Aim Lab PathFinder 350S User manual

PathFinder 350S
Specimen Sorter
Service Manual
Specifications are subject to change without notice.
Aim Lab Pty Ltd ABN 76 009 938 498
10–22 Hornibrook Esplanade, Clontarf
Queensland 4019, Australia.
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Web: www.aimlab.com
Issue: Rev E
Part Number PS-U-SM002
© Aim Lab Pty Ltd. All rights reserved. No part of this publication may be
reproduced, transcribed, translated, or reverse engineered into a computer,
software program or other manual without the express written permission of Aim
Lab Pty Ltd

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Disclaimer
The Pathfinder 350S Service Manual is provided AS IS, without warranty of any
description.
Aim Lab Pty Ltd does not warrant, guarantee, or make any express or implied
representations regarding the use of this manual in terms of correctness, accuracy,
reliability and currency, or otherwise.
Aim Lab Pty Ltd reserves the right to revise the content of this manual without
obligation to notify any person or organization of such revision or changes.
This manual is intended for trained service technicians performing maintenance on
the PathFinder 350S.
Designed and Manufactured by:
Aim Lab Pty Ltd
10–22 Hornibrook Esplanade
Clontarf Qld 4019
Australia
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Web: www.aimlab.com
Authorised European Representative
Emergo Group
Molenstraat 15
2513 BH The Hague
The Netherlands
Phone: [phone]
Fax: [phone]

PathFinder 350S Service Manual
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Table of Contents
1. Introduction............................................................................ 8
1.1 Safety Precautions ..............................................................8
1.2 General Safety...................................................................9
1.3 Emergency Off...................................................................9
1.4 Approvals ....................................................................... 10
1.5 Trademarks and Copyrights.................................................. 10
2. Specifications .........................................................................11
2.1 General Specifications........................................................ 11
2.2 Electrical ....................................................................... 12
2.3 Communications............................................................... 13
2.4 Embedded PC .................................................................. 13
3. The PathFinder 350S................................................................14
3.1 Modules ......................................................................... 14
3.1.1 Sorter Module ........................................................ 14
3.1.2 Specimen Tray ....................................................... 14
3.1.3 Carousel............................................................... 14
3.1.4 LCD Monitor........................................................... 15
3.1.5 Sorter Covers......................................................... 15
3.1.6 Services Module...................................................... 15
3.1.7 Racks (optional)...................................................... 15
3.2 Sorter Module.................................................................. 16
3.2.1 Tombstone Electronics.............................................. 17
3.2.2 X-Axis and Theta-Axis............................................... 19
3.2.3 Gripper Arm (Z-Axis) ................................................ 21
3.3 Workcell Controller ........................................................... 24
3.3.1 Workcell Controller PC.............................................. 25
3.3.2 Sorter Main PCB...................................................... 25
3.4 Carousel......................................................................... 26
3.5 Services Module................................................................ 27
3.6 Specimen Tray ................................................................. 29
3.7 PathFinder 350S GUI .......................................................... 30
3.7.1 The Graphical User Interface (GUI)............................... 30

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3.7.2 Switching Between Windows and the GUI ....................... 34
3.8 Service Applications .......................................................... 35
3.8.1 SAM-BA ................................................................ 35
3.8.2 pgAdmin............................................................... 35
3.8.3 PDS..................................................................... 35
4. Installation ............................................................................ 39
4.1 Electrical Safety............................................................... 39
4.2 Sorter Module.................................................................. 40
4.3 Carousel ........................................................................ 41
4.4 Covers........................................................................... 42
4.4.1 Rear Cover............................................................ 42
4.4.2 Front Cover........................................................... 43
4.5 LCD Monitor.................................................................... 44
4.6 Specimen Tray................................................................. 45
4.7 Services Module ............................................................... 46
4.8 Pre-Power checks ............................................................. 47
4.9 Initial Power Up ............................................................... 47
4.10 Post Installation............................................................... 48
4.10.1 Handover Point Calibration ........................................ 48
4.10.2 System Validation (Self Test)...................................... 49
4.11 Initial Configuration .......................................................... 51
4.11.1 Rack registry ......................................................... 51
4.11.2 Network Setup ....................................................... 53
4.11.3 LIS Interfacing........................................................ 54
5. Configuration ......................................................................... 55
5.1 Specimen Tray................................................................. 55
5.2 Locations ....................................................................... 56
5.3 Profile Gates................................................................... 57
5.3.1 Some Profile Gates Rules........................................... 58
5.4 Specimen Types ............................................................... 58
5.5 Application Example.......................................................... 60
5.5.1 Specimen Types...................................................... 61
5.5.2 Rack Setup............................................................ 61
5.5.3 Tray Setup............................................................ 62

