disposable tips, the wash/waste positions are equal. This means the
position values for X/Y/Z can be taught to the same X/Y/Z coordinates than done be-
fore with the wash position.

Pipettor Evolis
Teaching
11.7.11 Teaching Sample and Reagent Area
For teaching of the patient sample and reagent rack, the rack teaching tool (see
chapter 11.7.1 on page 11-44) has to be used and must be inserted in the far left position
of the rack. The three positions must to be taught.
Figure 11-68: Positions in the primary area
Clicking on the above shown area on the screen makes the pipettor move to X- and
Y-coordinates of position 1. The correct position is reached if the tip adapter touches
the reference point of the rack teaching tool. If this position has been adjusted, it can
be stored by pressing the O K button.
Figure 11-69: Adjust position with teaching tools
This procedure is to be repeated for positions 2 and 3. For teaching position 3 re-
move the rack tool from the far left position and insert the tool in the far right position
of the sample and reagent rack.

Evolis Pipettor
Teaching
11.7.12 Teaching MTP's
Normally there isn’t a need to use a tip to teach in the MTP’s.
Change the value MTPs (area [OFFSETS]) in the teacher ini-file (4psCoo.ini - stored
in the user software directory) to teach with:
• Tip adapter: 0
• 300 µl tip: -2440
• 1100 µl tip: -4845
There are master files for the different MTP's available:
• Micro plate (8x12.mpc)
• Dilution plate (mtpdil2.mpc)
These files are stored in the directory C:\Biorad\System.
There is no additional teaching necessary for these MTP's!
A disk is included by the 4 PS where all the files are stored as backup.
The coordinates which will be set for a specific MTP will be related to the coordinates
which have been taught in the above mentioned steps. Therefore a specific MTP has
to be taught only in one position. In our case, we use the pipette position 2.
For both plates the same procedure can be use as explained below.
Therefore, the micro plate in a plate carrier has to be positioned in position '4-1' (see
chapter 11.7.2 on page 11-45). The changing in the setting of the MTP's can be done by
clicking on the M T P ' s button on the screen. The following window appears on the
screen:

Pipettor Evolis
Teaching
Figure 11-70: MTPlate selection dialogue
Select the MTP file which shall be edited and click on the E d i t button. Now the win-
dow shown below appears.
Figure 11-71: MTPlate edit dialogue
In this window the changes concerning the actual micro plate can be done. In the
M T P D e t a i l s , the number of cavities in the X- and Y-direction and even the diam-
eter of the cavity must be inserted. Pressing the T ea c h button, the adjust window
appears on the screen. The pipettor moves to the previous set X- and Y-coordinates
for position 1. The correct coordinates can be set in the usual way. The tip shall be
in the centre of the cavity A1.

Evolis Pipettor
Teaching
The Zmax position is adjusted in a way that the tip adapter is touching the bottom of
the well and then moved up 4 steps with minimal step size. Positions 2 and 3 have
to be taught in the same way. After confirming the correct position for 3, the user is
asked to set the Z-dispense position.
Therefore the pipettor has to be moved up until the end of the tip adapter is in the
same plane as the top of the MTP plus one step with minimal steps size down.
Figure 11-72: Z-dispense position
After confirming the correct position for Z-dispense adjust the Z-travel. Therefore the
pipettor has to be moved up until the end of the tip adapter is in the same plane as
the top of the MTP plus 8 steps with minimal step size up.
11.7.13 Teaching Racks
There are master files for the different racks available:

• Samples racks T, U, V, W, and Y (T.rac, U.rac, V.rac, W.rac, and Y.rac)
• Archive rack Z (Z.rac)
• Reagents rack 1 (0.rac)
These files are stored in the directory C:\Biorad\System.
There is no additional teaching necessary for these racks!
A disk is included by the analyser where all the files are stored as backup.
There is a need to use a 300 µl tip to teach in the racks.
The rack which has to be taught must be inserted in track 1 (far left position).

Pipettor Evolis
Teaching
The coordinates which will be set for a specific rack will be related to the coordinates
which have been taught in chapter 11.7.11 on page 11-54. Therefore a specific rack has to
be taught only in one track.
For teaching the rack positions, the R a c k s button on the screen has to be clicked
with the mouse. The rack you want to adjust can be selected by marking it with the
cursor. It will be highlighted.
Figure 11-73: Rack selection dialogue
Select a rack is selected and press on the E d i t button.
Figure 11-74: Rack definition dialogue
In the upper part of the R a c k D e f i n i t i o n dialogue, the number of positions of the

selected rack are displayed. Under this, the actual set position is shown. The position
you want to teach can be selected by the up and down arrow buttons. When you
open the dialogue, it is usually position 1. Enter the tube surface (mm2) of the tube

Evolis Pipettor
Teaching
which is positioned in position 1 and begin the teaching by pressing the T e ac h but-
ton. Pressing this button makes the pipettor move to the previously stored X and Y
coordinates of position 1. For each position in the rack, X/Y/Zmax has to be taught
first, then Z-dispense.
11.7.13.1 Samples Rack 'T'

Definition of samples rack 'T':
Positions 1 to 20:
Tube surface 78 mm2

X/Y Insert a small 10 mm tube into the rack and centre
the tip for X and Y.
Zmax Touch the bottom of the tube and move 4 steps (min-
imum step size) up.
Z-dispense Z-Dispense = Z-Travel
Figure 11-75: Samples rack ’T’
11.7.13.2 Sample Racks ’U’, ’V’, ’W’, and ’Y’

See section "Sample Rack ’T’" on page 11-59.
11.7.13.3 Archive Rack ’Z’

See section "Sample Rack ’T’" on page 11-59.
11.7.13.4 Reagents Rack '0'

Reagents rack '0' has 21 positions to teach in. This rack is designed for three different
bottle types, so three rack definitions with different tube Surface are necessary.
Definition of reagents rack '0':
Positions 1 to 8:
Tube surface 1190 mm2

X/Y (see figure 11-76: on page 11-60)
Zmax Touch the bottom of the bottle and move 4 steps
(minimum step size) up.
Z-dispense 3000

Pipettor Evolis
Teaching
Positions 9 to 18:

X/Y Insert a bottle into the rack and centre the tip for X
and Y.
Z-dispense 5000
Positions 19 to 21:

and Y.
Z-dispense 3000
Figure 11-76: Reagents rack 0 – X/Y-alignment of Position 1 to 8
Figure 11-77: Reagents rack 0 – back side
Figure 11-78: Reagents rack 0 – front side

Evolis Pipettor
Teaching

Positions 1 to 13:

and Y.
Z-dispense 3000

Positions 1 to 20:

and Y.
Z-dispense 5000

Pipettor Evolis
Check and Verification
11.8 Check and Verification
11.8.1 Check Function of Disposable Tip Adapter

2. Open metal sheet '1' (see chapter 11.2 on page 11-2)
3. Switch on the system.
4. Start the service software (see chapter 11.9 on page 11-63).
5. Initialise the pipettor with the service software.
6. Move to position 2.
7. Watch the LED in front of the pipettor PCB (see chapter 11.4 on page 11-7).
Disp. Level Init +5 V +24 V
If there is no tip at the adapter and no

light barrier interrupted.
Lift the tip discarding device 'G' (see

figure 11-4: on page 11-5).
Normal condition of tip adapter after

0.5 sec off (level LED).
Lift the tip discarding device 'G'. Touch

a little the metal top with finger.
Lift the tip discarding device 'G'. Touch

more the metal pick up 'H' with finger.
Press the Z init pin 'E' at the top of the

adapter.
Interrupt the light barrier '7' and/or 19'.
LED on: LED off: LED on/

off:
Table 11-7: Check function of disposable tip adapter

9. Install metal sheet '1'.

Evolis Pipettor
Service Software
After start of service software and the selection of the pipettor (with double-click) the
following dialogue appears:
Figure 11-79: Pipettor start up dialogue
Operator Here the user name of the log in dialogue box is

shown. For the pipettor this name can be changed.
Serial Number Enter the serial number of the machine.
Arm Type Arm type of the pipettor:
• Left Arm
Don’t use an other arm type!
Needle Type Left Number of needle adaptors:
• One Needle
Don’t use the F o u r N e e d l e entry!
Extended Protocol Activates the recording of the communication in the
protocol file (PIP000000.txt).
Path and Name of Path and name of the coordinate file should be auto-
Coordinates matically indicated. If this field is empty, the path in
the configuration file (gService.ini) must be cor-
rected.
Cartesian Coordi- Type of coordinate system.
nates Default!
Polar Coordinates Don’t use this coordinate system!
OK Starts the pipettor main dialogue.
Don’t know If you don't know the correct parameters and press
the Do n 't K n o w button a warning is shown.
Table 11-8: Fields and buttons of the S e t u p P a r a m e t e r s dialogue

Pipettor Evolis
Service Software
The pipettor might crash if the parameters aren't correct. This button should
only be used to have a look on the dialogues but not to work with.
After successful input, the pipettor main dialogue is shown.
Figure 11-80: Pipettor main window

Evolis Pipettor
Service Software
11.9.1 Functions of the Pipettor Service Software
11.9.1.1 Setup Parameters
Operator Shows the user name.

Serial Number Shows the serial number of the machine.
Machine Type of the machine (FPS).
Firmware Shows the firmware version number, if connection is
Path and Name of Path and name of the coordinate file.
Coordinates
Type Shows type of coordinate system.
• Default: Cartesian coordinates.
Arm Type Arm type of the pipettor:
• Default: Left arm
Needle Type Number of needle adaptors:
• Default: One needle left
Change The parameters can be modified if necessary.
i The version of the pipettor-DLL (service software) is
shown.
Table 11-9: Fields and buttons of the S e t u p P a r a m e t e r s area
11.9.1.2 Single Components
Pipettor (see chapter 11.9.2 on page 11-66)

Pumps (see chapter 11.9.3 on page 11-70)
Coordinates (see chapter 11.9.4 on page 11-72)
Prime (see chapter 11.9.5 on page 11-74)
Level Sensor (see chapter 11.9.6 on page 11-75)
Automatic Module (see chapter 11.9.7 on page 11-77)
T es t
Firmware upgrade (see chapter 11.10.1 on page 11-78)
Table 11-10: Fields and buttons of the S i n g l e C o m p o n e n t s area

Pipettor Evolis
Service Software
11.9.1.3 General

play devices reply.
11.9.2 Pipettor Dialogue
The pipettor dialogue looks as follows:
Figure 11-81: Pipettor dialogue
Depending on the pipettor type and previous actions, some buttons are activated or
deactivated.
11.9.2.1 Initialize
Left Arm First, the pipettor must be initialised.
Table 11-12: Fields and buttons of the I n i t i a l i z e area
During a movement the following dialogue appears:

Evolis Pipettor
Service Software
Figure 11-82: Pipettor moving dialogue
Canc el Only the current sending of commands will be

stopped.
Emergency Stop An emergency stop command is sent to the pipettor.
After this, the pipettor must be initialised again.
Table 11-13: Fields and buttons of the D e v i c e i s b u s y dialogue
After the first initialisation you automatically get to the C o o r d i n a t e s dialogue (see
11.9.2.2 Relative Movement
Steps Enter the number of steps for relative movement.