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5.5.4 Locations.............................................................. 62
5.5.5 Profile Gates.......................................................... 63
6. Troubleshooting ......................................................................64
6.1 Troubleshooting Tools ........................................................ 64
6.2 Operational Errors (GUI) ..................................................... 64
6.3 LIS / Networking Errors....................................................... 64
6.4 Hardware/Component Failures ............................................. 64
6.4.1 PDS..................................................................... 64
6.4.2 Initialisation .......................................................... 66
6.4.3 Specific Failure Modes .............................................. 70
6.5 Workcell Controller / Software Failures................................... 73
6.5.1 Communications Failure............................................ 73
7. Repairs .................................................................................77
7.1 Services Module................................................................ 77
7.1.1 Attaching Auxiliary Air.............................................. 77
7.1.2 Piston Cup Seal....................................................... 78
7.1.3 Replacing Fuses ...................................................... 82
7.2 Carousel......................................................................... 84
7.2.1 Carousel PCB ......................................................... 84
7.2.2 Tube Spin O-Ring..................................................... 85
7.2.3 Barcode Reader Alignment......................................... 86
7.3 Sorter Module.................................................................. 87
7.3.1 Sorter Axes Electronics ............................................. 87
7.3.2 Main PCB .............................................................. 91
7.3.3 Workcell Controller Hard Drive.................................... 92
7.3.4 ATX Power supply.................................................... 93
7.3.5 Workcell Controller Mother Board ................................ 94
7.3.6 Theta-Axis FFC Cables .............................................. 96
7.3.7 X-Axis Drive Belt ..................................................... 98
7.3.8 Z-Axis Drive Belt ....................................................100
7.4 Specimen Tray ................................................................101
7.4.1 Specimen Tray PCB.................................................101
7.5 Customising the Specimen Tray............................................102
7.5.1 Removing a Fence ..................................................103
7.5.2 Adding Fences.......................................................104

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7.5.3 Naming the Tray....................................................106
7.5.4 Configuring the PathFinder 350S................................. 107
7.6 Configuration Variables .....................................................109
7.6.1 Saving (Backup).....................................................110
7.6.2 Writing (Restore) ...................................................110
7.7 Loading Firmware............................................................111
7.7.1 PDS....................................................................111
7.7.2 SAM-BA ...............................................................112
7.8 Calibration ....................................................................115
7.8.1 Grippers..............................................................115
7.8.2 Sorter.................................................................119
7.8.3 Handover Position..................................................123
7.9 Database.......................................................................124
7.9.1 Backup ...............................................................124
7.9.2 Restore...............................................................125
7.9.3 Pre Packaged Scripts...............................................128
7.9.4 Resetting PostgreSQL ..............................................129
7.10 Updating the GUI.............................................................131
8. Preventative Maintenance ....................................................... 133
8.1 6 Months or 250,000 Tubes .................................................133
8.2 5 Years or 2,500,000 Tubes.................................................134
9. Returns............................................................................... 135
9.1 General Warranty ............................................................136
10. Recommended Spares............................................................. 137
11. Appendix A Default Tray Configurations .................................... 138
11.1 PS-SRT-A001 6 Position Specimen Tray .................................139
11.2 PS-SRT-A028 7 Position Specimen Tray .................................140
11.3 PS-SRT-A019 8 Position Specimen Tray .................................141
11.4 PS-SRT-A027 9 Position Specimen Tray .................................142
11.5 PS-SRT-A029 10 Position Specimen Tray................................143

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1. Introduction
The PathFinder 350S Specimen Sorter, hereafter referred to as the PathFinder 350S,
is an automated robotic workcell that registers and sorts specimen tubes into
sample racks.
This Service Manual details the parts and procedures required to carry out
configuration, repairs and preventative maintenance on the PathFinder 350S.
This manual is designed for use by Service Technicians. Only trained and certified
Service Technicians should attempt repairs on the PathFinder 350S Sorter.
The reader may also find relevant information in the following documentation
PathFinder 350S User Manual (PS-U-UM002)
PathFinder 350S LIS Interface Manual (PS-U-UM008)
PathFinder 350S Spare Parts Catalogue (PS-U-SM010)
1.1 Safety Precautions
The PathFinder 350S complies with the safety requirements set out in IEC 61010-
1, Safety Requirements for Electrical Equipment for Measurement, Control, and
Laboratory Use, Part 1: General Requirements.
This manual contains warnings and cautions which, when properly followed, can
prevent personal injury and damage to the PathFinder 350S.
Technicians must observe all warnings and cautions outlined in this manual.
Warnings are presented in the following formats.
NOTE
Highlights important information for the technician.
MECHANICAL HAZARD
Alerts the reader to potential mechanical hazards that pose an injury risk
to the Technician and/or damage to the PathFinder 350S.