The steps can be entered positive or negative
depending on the desired direction of the movement.
X , Y, and Z Select the axis to move. The Z-axis moves to ZTravel
before each movement, so it can be avoided that the
Z-axis is too deep and possibly hangs during an XY-
movement. That means that it also moves to ZTravel
if the Z-axis itself is to move. The relative movement
then starts from this height.
Move By pressing the button, the selected arm moves with
the selected axis the entered number of steps.
Table 11-14: Fields and buttons of the R e l a t i v e M o v e m e n t area

Pipettor Evolis
Service Software
11.9.2.3 Absolute Movement (XY only)
Position-No. Enter the absolute position number. These numbers

must correspond with those of the transmitted coordi-
nates.
Move By pressing the button, the selected arm moves to
this position without moving the Z-axis.
At the third position of the system (EJECT position)
the Z-axis is moved to the top before the movement,
so the arm doesn't get caught. This applies to each
movement to the third position with the system.
Table 11-15: Fields and buttons of the A b s o l u t e M o v e m e n t ( X Y

o n l y ) area
11.9.2.4 Coordinates
In the area C o o r d i n a t e s appear the coordinates sent to the pipettor.
Move to selected If you select some coordinates (marking with the

Coord(s) mouse by pressing the key Shift or Ctrl while marking
several coordinates that are not contiguous can be
selected), the button M o v e t o s e l e c t e d
C o o r d ( s ) becomes active. By pressing this button
the pipettor moves to the selected coordinates.
Repeat Enter the number of repetitions of the movements.
Step by Step The pipettor waits before each movement for the
confirmation of the user.
Table 11-16: Fields and buttons of the C o o r d i n a t e s area
11.9.2.5 Random Movement
M o v e t o A l l C o o r d i - By pressing the button, the pipettor moves to all

nates coordinates in the same order as sent before. The
pipettor will move alternately with the defined arm.
Repeat Enter the number of repetitions of the movements.
Table 11-17: Fields and buttons of the R a n d o m M o v e m e n t area

Evolis Pipettor
Service Software
11.9.2.6 Disposable Tips
L o n g T i p s and S h o r t Select the type of the used disposable tips.

T i ps
Pickup The pipettor will move down and pickup a tip.
Eject To eject a tip, the pipettor must be moved to the eject
position (FPS: No 3). Only there, the button E j e c t
becomes active and can be pressed. The tip then is
ejected.
Eject after Init If there are a disposable tip attached to the needle
after an initialisation, they can be ejected immedi-
ately after the initialisation by pressing the E j e c t
after Init button.
Table 11-18: Fields and buttons of the D i s p o s a b l e T i p s area
After each picking up or ejecting of tips, the result is checked and a N o t i p . . . mes-
sage is reported on the screen if necessary.
11.9.2.7 General
OK Closes the window and returns to main pipettor win-

dow.

Pipettor Evolis
Service Software
11.9.3 Pumps Dialogue
If the pipettor was not initialised with the pipettor dialogue (see chapter 11.9.2 on page 11-
66) or there were no coordinates sent, the question "Pipettor initialized and Coordi-
nates sent?" is shown when calling the P u m p s dialogue. This question appears
only once. By pressing Y e s, the pipettor moves to the waste position and the pumps
dialogue is shown.
Figure 11-83: Pumps dialogue
11.9.3.1 Wash Pump(s)
Time Enter the time of switching on the wash pump.

On Switches the wash pump on
Table 11-20: Fields and buttons of the W a s h P u m p ( s ) area
If the wash pumps are turned on, the waste pump isn’t switched on automat-
ically! The wash position can overflow then.
11.9.3.2 Waste Pump
Time Enter the time of switching on the waste pump.

On Switches the waste pump on
Table 11-21: Fields and buttons of the W a s t e P u m p area

Evolis Pipettor
Service Software
11.9.3.3 Syringe Pump(s)
Firmware Versions By pressing the button, the firmware version of the

selected pump is shown.
Init - Input - Output - By pressing the corresponding button, the movement
Bypass of the plunger (initialisation or normal movement) or
of the valve (movement to input-, output- or bypass-
position) can be tested.
Move With the button, the pump moves 3000 steps, alter-
nating downward or upwards.
For the movement, the currently programmed speed
parameters are used. That means that the pump
moves quite slow after an initialisation but faster after
a prime cycle.
Table 11-22: Fields and buttons of the S y r i n g e P u m p ( s ) area
While a pump is working the dialogue "Device is busy" appears (see chapter 11.9.2 on
page 11-66).
11.9.3.4 General
OK Closes the window and returns to main pipettor win-

dow. Parameters are stored.
Canc el Closes the window and returns to main pipettor win-
dow. Parameters aren’t stored.

Pipettor Evolis
Service Software
11.9.4 Coordinates Dialogue
66), the question "Pipettor initialized?" is shown when calling the coordinates dia-
logue. This question appears only once. By pressing the Yes , button the coordi-
nates dialogue opens.
After the first initialisation, the coordinates dialogue is shown automatically.
Figure 11-84: Coordinates dialogue
11.9.4.1 Racks and µPlates
Racktype Select the type of the rack (name of the rack file).
Track-No Enter the number of the track where the rack is
placed. The numbering of the tracks starts with zero.
Add Take over the racktype and the track-number and
add the rack into the list.
R em o v e s e l ec t e d By marking one or several racks and pressing
Rack(s) R e m o v e s e l e c t e d R a c k ( s ) , these racks
can be removed from the list.
Table 11-24: Fields and buttons of the R a c k s area

Evolis Pipettor
Service Software
11.9.4.2 µPlates
Platetype Select the type of the plate (name of the plate file).
Position Enter the number of the plate position. The number-
ing of the plate positions starts with zero.
Add Take over the plate type and the position and add the
plate into the list.
R e m ov e s e l ec t e d By marking one or several plates and pressing
Plate(s) R e m o v e s e l e c t e d P l a t e ( s ) , these plates
can be removed from the list.
Table 11-25: Fields and buttons of the µP l a t e s area
11.9.4.3 Send all Coords
OK By pressing O K , the static coordinates (init position,

wash- and waste position) are sent together with the
just entered dynamic coordinates if they are defined
in the coordinates-file.
While the coordinates are sent the dialogue "Device
is busy" appears (see chapter 11.9.2 on page 11-66).
After transmitting the coordinates, you get back to
the pipettor main dialogue (see chapter 11.9 on page 11-
63), except after the first initialisation. Then you get
back to the pipettor dialogue (see chapter 11.9.2 on
page 11-66).
If you want to change the dynamic coordinates you
get, go again to the C o o r d i n a t e s dialogue by
pressing the C o o r d i n a t e s button in the main dia-
logue. Have already coordinates been sent, the
warning messages "Old Coordinates will be deleted!"
appears.
By pressing O K , the old coordinates in the service
software are deleted and the coordinates dialogue
appears.
Canc el Drops all parameters, closes window and returns to
main pipettor window.
Table 11-26: Fields and buttons of the S e n d a l l C o o r d s area

Pipettor Evolis
Service Software
11.9.5 Prime Dialogue
66) or there were no coordinates sent, the question "Pipettor initialized and Coordi-
nates sent?" is shown when calling the prime dialogue. This question appears only
once. By pressing Y e s, the pipettor moves to the waste position and the prime dia-
logue is shown.
Figure 11-85: Prime dialogue
11.9.5.1 Primeparameters
Number of Primecy- Enter the number of prime cycles.

cles
Time Bypasspump Enter the time of switching on the bypass pump.
On
Table 11-27: Fields and buttons of the P r i m e p a r a m e t e r s area
11.9.5.2 General
OK By pressing O K the priming starts. First, the valve of

the pump is turned to the bypass position and the
bypass pump is switched on for the specified time.
After that the pump moves for the given number of
cycles. In the meantime the "Device is busy" dia-
logue is shown (see chapter 11.9.2 on page 11-66).
Cancel Closes window and returns to main pipettor window.

Evolis Pipettor
Service Software
11.9.6 Level Sensor
When calling the level sensor dialogue, some buttons are active and some are inac-
tive according to previous actions.
If there are no coordinates sent to the pipettor, no level sensor test can be started.
Figure 11-86: Level sensor dialogue
11.9.6.1 Coordinates
The transmitted coordinates are shown in the area C o o r d i n a t e s .
Submerge Steps Not used for service.

track Not used for service.
Table 11-29: Fields and buttons of the C o o r d i n a t e s area
11.9.6.2 LLD-Frequency
Left The actual LLD-Frequency is shown. The value is

updated every half second if no level sensor test is
running. When a test is started, the updating stops.
Table 11-30: Fields and buttons of the L L D - F r e q u e n c y area

Pipettor Evolis
Service Software
11.9.6.3 Results
Clear List With the C l e a r L i s t button you can clear the

result list in the display.
Load from File If a file of target coordinates exists, it can be loaded
now by pressing L o a d f r o m F i l e.
Write to File After the test has finished the result list can be stored
by pressing W r i t e t o F i l e . At the same time a
target data file is created.
Table 11-31: Fields and buttons of the R e s u l t s area
11.9.6.4 General
Repeat In the field R e p e a t , the number of repetitions can

be entered.
S t a r t L ev e l Te s t Before pressing S t a r t L e v e l T e s t load a target
coordinates file (L o a d f r o m F i l e ). Otherwise,
the target coordinates for the test must now be
selected (marking with the mouse by pressing the
key Shift or Ctrl while marking several coordinates
that are not contiguous can be selected). The
marked coordinates are copied automatically into the
R e s u l t s area.
After pressing S t a r t L e v e l T e s t , the test starts.
The pipettor moves to the selected coordinates one
after the other and searches for liquid at each posi-
tion. At the same time the result list is continuously
updated. The minimum and the maximum height are
determined as well as the number of positive and
negative results.
During the test the "Device is busy" dialogue is
shown (see chapter 11.9.2 on page 11-66).
OK If you leave a dialogue with the O K button the soft-
ware remembers the entered values when reopening
the dialogue.
Cancel With C a n c e l the entered values are not stored.

Evolis Pipettor
Service Software
11.9.7 Automatic Module Test Dialogue
The automatic module test runs almost completely independently. Only at the begin-
ning tips and a rack must be placed. The different parts can be deselected by remov-
ing the ticks in the check boxes except for the initialisation.
Figure 11-87: Automatic module test dialogue
After deselecting some parts the display changes from T o D o to S k i p p e d .

By pressing S t a r t the automatic module test starts.
1. First, short tips must be placed at the shown position.
3. Long tips must be placed at the position that is shown now.
5. A T-rack filled with tubes (with and without liquid) must be placed on the first
track.
The test runs itself with the selected parts. The result window for the level detection
is constantly updated. At the end a log file is created automatically.

Pipettor Evolis
Firmware Upgrade
Invokes the F i r m w a r e U p g r a d e dialogue box. It is assumed the new firmware

file *.h86 resides within the washer sub-directory, as described within the INI file. Oth-
erwise, you may browse all available drives.
Direct connection allows upgrade using a RS232 cable directly connected to a PC.
In the first field the name and the path of the new firmware can be entered. If the
name and the path shown as default are not correct, the correct file can be searched
with the Br ows e.. . button.
The upgrade process starts by pressing O K . The dialogue is left without upgrading
by pressing C a n c e l .
After the upgrade process, the following message is shown:
Figure 11-89: Message after firmware upgrade
The pipettor must be reinitialised after an upgrade process and the coordinates have
to be transmitted again.