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ELECTRICAL HAZARD
Alerts the reader to potential electrical hazards that pose a shock risk to
the Technician and/or damage to the PathFinder 350S
BIOLOGICAL RISK
Alerts the reader to a potential biological risk.
1.2 General Safety
To ensure the occupational health and safety of technicians working with the
PathFinder 350S, ALL operators and service technicians must be aware of the risks
involved with:
Handling potentially infectious specimens, and
Working with an electrically and pneumatically driven robotic system.
The PathFinder 350S is designed to process clinical laboratory specimens, some of
which may present a biological risk. It is important to follow standard laboratory
practice for protection from biological risks when processing specimens, and when
performing maintenance and troubleshooting procedures.
All materials that come in contact with patient samples should be
considered a biological risk, and treated according to your laboratory’s
safe handling and disposal procedures.
1.3 Emergency Off
In case of an emergency, use the main power switch on the services module to turn
the power OFF.
The power to the PathFinder 350S and its control computer will be cut instantly.
Restarting will take a few minutes, because it will be necessary to re–boot the
control computer and its programs.

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1.4 Approvals
The PathFinder 350S is marked to C-Tick, CE and FCC standards.
The CE mark is based on compliance to the Low Voltage Directive (2006/95/EC) and
the EMC Directive (2004/108/EC).
The PathFinder 350S is RoHS compliant.
1.5 Trademarks and Copyrights
Windows is a trademark of Microsoft ®. © 2001 Microsoft Corporation. All rights
reserved.
FireFox is a trademark of the Mozilla Foundation © 2006 FireFox Contributors.

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2. Specifications
The tables below outline the specifications of the PathFinder 350S.
Aim Lab Pty Ltd reserves the right to change these specifications at any time
without notice.
2.1 General Specifications
Item Specification
Footprint 100cm L x 45 cm W x 52 cm H (40” x 18” x 21”)
Shipping Dimensions Multiple boxes totalling 0.7m3
Module Net Weight Sorter Module 30Kg (66 lbs)
Services Module 10Kg (22 lbs)
Specimen Tray 5Kg (11 lbs)
Shipping Weight Approximately 76 Kg (167 lbs)
Air Supply 4 bar filtered and regulated output. (Self Supplied)
6-8 bar auxiliary input.
User Interface Touch-screen LCD Monitor.
Optional USB Keyboard.
Temperature range: Non-operating 5oC – 40oC (41oF – 113oF)
20 – 80% RH non-condensing
Temperature range: Operating 10oC – 35oC (50oF – 95oF)
8 – 80% RH non-condensing
Maximum Thermal Output Approximately 200W
Maximum Sound Power Levels <60dB at 1m.
Max number of Specimens 250 when using 5 x 50way PathFinder Racks
Maximum Throughput Up to 350 specimens per hour.
Tube Dimensions 12-16mm OD, 63 – 120mm Length
Tube Identification CCD Barcode Reader
Supported Barcode Formats Code 39 Family (with check digit)
Code 128 Family (incl. EAN and ISBT)
CODABAR Family (with start/stop control)
Interleaved 2/5 (with check digit)
EAN/UPC without ADD-ON
Rack Capacity Up to 5 PathFinder 50 way racks + Error rack
Up to 9 PathFinder 20 way racks + Error rack

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Item Specification
Or combinations of 50 and 20 way racks.
Refer to Appendix A for default Tray Configurations
Compatible Racks PathFinder 50 and 20 way racks.
Various third-party analyser racks are supported with the
use of rack adaptors.
Safety Certifications AS61010-1:2003
EN61010-1:2001
Table 1 General Specifications
2.2 Electrical
Item Specification
Services Module Input Supply 100 – 240VAC, 50-60Hz, 250 W
Input filtered.
Mains Input Fuse Rating 5A Slow Blow
Services Module Output 24VDC, 240W
Output Fuse Rating 10A Slow Blow.
Sorter Power Supply 24V DC, (approx 50W) supplied by services module
Specimen Tray Power 24V DC, (approx 10W) supplied by services module
Carousel Power 24V DC, (approx 20W) supplied by services module
PC Power Supply Pico-PSU 80W ATX Power Supply, Motherboard mounted.
LCD Display Power 12V DC, supplied by ATX Power Supply.
Barcode Reader Power 5V DC, supplied by ATX Power Supply.
EMC Certifications EN61326-1:2006
EN61326-2-1:2006
FCC Rules, Part 15, Subpart B
Table 2 Electrical Specifications