3. Click on the P i p e t t e tab.

Evolis Pipettor
Firmware Upgrade
The file (PDANCE.H86) used to update the firmware must be stored in the


Pipettor Evolis
Firmware Upgrade

Evolis Pipetting Station
Safety and Hints
12 Pipetting Station

Every time the pipetting station or plate transport is disturbed, the calibration

Pipetting Station Evolis
Figure 12-1: Pipetting station (rack system removed)
1 Pipetting station 1 (front side of the instrument)

2 Pipetting station 2
3 Pipetting station 3
4 Pipetting station 4 (back side of the instrument)
5 Plate carrier guide (8x)
6 Stainless steel COP cover
7 Cable throughput to COP

Evolis Pipetting Station
Maintenance
8 Incubator (back view)

9 Plate transport
10 Tip eject pin
The positions of the pipetting stations are reversed in the teacher software
(e. g. pipetting station 1 = teach position 4) (see chapter 11.7 on page 11-44)!
12.3 Maintenance
Every time the pipetting station or plate transport is disturbed, the calibration
12.3.1 Replacement of Light Barriers
Removal

3. Open stainless steel cover '6' (see chapter 12.2 on page 12-2).
4. Remove the rack system (see chapter 14.4.1 on page 14-4).
5. Remove both retaining screws of the faulty light barrier.
6. Disconnect the connector ST40, ST42, ST43 or ST44 of the faulty light bar-
rier (see chapter 8.4 on page 8-5).
7. Remove the faulty light barrier.
Installation 8. Install the new light barrier.

9. Connect the connector of the light barrier.
10. Tighten the retaining screws.
11. Install the plate transport cover.

Pipetting Station Evolis
Maintenance

Evolis Stacker
Safety and Hints
13 Stacker

set!
Every time the stacker module or plate transport is disturbed, the calibration
Figure 13-1: Stacker in opened drawer (back view)
1 Stacker position 1 (front side of the instrument)

2 Stacker position 2 (front side of the instrument)
3 Stacker position 3 (back side of the instrument)
4 Stacker position 4 (back side of the instrument)
5 Photometer
6 Stacker housing
7 Plate transport PCB cover
8 Washer

Stacker Evolis
Maintenance
13.3 Maintenance
Every time the stacker module or plate transport is disturbed, the calibration
13.3.1 Replacement of Light Barriers
Removal

4. Remove plate transport cover '7' (seechapter 13.2 on page 13-1 and chapter 8.5.3 on
page 8-9).
5. Remove both retaining screws of the faulty light barrier.
6. Disconnect the connector ST4, ST11, ST12 or ST13 of the faulty light barrier
(see chapter 8.4 on page 8-5).
7. Remove the faulty light barrier.
Installation 8. Install the new light barrier.

9. Connect the connector of the light barrier.
11. Install the plate transport cover.

Evolis Rack System
Safety and Hints
14 Rack System

Do not touch the glass windows and mirror surfaces with fingers!
Do not damage the coated surface of glasses!
For all actions it's necessary to remove the rack system (see chapter 14.4.1 on
page 14-4)!

Rack System Evolis
Figure 14-1: Mechanical architecture
1 Bar code scanner

2a Rack insert detection light barrier emitter
2b Rack insert detection light barrier sensor
3 Door switch
4 Rack fixing
5 Rack system PCB

Evolis Rack System
Figure 14-2: Rack system PCB
ST1 Main Connection (Power and Data)

ST2 not used
ST3 Door switch
ST4 not used
ST5 Rack insert light barrier
ST6 not used

Rack System Evolis
Maintenance
14.4 Maintenance
14.4.1 Replacement of Rack System
Removal

3. Remove tip disposal ramp cover.
4. Remove the stainless steel cover at the backside left to reach the COP PCB.
5. Loosen rack fixing screws '4' turn two times only (see chapter 14.2 on page 14-2).
6. Pull out the rack about 10 cm to the front.
7. Disconnect the 15 pin connector of the Sub-D bar code scanner.
8. Disconnect the 2 pin connector at COP PCB (ST18 Mirror).
9. Disconnect the 16 pin flat cable connector at rack system PCB '5'.
10. Remove the rack system.
Installation 11. Insert the rack system.

12. Connect the 16 pin flat cable connector at rack system PCB ’5’.
13. Connect the 2 pin connector at COP PCB (ST18 Mirror).
14. Connect the 15 pin connector of the Sub-D bar code scanner.
15. Tighten the rack fixing screws ’4’.
16. Install the stainless steel cover at the backside left to reach the COP PCB.
17. Install dispose ramp.
18. Teach the rack system (see chapter 11.7.11 on page 11-54).
14.4.2 Replacement of Bar Code Scanner
CAUTION: Laser radiation - do not stare into beam!
Removal 1. Remove the rack system (see chapter 14.4.1 on page 14-4).
2. Remove the two nuts 'A'.

Evolis Rack System
Maintenance
Figure 14-3: Bar code scanner at rack system (right view)
3. Remove Phillips screws 'B'.

4. Open rack door and remove screw 'C' from inside of the rack.
5. Remove the bar code scanner.
Installation 6. Install the new bar code scanner.

7. Open rack door and tighten screw 'C' from inside of the rack.
8. Tighten Phillips screws 'B'.
9. Tighten the two nuts 'A'.
10. Install the rack system (see chapter 14.4.1 on page 14-4).
14.4.3 Replacement of Rack Insert Light Barrier
Removal 1. Remove the rack system (see chapter 14.4.1 on page 14-4).
2. Disconnect rack insert light barrier connector on rack system PCB (see
3. Replace rack insert light barrier emitter '2a'.
4. Replace rack insert light barrier sensor '2b'.

Rack System Evolis
Maintenance
Figure 14-4: Rack insert light barrier and cable
Installation 5. Install the new rack insert light barrier sensor '2b'.
6. Install the new rack insert light barrier emitter '2a'.
7. Connect rack insert light barrier connector on rack system PCB (see
14.4.4 Replacement of Door Switch
Removal 1. Remove the bar code scanner (see chapter 14.4.2 on page 14-4).
2. Disconnect door switch connector on rack system PCB (see chapter 14.3 on
page 14-3).
3. Remove nuts.
4. Remove the faulty door switch.
Installation and 5. Insert the new door switch

Adjustment 6. Install the nuts. Don’t tighten the nuts!
7. Close the rack door.
8. Hold parallel the outer edge of the rack door to the edge of the stainless steel
housing.
Figure 14-5: Adjustment of rack door switch

Evolis Rack System
Maintenance
9. Tighten nuts.
10. Install the bar code scanner (see chapter 14.4.2 on page 14-4).

Rack System Evolis
Service Software
When the rack system is invoked, the application attempts to communicate to the
system and rack system module. When successful the following dialogue will be dis-
played with the firmware version number, and serial number displayed. Bar code op-
tions will be read from the module EEPROM and shown. If no module is detected,
nothing will be shown for the firmware version number.
Figure 14-6: Rack system main window
14.5.1 Functions of the Rack System Service Software
14.5.1.1 Instrument

number.

Evolis Rack System
Service Software
14.5.1.2 Rack Sensor Status
1 - 12 Each of the twelve check boxes indicate the status of

the corresponding rack position. Checked means
occupied.
Door Open The door open field is checked when the door sensor
detects an open door
Trigger The trigger is checked when the light barrier across
the opening of the rack is broken by a rack insertion.
Get Status Updates the status for the rack sensors, door sensor
and trigger.
Table 14-2: Fields and buttons of the R a c k S e n s o r S t a t u s area
14.5.1.3 Scanner Configuration
Scanner Version Shows the scanner version number.

Bar code types To enable specific bar code types check the appro-
priate boxes (see note). For the most reliable opera-
tion only enable bar codes actually used.
Lengths: To improve the reading detection further, the user
• Min. can program the minimum and maximum character
• Max. length a specific bar code must be. If a bar code is
read outside these limits, it presumed invalid.
Load Orientation 1 Load orientation check boxes allows the user to
- 12 define a rack position for horizontal bar codes.
Get Version Retrieves and displays the firmware version of the
bar code scanner.
Set Parameters Sends the enabled bar code types to the scanner.
Get Parameters Returns scanner configuration, bar code types ena-
bled and default horizontal rack settings.
Mirror Horiz. Not used.
Set Mirror When the mirror horizontal check box is enabled, this
will set the mirror to the horizontal position.
Table 14-3: Fields and buttons of the S c a n n e r C o n f i g u r a t i o n area
A maximum of 8 bar code types can be enabled. This configuration does not
effect the configuration when using the pc software to run the system.

Rack System Evolis
Service Software
14.5.1.4 Barcodes
Displays the bar codes read for all the rack positions.
Read barcodes Reads the bar codes currently read within the sys-
tem.
Table 14-4: Fields and buttons of the B a r c o d e s area
I n i t i a l i s e a n d S e l f t - (see chapter 14.5.2 on page 14-11)

est
Auto Load Starts the auto load sequence. The value in the
R a c k P o s i t i o n field sets the starting rack posi-
tion.
Auto load mode is used, so that the user can quickly
load a selection of sample racks without the need for
control from the PC. This allows racks to be loaded.
The bar codes can be read later using the read bar-
codes button. Note that auto load mode should be
stopped before trying to send other commands to the
rack by pressing the S t o p A u t o L o a d button.
Stop Auto Load Stops the auto load sequence. The rack will be
returned to the idle state.
Rack Position The value sets the starting rack position.
Reset The scanner will be initialised.
F oc us Sets laser focus to current rack position.
Laser On Turns on the laser of the scanner.
Laser Off Turns off the laser of the scanner.

Evolis Rack System
Service Software
Horizontal Option Check the Hor i zont al Option Fitt ed if the

Fitted mirror mechanism for reading horizontal and vertical
bar codes is fitted.
Test LEDs... Performs the LED test. This will illuminate each LED
for a short period of time starting at position 1 on the
left of the rack.
RS485 Test... Performs the RS485 test. Performs a loop back test
on the RS485 communications link.
This does not check that the scanner is function-
ing!
14.5.1.7 General

play devices reply.
14.5.2 Initialise and Self Test
Sends the commands to the rack scanner to initialise and execute its self test. Resets
the laser scanner bar code. The rack bar code scanner is initialised ready for use dur-
ing rack loading. This command can take over 30 seconds to complete.
The scanner is configured as below:
1. External trigger signal disabled ("PT00026001")
2. Reset with the scanner 'H' command
3. Motor is turned on and the motor status is monitored for the motor to turn on.
4. Scanner focused at position 0.
5. Scanner focused at position 11.
6. Laser turned on.
7. Laser turned off.
The response will contain any error messages.
This command must be sent before the scanner can be used for any rack loading
operations.

Rack System Evolis
Service Software
Performs a sequence of tests to verify the rack module. When the Module Test button
is pressed, the following sequence is performed. The user must update the user field,
this data is stored in the results file.
1. Selftest
Performs the selftest. Performs the following tests in sequence:
• Door test
• Trigger test
• LED test
• Sensors test
• RS485 test
• Tests the scanner
• Executes a selftest
2. Rack RS485
Performs a loop back test on the bar code scanner RS485 link. No external
connection is required for this test.
3. Rack scanner communications
Checks the BCL148 is communicating by obtaining it's firmware version.
4. Rack LEDs
Tests each LED is working correctly.
5. Rack sensors
Checks that each rack sensor is working.
6. Rack door sensor
Checks the door sensor in functioning.
7. Rack trigger
Checks the rack trigger sensor is functioning.

Evolis CPS Module (COP)
Safety and Hints
15 CPS Module (COP)

Figure 15-1: COP
ST1 LED 01 - LED front left ERROR/DRAWER

ST2 LED 23 - LED front left POWER/READY
ST3 BSL
ST4 PC RS232 (back side)
ST5 Lock sensor right

CPS Module (COP) Evolis
ST6 Lock sensor left

ST7 Left and right closed
ST8 Tip closed
ST9 Cover sensor
ST10 Tip lock sensor
ST11 Sample rack
ST12 Plate bar code SQ 40
ST13 Spare Out
ST14 Plate bar code SRP100
ST15 Lumino / RS232
ST16 Pipettor / RS232
ST17 POWER
ST18 Tip draw lock
ST19 Left and right lock
ST20 Power lumino
ST21 Power pipettor
ST22 Washer / RS232
ST23 Reader / RS232
ST24 Module 3 / RS232
ST26 Sample rack bar code
ST27 Power washer
ST28 Power reader
ST29 Power module 3
ST30 Power module 2
ST32 Plate bar code / RS232
ST34 Plate transport / RS232
ST35 Incubators / RS232
ST36 Power Plate bar code
ST37 Power module 8
ST38 Power Plate Transport
ST39 Power Incubators
ST40 Pipette station area 1
ST41 Waste sensor


ST45 LED 67 - LED front right (LED Reserve)
ST46 LED 56 - LED front right (LED Instrument Drawer and Plate
load / unload)
ST47 System fluid
ST48 Rack and mirror
ST49 Left and right lock

Maintenance
15.3 Maintenance
15.3.1 DIP-Switches
Positions of DIP-Switch 1 (SW1) and 2 (SW2) see chapter 15.2 on page 15-1.
DIP switch Function OFF ON
1 Download no yes
2 Reset no yes
3 - x -
4 - x -
Table 15-1: DIP-Switch 1 (SW1)
DIP switch Function OFF ON
1 SRP100 no yes
2 SRP100 no yes
3 SQ40 no yes
4 SQ40 no yes
Table 15-2: DIP-Switch 2 (SW2) - bar code scanner selection SRP100
15.3.2 Replacement of COP PCB
Removal

3. Open stainless steel cover above the tip drawer.
4. Disconnect all connectors.
Figure 15-2: COP PCB

Maintenance
Pay attention to the lettering of the connectors!
5. Open the retaining screws.

6. Remove the COP PCB.
Installation 7. Set the DIP switches (see chapter 15.3.1 on page 15-4).
8. Install the new COP PCB.
10. Connect all connectors (see back of the metal sheet or chapter 15.2 on page 15-1).
11. Install the firmware (see chapter 15.5 on page 15-13).

Service Software
When the COP module is invoked, the application attempts to communicate to the
system and COP module. When successful the following dialogue will be displayed
with the firmware version number and serial number displayed. If no module is de-
tected, nothing will be shown for the firmware version number and serial number.
Figure 15-3: COP module main window
15.4.1 Functions of the COP Service Software
15.4.1.1 Instrument

number.
washer. It will only accept up to 16 alphanumeric
update.

Service Software
15.4.1.2 Rack
1 - 12 Each of the twelve check boxes indicate the status of

the corresponding rack position. Checked means
occupied.
Trigger The trigger is checked when the light barrier across
the opening of the rack is broken by a rack insertion.
Door Open The door open field is checked when the door sensor
detects an open door
Get Status Updates the status for the rack sensors, door sensor
and trigger.
Get Version Retrieves and displays the scanner firmware version
number.
Test LEDs... Tests operation of the rack indicator LEDs.
Table 15-4: Fields and buttons of the R a c k area
15.4.1.3 Plate Carrier Sensor
#1 - #4 Shows for each of the 4 pipette positions the status

of the plate carrier sensor. No displayed if empty. Yes
if plate carrier detected.
Get Status Updates the status in status display boxes.
15.4.1.4 Waste and Fluid Sensors
Waste Full Check boxes will be checked, if sensor active.

System Fluid Low Check boxes will be checked, if sensor active.
Get Status Updates the status in status display boxes.
Table 15-6: Fields and buttons of the W a s t e a n d F l u i d S e n s o r s

area

Service Software
15.4.1.5 Instrument Draw
Open The check box indicates the status of the draw,

checked means open.
Lock Locks the drawer, the open status is updated.
Unlock Unlocks the drawer, the open status is updated.
Table 15-7: Fields and buttons of the I n s t r u m e n t D r a w area
15.4.1.6 Microplate Barcode
IC Version The bar code IC version will be read and displayed.

Barcode Enabled The check box turns on the scanner laser when the
S e t E n a b l e button is pressed to send the com-
mand to the bar code reader.
Set Enable If the barcode enable check box is active, pressing
this button sends the command. Only the last code
read can be stored for retrieval by the read com-
mand.
Read Prompts the user to load a plate and read the code.
This requires the plate transport service software
to be active!
Selftest The decoder IC is sent a hard reset command. The
configuration string, a disable scanning command,
and the version string is checked to ensure the
decoder IC is communicating.
Table 15-8: Fields and buttons of the M i c r o p l a t e B a r c o d e area
15.4.1.7 Tip Draw
Open The check box indicates the status of the draw,

checked means open.
Lock Locks the draw, the open status is updated.
Unlock Unlocks the draw, the open status is updated.
Table 15-9: Fields and buttons of the T i p D r a w area

Service Software
15.4.1.8 Cover
Open The check box indicates the status of the cover,

checked means open.
Lock Locks the cover, the open status is updated.
Unlock Unlocks the cover, the open status is updated.
Table 15-10: Fields and buttons of the C o v e r area
Selftest Performs the selftest. Performs the EEPROM check-

sum and the UART serial ports tests in sequence.
If an error occurs during any test, the appropriate
error response is given and the test stops.

Firmware...
15.4.1.11 LEDs
Control for the 4-PS system LEDs.
P o w e r , R e a d y, Check the appropriate box to turn on a specific indi-

Error, Tip Draw, cator LED.
P l a t e L o a d, and
Instrument Draw
Set LEDs Depending on the status of each LED's check box,
this command turns on or off the LED.
Table 15-13: Fields and buttons of the L E D s area

Service Software
15.4.1.12 General

play devices reply.
Runs the sequence of tests that verify correct operation of the COP module. When
the M o d u l e T e s t . . . button is pressed, the following sequence is performed. The
user must update the user field, this data is stored in the results file.
1. Unique identification
3. Serial number
4. Parameter
5. Selftest
Performs selftest.
6. LED
Tests status LEDs
7. Plate carrier sensors
Tests plate carrier sensors.
8. Waste sensor
Tests waste sensor.
9. System fluid sensor
Tests system fluid sensor.
10. Instrument draw sensor
Tests draw sensor.
11. Instrument draw lock
Tests draw lock.
12. Tip draw sensor
Tests draw sensor.
13. Tip draw lock
Tests tip draw lock.
14. Serial port test
Loop back test on each serial port. Requires look back cable.
15. Rack RS485
Loop back test on RS485 communication link.
Reads scanner firmware version.
17. Rack LEDs
Flashes each rack LED.

Service Software
18. Rack Sensors

Tests each rack sensor.
19. Rack door sensor
Tests door sensor.
20. Rack trigger
Tests trigger signal.
21. Micro plate barcode
Reads the HP decoder IC version.
Runs the sequence of tests that verify correct operation of the COP board. When the
B o a r d T e s t . . . button is pressed, the following sequence is performed. The user
must update the user field, this data is stored in the results file.
1. Unique identification
3. Serial number
4. Parameter
5. Selftest
Performs selftest.
6. LED
Tests status LEDs
7. Plate carrier sensors
Tests plate carrier sensors.
8. Waste sensor
Tests waste sensor.
9. System fluid sensor
Tests system fluid sensor.
10. Instrument draw sensor
Tests draw sensor.
11. Instrument draw lock
Tests draw lock.
12. Tip draw sensor
Tests draw sensor.
13. Tip draw lock
Tests tip draw lock.
14. Serial port test
Loop back test on each serial port. Requires look back cable.
15. Rack RS485
Loop back test on RS485 communication link.
Reads scanner firmware version.
17. Rack LEDs
Flashes each rack LED.

Service Software
18. Rack Sensors

Tests each rack sensor.
19. Rack door sensor
Tests door sensor.
20. Rack trigger
Tests trigger signal.
21. Micro plate barcode
Reads the HP decoder IC version.

Firmware Upgrade
1. Invokes the firmware upgrade dialogue box with the Up g r a d e

F i r m w a r e . . . button. It is assumed the new firmware file *.h86 resides
within the COP sub-directory, as described within the INI file.
If front panel LEDs don’t light up then firmware upgrade didn’t take!
Figure 15-4: COP firmware upgrade dialogue
If no firmware has ever been installed you must use recovery mode or if an
error occurred during a previous upgrade!
2. After you press the O K button the message to enter recovery mode is dis-
played.
3. Assuming power is applied to the board, on the 4-way DIP switch SW1 turn
ON Pin 1 (see chapter 15.2 on page 15-1).
4. Switch off the instrument.
5. Switch on the instrument.
6. Toggle Pin 2, this will put the board into bootstrap (or Recovery) mode.
7. Press the O K button.
The download should then follow.
8. If the progress indicator does not change, press the Ca n c e l button, cycle
the power, and repeat the process.
9. Once the download is complete, you must turn OFF Pin 1. Otherwise the
device remains in bootstrap mode and will not work.

3. Click on the Sy ste m tab.

Firmware Upgrade
The file (COP.H86) used to update the firmware must be stored in the PC
software directory (e. g. C:\BioRad\System).
If an error should occur during the upgrade carry out the following steps or
use the service software (see chapter 15.5.1 on page 15-13)!
4. Assuming power is applied to the board, on the 4-way DIP switch SW1 turn
ON Pin 1 (see chapter 15.2 on page 15-1).
5. Toggle Pin 2, this will put the board into Bootstrap (or Recovery) mode.
8. Once the download is complete, you must turn OFF Pin 1, otherwise the
device remains in bootstrap mode and will not work.
9. When finished click the O K button.

Evolis Power Supply
Safety and Hints
16 Power Supply

16.2 Maintenance
16.2.1 Replacement of the Power Supply
There are no serviceable parts! When it is faulty, then replace the power sup-
ply!
Removal

3. Open stainless steel cover above the tip drawer.
4. If no short cross tip screwdriver is available, then remove the rack system (see
5. Pull out the tip drawer.
6. Disconnect the power connector at COP PCB ST17 (see chapter 15.2 on page 15-
1)
7. Open the nuts of the earth bolt.
8. Remove the toothed washers and the ground wires.
Figure 16-1: Power supply

Power Supply Evolis
Maintenance
Figure 16-2: Earth bolt
9. Remove screws 'A' at the ground plate.

10. Lift out the power supply unit.
11. Remove screws from ground plate back side.
12. Remove the power supply.
Installation 13. Insert the new power supply.

14. Tighten screws from ground plate back side.
15. Insert the power supply unit.
16. Tighten screws 'A' at the ground plate.
17. Install the toothed washers and the ground wires. Consider the order.
18. Tighten the nuts of the earth bolt.
19. Connect the power connector at COP PCB ST17 (see chapter 15.2 on page 15-1)
20. Push in the tip drawer.
22. Close stainless steel cover ’1’ above the tip drawer (see chapter 11.2 on page 11-
2).