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2.3 Communications
Item Specification
Control PC to Sorter RS232, 115200 BAUD over internal serial link (COM 2)
Sorter to Accessories RS485, 38400 BAUD. Daisy chained running OEM protocol.
Control PC to LIS Ethernet 10/100/1000.
File I/O using NCCLS LIS2-A (ASTM1394) format messages.
Table 3 Communications Specifications
2.4 Embedded PC
Item Specification
Motherboard Mini- ITX Form factor Embedded PC
1.2 GHz Eden CPU (Fanless)
SATA HDD interface ( IDE )
Onboard video, sound, I/O, USB 2.0
Ethernet 10/100/1000.
1394 Firewire (via internal header)
VGA, RGB, Component and S-Video outputs.
Hard Drive 2.5 inch form factor
80 GB
7200+ RPM
<10.5ms Access Time
24/7 runtime rating
RAM 1GB, DDR2 633MHz
Monitor 800 x 600 DPI LCD TFT Monitor
4-wire Resistive Touchscreen – USB
Table 4 Embedded PC Specifications

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3. The PathFinder 350S
The PathFinder 350S Workcell is made up of a number of modules. A module is a
functional unit that can be deployed and replaced as a single component.
The collection of modules is referred to as a Workcell. The Workcell can include
multiple PathFinder modules such as Sorters, Cappers, Aliquoters etc. The Workcell
is coordinated by the Workcell Controller.
The Workcell Controller is a PC that hosts the Workcell Controller Software, the web
server for the Graphical User Interface (GUI), and communicates with the Lab
Information System (LIS).
In the case of the PathFinder 350S, because there is only one Sorter module, the
Workcell Controller has been integrated into the Sorter module to save bench space
and create an integrated ‘out-of-the-box’ system.
This Section provides a breakdown of the PathFinder 350S modules and
subcomponents. Part numbers are provided for selected components; these are
components that may be replaced in the field.
Note that cables have not been called out. All cables are labelled with a description
and part number for ordering spares.
3.1 Modules
The PathFinder 350S Workcell consists of the following modules:
3.1.1 Sorter Module
The Sorter does the physical work of picking and placing specimen tubes into the
appropriate racks. It is the primary module to which the other modules attach.
It contains the Sorter Main PCB that co-ordinates all the modules, and the Workcell
Controller (embedded PC) that communicates with the LIS and hosts the GUI via the
LCD Monitor.
3.1.2 Specimen Tray
The Specimen Tray fits into the base of the Sorter and locates the specimen racks.
The Specimen Tray may differ from the photos in this manual since the tray is
configurable to accept a variety of racks.
3.1.3 Carousel
The Carousel module identifies the tubes placed on the Sorter. It reads the barcode
of the presented tubes which is then sent as a query to the LIS. Holding four tubes
on the Carousel at any one time prevents LIS delays from affecting throughput.

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3.1.4 LCD Monitor
The LCD Touchscreen Monitor provides the GUI to the Workcell Controller. It is
mounted to the front of the Sorter robot.
3.1.5 Sorter Covers
The acrylic covers fit to the Sorter to provide protection against moving parts. They
also help to protect uncapped samples from dust and other airborne contaminants.
3.1.6 Services Module
The Services module provides the 24 VDC power and compressed air to the other
modules.
3.1.7 Racks (optional)
The PathFinder 350S may be supplied with PathFinder racks (20 or 50 way). In
addition the system may include rack adaptors to allow analyser racks to be grouped
and placed on the Specimen Tray.
Also supplied will be one error rack. The error rack has 4 error wells, 1 STAT tube
well, and an open bin. It is fitted to the last gate in the Specimen Tray.