Evolis Troubleshooting and Error Messages
Error Messages of the User Software
17 Troubleshooting and Error Messages
displayed messages! I. e., the displayed X-coordinate means the technical Y-
17.1 Error Messages of the User Software
System messages appear in the status bar of the user software, error messages are
displayed in a separate window, which has to be confirmed.
"%1" and "%2" are place holders for a system module or the designation of a plate,
a reagent or an error number.
Error: Cause: Action:
Argument error in com- During initialisation procedure. Reinstall the firmware for the con-
mand ... Faulty firmware is installed. cerning module (see chapter 17.2 on
page 17-12, chapter 17.3 on page 17-19, or
chapter 17.4 on page 17-20). If error
recurs the PCB of concerning mod-
ule has to be checked.
Aspirate check failed During the run. R e t r y button: pipettor will dispense
for reagent %1 Aspirate step of reagent was faulty. back the aspirated liquid and repeats
the aspirate step.
A b o r t P l a t e button: Plate will be
aborted.
C o n t i n u e button: System goes
on but all concerning samples will be
flagged.
Clot detected in patient During the run. S k i p S a m p l e button: system will
sample %1 skip the concerning sample and will
go on with the worklist.
A b o r t P l a t e button: plate will be
aborted.
C o n t i n u e button: system goes on
but concerning sample will be
flagged.
Colorimeter %1 not During initialisation procedure or Please, restart the software and sys-
homed during a reading step. tem. If the error recurs the colorime-
The X-motor of the colorimeter is not ter module has to be checked (see
in the home position. chapter 6 on page 6-1). If the error
occurs during a run, please press
the A b o r t button to cancel the
worklist. After this error occurs a
recovery isn’t possible.

Troubleshooting and Error Messages Evolis
Colorimeter A/D error During the initialisation procedure or Please, restart the system. If the
during a run. error recurs, the colorimeter module
Error of the analog/digital converter has to be checked (see chapter 6 on
of the colorimeter. page 6-1).
Colorimeter A/D over During the initialisation procedure or R e t r y button: system will try to
range error during a run. repeat the last step.
Upper limit of colorimeter A/D has I g n o r e button: not advisable
been exceeded due to the signal cause system cannot go on without
height of the pre-selected resolution. sequence errors.
Press the R e t r y button. If the error
recurs, abort the worklist and check
the filters. If error recurs after check-
ing the filters, the whole colorimeter
module has to be checked (see
chapter 6 on page 6-1).
Colorimeter A/D under During the initialisation procedure or R e t r y button: system will try to
range error during a run. repeat the last step.
Too less light reaches the electronic I g n o r e button: not advisable
of colorimeter. cause system cannot go on without
sequence errors.
A b o r t button: the worklist will be
aborted.
recurs, abort the worklist. The whole
colorimeter module has to be
checked.
The halogen lamp of the colorimeter
is faulty and has to be replaced. If
the error persists, the optical compo-
nents in the photometer (filter, upper
or lower optic block) may be dirty.
Clean the photometer or replace it
(see chapter 6 on page 6-1).
Colorimeter back- During the initialisation procedure or Restart the software to initialise the
ground light level error during a run. colorimeter again. Please check if
Typically occurs when light entered the colorimeter flap is closed and all
the measurement chamber. filters are installed.
Colorimeter EEPROM Error during EEPROM reading or Initialize the module again. If the
error writing. error recurs the colorimeter PCB has
to be checked. Replace the photom-
eter PCB or replace the photometer
(see chapter 6 on page 6-1).
Colorimeter filter %1 During initialisation procedure. Restart the software to initialise the
error The gain factor for the respective fil- colorimeter again, after checking the
ter cannot be identified. filter configuration. If error recurs,
change the concerning filter (see

Colorimeter filter motor During the initialisation procedure. Restart the software. If the error
home error The system does not recognize the recurs, the filter wheel has to be
current position of the filter motor. checked.
Colorimeter filter motor During the initialisation procedure. Restart the software. If the error
movement error The movement of the filter wheel is recurs, the filter wheel has to be
faulty. checked.
Colorimeter lamp error During the initialisation procedure. Replace the halogen lamp (see
Halogen lamp of colorimeter is chapter 6.5.3 on page 6-9) and restart
faulty. the software to initialize the colorim-
eter again.
Colorimeter optic chan- During the initialisation procedure. Clean the optical blocks or replace
nel %1 error One of the optical channels is dirty the photometer (see chapter 6 on
or faulty. page 6-1).
Colorimeter plate motor During the initialisation procedure. Restart the software to initialize the
movement error The plate movement is faulty. colorimeter again. If the error recurs
the moving mechanism has to be
checked (see chapter 6 on page 6-1).
Colorimeter plate motor During the initialisation procedure. Restart the software to initialize the
movement home error The plate doesn’t find its home posi- colorimeter again. If the error recurs
tion. the light barriers have to be
checked.
COMGEN error '%1' At start-up. Check correct connection between
Cable connection between PC and PC and analyser. Start PC and ana-
analyser is faulty. lyser again.
COP serial port test At start-up. Check connection between PC and

error Error in serial interface on COP analyser. Start PC and analyser
board. again. Check the connections
between COP and the other compo-
nents. If error recurs, the COP has to
replaced.
Crash cover file After power failure. Y e s button: following message
detected. Do you want appears “Is the system still running”
to try and recover the N o button: software continuous with
worklist? initialising the system. Old worklist
will be deleted.
• Is system still running:
Y e s button: systems continuous
with the next worklist step.
N o button: system initializing
first the modules before continu-
ous the next worklist step.
Error during assay lay- After adding assay and patient to the Push O K button and reduce the
out reduction. Reduce plate. Too many samples are used numbers of patients, that a maxi-
the number of patient on this plate. mum of 96 wells on one plate are
samples. Check that used.
the assay layout is
reducible.

Error scheduling plate After adding plate and assay. The worklist or the assay has to be
'...' The Assay programming is not cor- changed accordingly.
rect or the combination of different
plates cannot be scheduled.
Error: Argument error in During initialisation procedure. Restart software and analyser. If the
... Component cannot be actuated. error recurs, the concerning module
has to be checked (see chapter 17.2 on
page 17-12, chapter 17.3 on page 17-19, or
Incubator heater %1 During the initialisation procedure or The heater foil of concerning incuba-
error during the run. tor box has to be checked (see
The heater foil of incubator box %1 chapter 10 on page 10-1).
is faulty.
Incubator sensor %1 During the initialisation procedure or The temperature sensor of concern-
error during the run. ing incubator box has to be checked
The temperature sensor of incubator (see chapter 10 on page 10-1).
box is faulty.
Insufficient volume of During the run. R e t r y button: system will try to
pre-dilution %1 System cannot find enough volume repeat the last measurement of level
in pre-dilution. height.
A b o r t button: the concerning sam-
ple will be aborted.
A b o r t P l a t e button: the whole
plate will be aborted.
I g n o r e button: The concerning
sample will be flagged. System goes
on with the next pre-dilution.
Insufficient volume of At reagent check if volume of rea- A b o r t c h e c k button: reagent
reagent %1 gent is insufficient. check will be aborted. The system
goes on with the worklist.
R e f i l l b o t t l e button: software
jumps back to the l o a d i n g w i n -
d o w where reagents can be filled
up.
I g n o r e button: system will go on
with checking the next reagent.
To make sure that worklist will run
without miss pipetting errors, please
press the R e f i l l b o t t l e button
and make sure that enough reagent
liquid is available.

Insufficient volume of During the run if volume of sample is R e t r y button: system will try to
sample %1 insufficient. Only possible if R e a - repeat the last measurement of level
g e n t c h e c k is disabled. height.
A b o r t button: the sample will be
aborted.
A b o r t P l a t e button: the whole
plate will be aborted.
I g n o r e button: The concerning
sample will be flagged. Systems go
on with the next sample.
Invalid pipettor coordi- After adding plate and assay. The Push the O K button. Modify the
nates on plate ..., label assay programming is faulty. A label assay definition and restart the work-
sample … Check that of a sample is undefined. list.
the dispense and aspi-
rate labels are consist-
ent.
No disposable tips left During the run. Automatically appearance of the
No more tips available or found. loading window after system mes-
sage occurs. Load the correct tips to
the suggested position. After push-
ing the O K button the worklist will
go on.
No liquid detected for ... During a run. R e t r y button: system will check
Insufficient volume for sample ... or level of sample or reagent, again.
reagent ... I g n o r e button: system will go on
although if there is not enough liquid
in the bottle. All concerning samples
will be flagged.
Note: air can be pipetted if you
will push the Ignore button.
A b o r t button: The worklist will be
aborted. To make sure that the work-
list will run without miss pipetting
errors, push the A b o r t button and
enable the R e a g e n t c h e c k in the
panel options. After that, you have to
start the worklist again. The old
worklist cannot be recovered.
A b o r t P l a t e button: The plate
will be aborted.
The status is documented in the
active event log.
No respond to com- General software error. Communica- A b o r t button: the worklist will be
mand '%1' tion between PC and analyser is aborted.
interrupted. R e t r y button: PC will try to connect
to system again. If error message
recurs after pushing R e t r y, check
RS232 cable or restart analyser and
PC.

Pipettor error 0x0E - LX During a pipettor movement. R e t r y button: system will try to
position not reached Pipettor crashes or mechanical reach the position again, after the
problems. axis will initialize again.
I g n o r e button: not advisable
cause system cannot go on without
sequence errors.
A b o r t button: The worklist will be
aborted.
Press the R e t r y button to repeat
the last step, if the error recurs
please open system flap and check
if there any obstacles that disturb the
pipettor movement. If there are no
obstacles, the pipettor module has to
be checked.
Pipettor open loop/ Pipettor crash during a run. R e t r y button: system will try to
overload error. repeat the former pipetting step.
I g n o r e button: system will con-
tinue with the next pipetting step.
A b o r t button: the whole plate will
be aborted.
If system doesn’t go on after pushing
R e t r y or I g n o r e press A b o r t
and restart the system and the soft-
ware again.
Plate transport %1 During the initialisation procedure. After error message occurs check if
motor home error Plate transport cannot reach or find something jammed the plate trans-
the home position. port.
Press the O K button and restart
software to initialise the plate trans-
port again.If the error recurs, the
plate transport mechanism has to be
checked
Plate transport %1 During the initialisation procedure or R e t r y button: system will try to
motor movement error during the run. repeat the last movement step.
Plate transport motor (X, Y, or Z) I g n o r e button: not advisable
can’t reach the demanded position. cause system cannot go on without
sequence errors.
A b o r t button: plate will be aborted.
After error message occurs, make
sure that there are no obstacles that
jammed the plate transports move-
ment. Press the R e t r y button, if
the error recurs the plate transport

Plate transport %1 During the initialisation procedure. Restart software, to initialise the
motor not homed Plate transport motor (X, Y, or Z) plate transport again.
cannot find home position. If the error recurs, the light barriers
of plate transport have to be
Plate transport carrier During plate transport movement. R e t r y button: plate transport will
error Plate transport crashes at load/ try to load/unload the plate again.
unload movement. Plate holder does I g n o r e button: not advisable
not move far enough into the instru- cause system cannot go on without
ment, so that the light barrier is not sequence errors.
interrupted. A b o r t button: system will try to
abort the plate.
If error recurs after pressing the
R e t r y button the plate transport
position has to be aligned again (see
Plate transport EEP- EEPROM error while reading/writ- Restart system again. If error recurs,
ROM error ing procedure. the plate transport PCB has to be
changed (see chapter 6 on page 6-1).
Plate transport error Error in plate transport in case of Push the R e t r y button. If the error
increased resistance. recurs, try to locate the cause of the
resistance (blocking) and eliminate
it. If no mechanical blockage is evi-
dent, check the plate transport (see
Please close system During initialisation procedure. Sys- Close the system flap and push the
flap. tem flap isn’t closed. O K button. If the error recurs after
closing the flap the closing mecha-
nism has to be checked.
Please close the instru- During initialisation procedure. Close instrument drawer and push
ment drawer. Instrument drawer isn’t closed. O K button. If the error recurs after
closing the instrument drawer, the
closing mechanism has to be
checked.
Please close the load/ After loading/unloading the micro Close load/unload door and push
unload door. plate. O K button. If the error recurs after
closing load/unload door, the closing
mechanism or the door switch, has
to be checked.
Please close the tip During initialisation procedure. Tip Close tip drawer and push the O K
drawer. drawer isn’t closed. button. If the error recurs after clos-
ing the tip drawer, the closing mech-
anism has to be checked.
Please configure the After adding plate and assay. Wrong Push the O K button. Make sure
system in preparation pre-dilution area is defined. that correct pre-dilution area is cho-
for a standard worklist. sen for this assay and start worklist
Ensure that the dilution again.
tube rack is inserted.

Rack scanner focusing During a reading step of bar coded If error occurs please use the possi-
error sample/reagent rack. bility to allocate the reagents and
The bar code scanner of the reagent samples, manually. The bar code
and sample racks cannot be scanner has to be checked (see
focused. chapter 14 on page 14-1).
Rack scanner motor Motor error in scanner of reagent If error occurs please use the possi-
error and sample rack. Scanner firmware bility to allocate the reagents and
does not work correctly. Electronic or samples, manually. The bar code
mechanical problems of scanner. scanner has to be checked (see
Rack scanner not During the initialisation procedure. If error occurs please use the possi-
detected Bar code scanner of the loading bay bility to allocate the reagents and
is not connected. samples, manually. The bar code
scanner has to be checked (see
Reagent ... is undefined After adding plate, assay and sam- Open assay and add the missing
ple. reagent to reagent database. Restart
A reagent has not been defined. the worklist.
Note: the changes have to be saved,
with the S a v e button before they
will get active.
RS232 write error - Error in interface PC / analyser. Check connection between PC and
command: '%1' analyser. Start PC and analyser
again. If error recurs, the system has
to be checked.
Some required After the loading dialogue. Push the O K button. Load all
resources have not Not all required reagents have been resources from the unallocated
allocated to system allocated to a position. resources field into the appropriate
positions position (reagents, samples, dilution
tubes/plates, tips, buffers).
Suspect tip pick-up During tip pick-up After the error occurs the software
Pipettor cannot pick-up pipettor tip goes on with the next tip automati-
correctly (does not move deep cally, if the error recurs the teaching
enough into the tip). positions and the disposable tip
adapter have to be checked (see
System fluid low During the initialisation procedure or Fill up system fluid container with
during the run. deionised water and press the O K
System fluid for pipettor too low. button.
System waste full. During initialisation procedure or Emptying the waste container and
Empty the waste con- during the run. press the O K button. If the error
tainer. recurs after emptying the waste con-
tainer the level sensor has to check
The disposable tips During the tip type detection. After pushing the O K button the
have been incorrectly Software detected a wrong type of software displays to the loading dia-
loaded. tip. logue where you have to check if the
correct type of tips (300 µl or
1100 µl) are loaded to the correct
position.

The plate transport can- During the run. Abort the worklist, and restart soft-
not find a route from its Plate transport has no information ware to initialize the plate transport.
current position to its about its present position. Restart the worklist again. If the error
next destination recurs the plate transport has to be
There was an error After finishing a plate and getting a R e t r y button: software will try to
found when printing the result. start the print job, again.
Document …to LPT1: Canc el button: The print job will
The device is not con- be cancelled.
nected. Do you want to
Please check that the printer is
retry or cancel the job?
switched on and all cables are con-
nected. Make sure that the right
printer driver is installed.
Tip eject failure Error during the tip ejection. Remove tip manually from pipettor
or trigger eject mechanism manually.
Press the R e t r y button after
removing the tip manually. The sys-
tem goes on with the next step. If the
error recurs the disposable tip
adapter has to be checked (see
Unknown colorimeter Unknown photometer error. Restart system and software, if the
error code'%1' error recurs, the whole colorimeter
Unknown incubator Unknown incubator error. Restart system and software. If the
error code: '%1' error recurs, the whole incubator
Unknown plate trans- Unknown plate transport error. Abort the worklist, and restart soft-
port error code: '%1' ware to initialise the plate transport.
Restart the worklist. If the error
recurs the plate transport has to be
Unknown washer error Unknown washer error. Restart system and software, if the
code %1 error recurs, the whole washer mod-
ule has to be checked.
Unknown washer error Unknown washer error. Restart system and software. If the
code '%1' error recurs, the whole washer mod-
ule has to be checked (see chapter 7 on
page 7-1).
Verification failed: %1 During the colorimeter verification. If the error occurs, change the lamp
The reader has failed the validation and check the filter configuration.
criteria. Repeat the colorimeter verification
test. If the error recurs the colorime-
ter module has to be checked (see

Washer %1 motor not The washer motor %1 is faulty or the R e t r y button: system will retry to
homed washer isn’t initialised. reach the home position again.
aborted.
Press the “R e t r y button to repeat
the last step. If error recurs press
A b o r t P l a t e button and restart
the software to initialise the washer
again. If the error recurs, the washer
Washer aspirate pump During the initialisation procedure or R e t r y button: software will try to
error during a wash step. activate the aspirate pump again.
The washer aspirate pump or the A b o r t P l a t e button: plate will be
vacuum sensor is faulty. aborted.
Before pressing the Retry button,
please check that all tubes are con-
nected correctly. If the error recurs
the vacuum sensor and the aspirate
pump have to be checked (see
Washer dispense pump During the initialisation procedure or R e t r y button: software tries to
error during a wash step. repeat the dispensing step.
The washer dispense pump is faulty. A b o r t P l a t e button: the plate will
be aborted.
recurs the dispense pumps have to
be checked (see chapter 7 on page 7-1).
Washer EEPROM error EEPROM error while reading/writ- Restart system again. If the error
ing procedure. recurs the washer PCB has to be
changed (see chapter 7 on page 7-1).
Washer head home During the initialisation procedure or O K button: software will cancel the
movement error during a wash step. worklist and jump back to start
Washer lift cannot reach its home menu.
position. Press the O K button to come back
to the start menu, restart software
and system. If error recurs the Z-
motor and the light barriers have to
Washer plate home During the initialisation procedure. O K button: software will cancel the
movement error Washer X-sledge cannot reach the worklist and jump back to start
home position. menu.
Press the O K button to come back
to the start menu, restart software
and system. If error recurs the X-
motor and the light barriers have to

Washer plate motor During initialisation procedure or R e t r y button: System will try to
movement error during a wash step. activate the X-motor again.
aborted.
Press the R e t r y button, if the error
recurs the X-motor has to be
Washer plate move- During a wash step. R e t r y button: System will try to go
ment error Plate transport motor of washer on with the wash step.
faulty. A b o r t P l a t e button: plate will be
aborted.
Before pressing R e t r y check
washer if carrier sledge is jammed,
or a strip of the micro plate in not
inserted correctly.
Select the menu item U t i l i t i e s |
S e l f t e s t to initialise the system
again. If the error persists, check the
washer plate transport (see chapter 7
on page 7-1).
Washer reagent level After loading dialogue or during the R e t r y button: software checks the
low run. level sensor again.
One of the washing liquids is empty. A b o r t button: the worklist will be
aborted.
I g n o r e button: the worklist goes
on without filling up the buffer.
Refill the washer reagent and press
the. If the error recurs after refilling,
check the cables connections of
level sensors.
Washer strip error. Before wash step. R e t r y button: strip check will be
One of the strips of micro plate isn’t repeated.
inserted correctly. A b o r t P l a t e button: Plate will be
aborted.
After error occurs press the R e t r y
button. The system will go on, if the
error recurs abort the plate.
Washer waste full During initialisation procedure or R e t r y button: system will check
during the run. the level sensor again.
Waste bottle “1” is full. A b o r t P l a t e button: plate will be
aborted.
Empty washer waste bottle “1” man-
ually and press the O K button.
If the error recurs, the washer level
sensor has to be checked.
Table 17-1: Error messages of the user software

Plate System Error Messages
17.2 Plate System Error Messages
All error codes from the virtual module, plate transport, photometer/colorimeter,
washer and incubator are prefixed with the:
• Module ID (e.g. 42),
• Assembly code (e.g. 49),
• Control byte (usually 03 for errors),
• Sub assembly code(e.g. 56) and
• Reply code.
• The letters "ER" (hex: '45' + '52'). This indicates the command which
contained the error.
• The code following indicates the nature of the error as indicated below,
depending on the module.
The other devices do not follow the structure described above. Instead they
have individual codes.
Figure 17-1: Structure and example of an hex error string

17.2.1 Received String
First Byte: Mod- To recognize the module messages the first parameter in a command describes the
ule transmitted module.
ID Hex Module
41 Virtual module - Liquid container(see chapter 17.2.3 on page 17-14)

42 Plate transport (see chapter 17.2.4 on page 17-15)
43 Photometer/Colorimeter (see chapter 17.2.5 on page 17-16)
44 Washer (see chapter 17.2.6 on page 17-17)
45 Incubator (see chapter 17.2.7 on page 17-18)
00 COP (see chapter 17.3.1 on page 17-19)
Sample rack scanner (see chapter 17.3.2 on page 17-20)
FD Pipettor (see chapter 17.4.1 on page 17-21)
Table 17-2: First byte: module
Second Byte: As-

sembly
Hex Description
00 to FF Assembly code
Table 17-3: Second byte: assembly
Third Byte: Con-

trol
Hex Description
00 Normal reply
01 Report
03 Fatal ERROR
Table 17-4: Third byte: control
Fourth Byte: Sub

Assembly
Hex Description
00 to FF Sub assembly code
Table 17-5: Fourth byte: sub assembly
Further Byte(s):
Reply
Hex Description
00 to FF Reply can be different length
Table 17-6: Further byte(s): reply

17.2.2 ASCII Codes used in Plate System Error Messages
Hex ASCII Hex ASCII Hex ASCII
41 A 4A J 53 S
42 B 4B K 54 T
43 C 4C L 55 U
44 D 4D M 56 V
45 E 4E N 57 W
46 F 4F O 59 X
47 G 50 P 59 Y
48 H 51 Q 5A Z
49 I 52 R
Table 17-7: Hex-/ASCII-Codes
17.2.3 Virtual Module Errors (Module ID 41)
Reply: Reason: Action:
ERW System waste container is full. Empty the system waste con-
tainer.
ERF System fluid low. Refill the system fluid con-
tainer.
Table 17-8: Virtual module (module ID 41)

17.2.4 Plate Transport Errors (Module ID 42)
ERA Argument error in command. Check that the firmware is the

correct version for the version
of software being run.
ERB Plate transport bar code IC Replace the plate transport
error. bar code scanner.
ERBC The plate bar code scanned Replace the plate with the cor-
was not what was expected. rect one.
ERD Plate load/unload door is 1. Close the plate load/
open while trying to move. unload door.
2. Check the connectors to
the switch.
ERHn Motor not home. n shows the 1. None. The software will
position: reset the plate transport
• ERHX: X-axis home and try again.
• ERHY: Y-axis home 2. Check the function of the
• ERHZ: Z-axis home light barriers (X/Y/Z).
ERMn Motor jammed during move- 1. Clear the obstruction.

ment. n shows the axis: 2. Check movement without
• ERMX: X-axis motor power.
• ERMY: Y-axis 3. Grease and oil again.
• ERMZ: Z-axis 4. Check belt tension.
ERP Plate carrier sensor failure. 1. Check that plate carrier is

breaking the sensor.
2. Check connectors and
function of light barrier.
ERR Firmware was unable to com-
pute a safe route between the
two positions.
ERW EEPROM error. 1. Download firmware.
2. Load global settings.
3. Replace the PCB.
Table 17-9: Plate transport (module ID 42)

17.2.5 Photometer/Colorimeter Errors (Module ID 43)
ERA Argument error in command. Check that the firmware is the

ERB Background light levels too 1. Check position of lamp.
high. 2. Check filter positions.
3. Replace the module.
ERC A/D conversion error. Replace the PCB.
ERFn Filter error. n shows the filter 1. Check luminosity of lamp.
position. 2. Replace the filter.
ERHn Motor not homed. n shows the 1. None. The software will
motor: reset the photometer and
• ERHX: X-motor (plate car- try again.
rier) 2. Check light sensors (func-
• ERHY: Y-motor (filter tion and position).
motor) 3. Check belt tension.
ERL Lamp has blown. Replace the lamp.