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3.2 Sorter Module
The Sorter module hosts all other modules to create the Workcell. The gripper arm
picks tubes from the racks and places them on the Carousel. Once an output is
determined for a tube, the gripper arm picks the tube from the Carousel and
delivers it to the destination rack.
The Sorter consists of three robotic axes.
The X-axis moves the gripper arm from left to right.
The Theta-axis is a rotary axis that turns the gripper arm.
The Z-axis moves the grippers up and down.
Each axis is driven by a stepper motor and has position feedback via an optical
encoder.
The motors are controlled by the Sorter Main PCB, which is housed in the tombstone
with the rest of the electronics. The Sorter Main PCB also coordinates the Carousel
and Specimen Tray via the accessories bus.
Figure 1 Sorter Components
Monitor
(PS-E-A288)
Rear Cover
(PS-SRT-P093)
Tombstone
Front Cover
(PS-SRT-A036)
Gripper Arm (Z-Axis)
X-Axis covers
Barcode Reader
(PS-E-A218)
Grippers Theta-Axis
RIGHTLEFT
FRONT

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3.2.1 Tombstone Electronics
The Sorter electronics, as well as the Workcell Controller, are housed in the casing
at the left hand end of the Sorter, otherwise referred to as the tombstone.
To access the electronics remove the rear cover by unscrewing the ten M3 screws
holding it to the tombstone.
Figure 2 Tombstone Electronics
FFC Breakout PCB
(PS-E-A186)
Comms Accessory PCB
RS485 – RS232 Adaptor
(PS-E-A281)
X-Axis Stepper Motor
(P-E-A005)
X-Axis Encoder
(P-U-A167)
X-Axis PCB
(PS-E-A187)
Sorter Main PCB
(PS-E-A282)
WCC Hard Drive
(G-C-P027)
Barcode Reader
(PS-E-A218)
Pico ATX Power Supply
(G-E-P288)
WCC Motherboard
(G-E-P357)
WCC RAM 1GB
(G-E-P358)
FRONT
BACK
Power Distribution
Harness
Distribution Block

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3.2.1.1 Sorter Main PCB
The Sorter Main PCB communicates with the Workcell Controller via an internal
serial cable.
It drives the Sorter stepper motors and contains the all the calibration information
necessary to position the gripper arm accurately.
It also synchronises the Carousel and Specimen Tray so tubes are handled properly.
It communicates with the other modules via the accessory bus. The accessory bus is
an RS485 network which is isolated from the Workcell Controller.
3.2.1.2 FFC Breakout PCB
The FFC cables are long Flat Flexible Cables that allow the gripper arm to move
along the X Axis. The FFC cables carry the motor drive, the encoder feedback, and
the gripper IO.
The FFC Breakout PCB allows the FFC signals to be accessed using standard cable
assemblies.
3.2.1.3 Comms Accessory PCB
The Comms Accessory PCB is an intelligent RS232 to RS485 converter. It sits on the
RS485 accessory bus and allows its three RS232 ports to be addressed by the Sorter
Main PCB.
This is used to allow the Sorter Main PCB to communicate with the Barcode Readers.
3.2.1.4 Power Distribution
24V DC power for the entire system is provided by the Services Module. The supply is
fused at the services module.
The 24V DC is distributed via the distribution block to the
Pico ATX power supply
Cooling fan.
Sorter Main PCB.
The Carousel PCB via the Carousel module cable.
The Specimen Tray PCB.
The 24V is broken into 5V and 12V rails by the Pico ATX Power Supply and
distributed by the power distribution harness.

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12V is delivered to the
LCD monitor
Comms Accessory PCB
5V is delivered to the
Comms Accessory PCB, which distributes to
oTombstone barcode Reader
oCarousel barcode reader via the Carousel module cable.
Tombstone barcode IR LED array.
Specimen Tray STAT sensor emitter.
The Workcell Controller Hard Drive
3.2.2 X-Axis and Theta-Axis
To access the X-axis and Theta-axis components, remove the top X-axis covers.
These are fastened to the tombstone and end plate by eight M4 screws shown
below.
The X-axis stepper motor and encoder wheel are in the tombstone.
Figure 3 X-axis Cover Screws
M4 Screws

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Figure 4 X-Axis and Theta-Axis Components
Every axis has similar functional parts.
A stepper motor
An encoder
An encoder PCB
A drive train (drive belt or gear)
The stepper motor drives the axis via a drive belt or gear. The encoder is attached
directly to the motor shaft and provides position feedback via the encoder PCB.
The components for each axis are decoupled from all other axes. That means that if
there is a fault on one axis, it will not involve components on the other axes. The
only exception to this is the Theta-axis PCB; this routes the Z-axis signals from the
Theta-axis FFC to the Z-axis FFC.
26way FFC cable
(P-E-P051)
12way FFC Cable
(PS-E-P004)
Theta Axis PCB
(PS-E-A188)
Theta Axis Encoder
(P-U-A168)
X Axis Drive Belt
(G-X-P097)
Stepper Motor
(P-E-A005)
X Axis Shafts