ERMn Motor is jammed. n shows the 1. Clear the obstruction.
motor: 2. Check movement without
• ERMX: X-motor (plate car- motor power.
rier) 3. Check belt tension.
• ERMY: Y-motor (filter
motor)
ERP Plate carrier error. 1. Check that the plate carrier
correctly breaks the sen-
sor.
2. Teach the plate transport
position again.
ERPD No scan data available. n
shows the filter position.
ERPOn A/D over-range error. n shows 1. Replace the PCB.
the filter position. 2. Check lamp position.
3. Check filters.
ERPUn A/D under-range error. n 1. Check filters.
shows the filter position. 2. Replace the PCB.
ERPW Reading over-run error. Replace the PCB.
ERR A/D reference voltage error. Replace the PCB.
ERTn Faulty optic channel. n shows Check that the optic channel
the filter position. is not obstructed.
3. Replace the PCB.
Table 17-10: Photometer/Colorimeter (module ID 43)

17.2.6 Washer Errors (Module ID 44)
ERA Argument error. Check that the firmware is the

ERE EEPROM error. 1. Load global settings.
2. Replace the EEPROM.
ERHn Motor not homed. n shows the 1. None. The software will
motor: reset the washer and try
• ERHX: X-axis home again.
• ERHZ: Z-axis home 2. Check function and posi-
tion of light barriers.
3. Check movement without
motor power.
4. Check function of Z- and
X-motor.
5. Check belt tension.
ERMn Motor has become jammed Clear the obstruction.
during movement. n shows
the motor:
• ERMX: X-motor
• ERMZ: Z-motor
ERP Plate carrier sensor error. Check that the plate carrier is
breaking the sensor.
ERSA Washer waste bottle is full. 1. Empty the washer waste
bottle.
2. Check cable connectors.
3. Check fill sensor
ERSR Reagent level is low. 1. Refill the reagent bottle.
2. Check cable connectors.
3. Check fill sensor
ERRA Aspirate pump error: Set the vacuum sensor.
Change the vacuum sensor.
Check aspirate pump electri-
cal connections. Replace the
aspirate pump.
ERRD Dispense pump error. 1. Check electrical connec-
tions.
2. Check tubing connections.
3. Replace the dispense
pump.
ERRW Waste pump error. Replace the waste pump.
ERV Valve error. Replace the valve.
3. Replace the PCB.
Table 17-11: Washer (module ID 44)

17.2.7 Incubator Errors (Module ID 45)
ERA Argument error. This is a criti- Check that the firmware is the
cal error condition. correct version for the version
ERHn Heater error. n shows the 1. Check cable connections.
incubator group number: 2. Replace the incubator.
• 1: Incubator 1 and 2
• 2: Incubator 3 and 4
ERKC Shake calibration failed. The
55% shake amplitude drive
signal value could not be
found.
ERKOI Shake override idle position Check the shake PCB and
frequency out of range. The hall-sensor are connected and
override off (or idle) position functional.
was outside of the acceptable
limits.
ERKOO Shake override on position Check the shake PCB and
frequency out of range. The hall-sensor are connected and
override on was outside of the functional.
acceptable limits.
ERKR Shake position frequency out Check the shake PCB and
of range. The shake fre- hall-sensor are connected and
quency measured did not functional.
appear to be a valid measure-
ment.
ERKT Shake position edge time out. 1. Open incubator and look
No edge was detected to the for mechanical obstruc-
frequency signal from the tions.
shake PCB. 2. Check the shake PCB and
hall-sensor are connected
and functional.
ERP Plate carrier sensor error. Check that the plate carrier
breaks the sensor.
ERTn Temperature sensor error. n 1. Check cable connections.
shows the sensor number or 2. Replace the incubator or
name: ambient sensor.
• A: ambient sensor is read-
ing outside of a valid range
• 0, 2, 4, 6: Incubator lower
sensor of incubator 1, 2, 3,
4
• 1, 3, 5, 7: Incubator upper
sensor of incubator 1, 2, 3,
4

COP and Sample Rack Scanner Error Messages

3. Replace the PCB.
Table 17-12: Incubator (module ID 45)
17.3 COP and Sample Rack Scanner Error

Messages
All error codes from the COP and the sample rack scanner are prefixed with the:
• Module ID (e.g. 00),
• Command ID (e.g. D0),
• Command Parameters (e.g. 54) and
• Reply code (e.g. 11).
17.3.1 COP Errors (Module ID 00)
Code: Reason: Action:
00D05410 COP EEPROM error. Replace the EEPROM.

00D05411 COP serial port error. Replace the COP PCB.
Table 17-13: COP (module ID 00)
Error message: Meaning:
Instrument Draw Error: 01 Switch not closed.

Pipettor: Cover Lock Error Cover not closed.
Tip Draw Error: 01 Switch (black) left not closed.
Tip Draw Error: 02 Switch (black) right not closed.
Tip Draw Error: 03 Lock mechanism left misaligned.
Tip Draw Error: 04 Lock mechanism right misaligned.
Table 17-14: Error messages

Pipettor Error Messages
17.3.2 Sample rack scanner errors (Module ID 00)
Code: Reason: Action:
00D5543C Scanner command timeout.

00D5543D Scanner not connected. Check the scanner connec-
tions.
00D5543E Rack command could not be
sent.
00D5543F Scanner motor error. Replace the scanner.
00D55440 Scanner focusing error. Replace the scanner.
Table 17-15: Sample Rack Scanner (module ID 00)
17.4 Pipettor Error Messages
displayed messages! I. e., the displayed X-coordinate means the technical Y-
All error codes from the Pipettor are prefixed with the:
• Module ID (e.g. FD),
• Error Classification:
• Fatal Error (FF),
• Warning (FE),
• Internal Time LSB and MSB (e.g. 3433),
• Error Code (e.g. 2A) and
• Parameters (e.g. 11).

17.4.1 Pipettor Errors (Module ID FD)
Error
Meaning: Fatal:
Code:
01 Unknown command. no
02 Execution delay. Unable to meet specified execution time. no
03 Transmission data lost. Receiver off line. no
04 The processor was reset by watchdog or trap. Software failure, yes
processor hardware failure.
0E Sledge drive (X-axis) position not reached. Too much friction. yes
10 DC-drive (Y-axis) position not reached. yes
12 Z-position not reached. yes
18 Access to undefined target. yes
1E Command parameter out of range. yes
2A Diluter answer time out (see table 17-18 on page 17-24). yes
2B Diluter checksum error (see table 17-18 on page 17-24). yes
2C Diluter error (see table 17-18 on page 17-24). yes
30 No liquid found. no
33 Not enough liquid. no
42 Can't clear reference switch. Reference switch does not turn yes
OFF.
43 Can't find limit switch / time out. Reference switch does not yes
turn ON.
45
50 Internal error. yes
5A No terminator in pump string. yes
5C Not enough parameters for specified command. yes
70 Disposable dropped. yes
82 Open loop / overload error. Missing encoder feedback. Motor yes
doesn't move. Excessive load, high friction
83 Left: No LLD signal. Missing cable connection to probe, hard- no
ware error.
85 Left: Bad LLD signal. Bad cable connection to probe, bad no
grounding conditions, not enough liquid.
Table 17-16: Pipettor Error Commands (module ID FD)
In the case that an axis parameter is included within the error message the following
assignment is valid:

Parameter Axis
0 X-axis
1 Y-axis
4 Z-axis
Table 17-17: Axis parameter

Parameter: Reason: Action:
00 No error -
01 Initialisation error This error occurs if the pump cannot be initial-
ised. Check the pump for possible obstruc-
tions or loose connections before you try a
new initialisation. The pump does not accept
commands as long as it was initialised suc-
cessfully.
02 Faulty command This error occurs if a faulty command was
given. Correct the command and send it again.
03 Faulty parameter This error occurs if a faulty parameter (<n>)
was entered with a command. Correct the
parameter and send the corrected command.
04 Faulty command This error occurs if the command structure or
sequence the communication protocol is faulty. Check
the command sequence and repeat the cor-
rected command sequence.
06 EEPROM error This error occurs if the EEPROM is faulty.
Check the pipettor PCB (see table 11 on page 11-
1).
07 Device not initial- This error occurs if the pump was not initial-
ised ised. To delete the error, initialise the pump.
08 No string found In the EEPROM no string was found at the
in EEPROM selected location. Select a correct location.
09 Piston over- This error occurs if the injector piston loses
loaded steps.The pump must be initialised new,
before a normal process can take place. This
error can be deleted by initializing the pump
new. Starting from firmware version 2.00, the
pump reports the error, but is able to continue
working. The actual absolute position is rede-
termined after losing steps. From this position
the next movement command is executed.In
connection with P- and D-commands (relative
movements) this may lead to aftereffects. If for
example, the plunger loses steps while moving
to position 100 and in the end stands at posi-
tion 97, then a following D100R-command
leads to a parameter error. Therefore, the
pump should be reinitialised after losing steps.
0A Valve overloaded This error occurs if the valve drive loses to
many steps. Frequent or repeated errors of
this kind indicate that the valve should be
replaced. This error can be deleted by initializ-
ing the pump new.
0B Piston movement If the valve is in [B]ypass (= flow-through posi-
not allowed tion) no piston movement commands are
allowed.

Parameter: Reason: Action:
0D Symbol Symbol sequence is too long for the EEPROM

sequence for (>63 bytes). Shorten the string.
EEPROM too
long
0E Excess Pressure This error occurs in connection with the Clot-
Detection, if the pressure becomes excessive
e.g. due to a total blockage. This error can
only be cleared by a new initialisation of the
pump. If the error appears also during initiali-
sation, the attached line and the needle must
be cleaned.
0F Command over- This error occurs if the buffer memory contains
flow too many symbols. Commands in the buffer
must be carried out first before further com-
mands can be sent.
Table 17-18: VP9100 precision syringe pump error codes parameter
17.4.2 Pipettor Troubleshooting
17.4.2.1 Testing the Function of the Z-Limit Switch

The function of the Z limit switch can only be tested if the 24V supply for the arm is
switched on. Therefore the pipettor must be initialised without initialising the drives.
Send Low-Level Command 'FD CF FF FF 00 00 00 00'. Now the LED displays
the limit switch status.
17.4.2.2 Open Loop Error Causes

The 'Open Loop/Overload' Error is generated if the closed loop driver remains satu-
rated too long. Distinguish the following cases for finding the problem:
1. The axis moves very fast (faster than normally)
• Missing Encoder Feedback
• Motor Polarity exchanged (only X drive)
2. The axis does not move at all.
• Motor not connected.
• Missing power supply for motors, fuse blown.
• Power stage defect.
3. Initialisation is successful, when moving fast the error occurs, sometimes as
a rare event.
• High friction.
• Axis can not move free, moving parts come in contact to housing.
• Belt tension too high.
• When initialising: Limit switch out of order. Drive moves against
mechanical limitation.
17.4.2.3 Y-Axis
When initialising the Y stepper motor, the encoder is not used. Successful initialisa-
tion does not proof the encoder function. DC drives always need the encoder.
17.4.2.4 LLD Trouble Shooting (Capacitive LLD)

Wrong Positive Detection:

• Bad contact from coax cable to the tip. Adapter screw not tightened or cor-
roded.
• Bad contact from coax cable shield to toothed rod. Screw not tightened or
corroded.
• Coax cable defective.
• Cable connection from oscillator to main board defect (1-tip arm).
• Air bubbles on the liquid surface.
• When moving down the tip comes in contact with anything else than the liquid
surface.
• Liquid inside the adapter makes a contact between tip and toothed rod.
Wrong Negative Detection:

• No contact from coax cable to the tip. Adapter screw not tightened or cor-
roded.
• Zstart below the liquid level.
• Zmax adjusted above the liquid level.
• Not enough liquid.
• Liquid with very low conductivity (deionised water).
• Liquid containment with very low capacity.
• Liquid inside the adapter makes a contact between tip and toothed rod.
• Disposable tip not conductive.
• LLD disabled (The software of some instruments has an enable switch for the
LLD).
• Instrument ground not connected to pipettor ground.
17.4.2.5 Standard Maintenance Procedure - Lubrication

Most of the problems are caused by insufficient lubrication of the guiding rack (see
17.4.2.6 Air Adjustment of the X-Axis

Check the axis regarding too tight adjustment of the air between the pulley and the
rack (see chapter 11.6 on page 11-27).
17.4.2.7 Adjustment of the X-Axis Rollers

In some cases the adjustment of the rollers on the sledge are too close to the sheet
metal guiding (see chapter 11.6 on page 11-27).
17.4.2.8 Adjustment of the Y-Axis Rollers

In some cases the adjustment of the rollers on the bridge are too close to the sheet
metal guiding (see chapter 11.6 on page 11-27).
17.4.2.9 Timing Belt Tension

• A too high adjusted timing belt tension can cause higher friction and so prob-
lems in the positioning of the bridge.
• A too low adjusted timing belt tension can cause a jumping of the timing belt
on the timing belt pulley. This is causing fault positioning of the system which
can not be recognized by the control software. So a too low adjusted timing
belt tension is dangerous!
See chapter 11.6 on page 11-27

17.4.2.10 Free Movement of the Bridge on the Guiding Mechanism

The bridge must have a free movement in the Y-direction (see chapter 11.6 on page 11-
27).
17.4.2.11 Free Movement of the Upper Rollers on the Guiding Mech-

anism
The bridge must have a free movement in the Y-direction (see chapter 11.6 on page 11-
27).
17.4.2.12 Wear of the Roller Bearings on the Guiding Mechanism

On several Evolis systems (serial number < 50) the following described wear on the
roller bearings can occur. In bad conditions (depending on force directions etc.) a
change of the left and right roller plate against new parts is necessary.
On new systems (serial number > 50) there is a wear protective washer between the
roller bearing and the aluminium roller plate mounted. This washer protects the bear-
ing of getting polluted by material of the roller plate.
See chapter 11.6 on page 11-27

Evolis Technical Data
Environment
18 Technical Data
18.1 Environment
Environment This standard applies equipment designed to be safe at least under the following
Conditions (IEC conditions:
61010-1) • indoor use;
• altitude up to 2000 m;
• temperature 5 °C to 40 °C;
• maximum relative humidity 80% for temperatures up to 31 °C decreasing lin-
early to 50 % relative humidity at 40 °C;
• mains supply voltage fluctuations up to 10 % of the nominal voltage;
• applicable rated pollution degree.
Operation Tem- • 15 °C to 25 °C
perature
18.2 Mains Voltage and Fuses
Analyser
Voltage range: 115 V to 230 V AC

Current range: 4 A (115 V) to 2 A (230 V)
Frequency range: 50 Hz to 60 Hz
Mains fuse: T4A
Computer, Moni- For electrical details of the PC equipment please refer to the technical documentation
tor and Printer of the OEM manufacturer.
18.3 Laser of the Bar Code Scanner
Laser of the rack

system bar code
scanner Class: Class 2 laser product
Maximal output radia- 1.3 mW
tion:
Pulse duration: 70 µs
Emitted wave length: 650 - 690 nm
Standards: EN 60825-1: 2001
Complies with 21 CFR 1040.10 and 1040.11
except for deviations pursuant to Laser Notice
No. 50, dated July 26th, 2001 at the date of man-
ufacture.

Technical Data Evolis
Weights and Dimensions
Laser of the plate

bar code scanner
Class: Class 2 laser product
Maximal output radia- 0.5 mW
tion:
Pulse duration: 10 µs
Emitted wave length: 660 - 680 nm
Standards: EN 60825-1: 2001
Complies with 21 CFR 1040.10 and 1040.11
except for deviations pursuant to Laser Notice
No. 50, dated July 26th, 2001 at the date of man-
ufacture.
18.4 Weights and Dimensions
18.4.1 System with Packaging
Analyser
Weight: 175 kg
Dimensions: 120 cm x 92 cm x 122 cm (W x D x H)
Accessories and
Cover Boxes
Weight: Approximate 90 kg
18.4.2 System without Packaging
Analyser with
Cover
Weight: 130 kg
(Depth with waste bag and completely opened
drawer)
Accessories
Weight: Approximate 84 kg
For details of the PC equipment please refer to the technical documentation of the
OEM manufacturer.

Evolis Circuit Diagrams
Photometer
19 Circuit Diagrams
19.1 Photometer
Figure 19-1: Photometer – Absorbance reader

Circuit Diagrams Evolis
Photometer
Figure 19-2: Photometer – C1610 processor

Photometer
Figure 19-3: Photometer – Plate drive

Photometer
Figure 19-4: Photometer – Power supply

Photometer
Figure 19-5: Photometer – Filter motor drive

Photometer
Figure 19-6: Photometer – Absorbance A/D

Photometer
Figure 19-7: Photometer – Lamp control

Washer
19.2 Washer
Figure 19-8: Washer

Washer
Figure 19-9: Washer – C1610 processor

Washer
Figure 19-10: Washer – Power supply

Washer
Figure 19-11: Washer – Plate drive

Washer
Figure 19-12: Washer – Head drive

Washer
Figure 19-13: Washer – Pump drives

Washer
Figure 19-14: Washer – Sensors

Washer
Figure 19-15: Washer – Wash verification interface

Plate Transport
19.3 Plate Transport
Figure 19-16: Plate transport

Plate Transport
Figure 19-17: Plate transport – C1610 processor

Plate Transport
Figure 19-18: Plate transport – Power supply

Plate Transport
Figure 19-19: Plate transport – X-drive

Plate Transport
Figure 19-20: Plate transport – Y-drive

Plate Transport
Figure 19-21: Plate transport – Z-drive

Plate Transport
Figure 19-22: Plate transport – LED drive

Plate Transport
Figure 19-23: Plate transport - Transition

Incubator
19.4 Incubator
Figure 19-24: Incubator

Incubator
Figure 19-25: Incubator – C1610 processor

Incubator
Figure 19-26: Incubator – Power supply

Incubator
Figure 19-27: Incubator – Heater drives

Incubator
Figure 19-28: Incubator – Temperature sensors

Incubator
Figure 19-29: Incubator – Shake control

Incubator
Figure 19-30: Incubator – Incubator shaker

Pipettor
19.5 Pipettor
Figure 19-31: Pipettor

Pipettor
Figure 19-32: Pipettor - X-Z PCB

Rack System
19.6 Rack System
Figure 19-33: Rack system

CPS Module (COP)
19.7 CPS Module (COP)
Figure 19-34: COP

CPS Module (COP)
Figure 19-35: COP – C1610 processor

CPS Module (COP)
Figure 19-36: COP – Power supply

CPS Module (COP)
Figure 19-37: COP – UARTS 1

CPS Module (COP)

CPS Module (COP)

CPS Module (COP)
Figure 19-40: COP – Logic

CPS Module (COP)
Figure 19-41: COP – Sensors, drives and LEDs

CPS Module (COP)
Figure 19-42: COP – IO expansion

CPS Module (COP)
Figure 19-43: COP – Rack and plate bar code decoder

CPS Module (COP)
Figure 19-44: COP – Module connections

CPS Module (COP)
Figure 19-45: COP – Isolated PC RS232

CPS Module (COP)
Figure 19-46: COP – SRAM

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EVOLIS

EVOLIS, BIO-RAD. All rights reserved.

We reserve the right to make changes in the course of technical development

EVOLIS System Manufacturer: BIO-RAD

1 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

EVOLIS - Service Manual - Version 1.3 TOC-1

3.9 Save System Files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

5 Service Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

TOC-2 EVOLIS - Service Manual - Version 1.3

6.6.1 Adjustment of Optical Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

8 Plate Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

EVOLIS - Service Manual - Version 1.3 TOC-3

8.5.2 Replacement of Plate Transport . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

9 Plate Bar Code Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

TOC-4 EVOLIS - Service Manual - Version 1.3

10.6 Adjustment and Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17

EVOLIS - Service Manual - Version 1.3 TOC-5

11.7.13Teaching Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-57

12 Pipetting Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

14 Rack System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1

15 CPS Module (COP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1

TOC-6 EVOLIS - Service Manual - Version 1.3

15.5.2Firmware Upgrade with User Software . . . . . . . . . . . . . . . . . . 15-13

16 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1

17 Troubleshooting and Error Messages . . . . . . . . . . . . . . . 17-1

18 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1

19 Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1

EVOLIS - Service Manual - Version 1.3 TOC-7

TOC-8 EVOLIS - Service Manual - Version 1.3

Evolis is a fully automated microplate analyser including such functions as sample

EVOLIS - Service Manual - Version 1.3 1-1

1.1 Typographical Conventions

Please consider the following typographical conventions.

1.1.1 Warning Messages

Caution, risk of danger! Consult instructions for use!

Caution, hot surface!

1-2 EVOLIS - Service Manual - Version 1.3

Consult instructions for use!

Disconnect mains power connector before servicing!

1.1.3 Symbol Keys

In Vitro Diagnostic Medical Device

EVOLIS - Service Manual - Version 1.3 1-3

1.1.4 Special Types

LEDs LEDs (light emitting diode) are printed in special type.

Buttons Buttons are printed in spaced type.

Keys Keys are printed in slanted type.

File examples File examples are printed in typewriter font.

1-4 EVOLIS - Service Manual - Version 1.3

1.2 Safety Instructions

Please always act according to the following safety instructions, before as

1.2.1 General Safety

Use the system only for the designated application.

EVOLIS - Service Manual - Version 1.3 1-5

1.2.2 Electrical Safety

Country-specific regulations regarding safe electrical operation of the in-

The instrument must be connected with a delivered connection cable to dedi-

Do not allow anything to rest on the power cord.

1-6 EVOLIS - Service Manual - Version 1.3

Don't position the equipment so that it is difficult to operate the disconnecting

1.2.3 Laser Safety