bioMerieux BACT/ALERT 3D 60 User manual

Service Manual
bioMérieux, Inc.
Box 15969, Durham, NC 27704-0969
http://www.biomerieux.com
©BIOMÉRIEUX 2002 Manual Part Number 48001-6 Rev A March 2003
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BacT/ALERT® 3D 60
Service Manual
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BioMérieux, Inc.
PO Box 15969
Durham, NC 27704-0969
USA
ASTM is a trademark of American Society for Testing and Materials. BacT/ALERT, BacT/LINK, BacT/VIEW
and MB are registered trademarks of bioMérieux in the USA and other countries. MS DOS is a registered
trademark of Microsoft Corporation. Zip is a registered trademark of Iomega Corporation. The logo is a
registered and protected trademark of bioMérieux, Inc. or one of its subsidiaries.
Distribution in over 130 countries

BacT/ALERT® 3D 60
Service Manual
This document will be updated for each software modification or any other change.
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BacT/ALERT® 3D 60 TABLE OF CONTENTS
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TABLE OF CONTENTS
0FRONT MATTER..................................................................................................................IX
0.1 APPENDICES.................................................................................................................IX
0.2 LIST OF TABLES...........................................................................................................XI
0.3 LIST OF ILLUSTRATIONS..........................................................................................XIII
0.4 TYPOGRAPHY AND GRAPHIC CONVENTIONS.....................................................XIX
0.4.1 Bullets..............................................................................................................xxi
0.4.2 Text Boxes .......................................................................................................xxi
0.4.3 Bracketed Italics................................................................................................xxi
0.4.4 Underlined Text.................................................................................................xxi
0.4.5 Bracketed Text.................................................................................................xxii
0.4.6 Text Within Quotation Marks.............................................................................xxii
0.4.7 Italicized (Whether Bold or Not) Text .................................................................xxii
0.5 SAFETY SUMMARY.................................................................................................XXIII
0.5.1 General Information to Follow ........................................................................... xxv
0.5.2 Electrical Warnings........................................................................................... xxv
0.5.3 Electrical Grounding .........................................................................................xxvi
0.5.4 Fuse Replacement Warning..............................................................................xxvi
0.5.5 Hazardous Voltages .........................................................................................xxvi
0.5.6 Cleaning Agents...............................................................................................xxvi
0.5.7 Health Risks ...................................................................................................xxvii
0.5.8 ESD Precautions.............................................................................................xxvii
0.5.9 Moving Parts...................................................................................................xxvii
0.5.10 Heating Element .............................................................................................xxvii

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1GENERAL INFORMATION..............................................................................................1-1
1.1 INTRODUCTION...........................................................................................................1-1
1.2 REFERENCE DATA.....................................................................................................1-2
1.3 EQUIPMENT DESCRIPTION.......................................................................................1-3
1.4 ASSEMBLY DESCRIPTIONS......................................................................................1-4
1.4.1 Electrical Components.......................................................................................1-4
1.4.1.1 Power Panel Assembly....................................................................1-5
1.4.1.2 Transformer Assembly.....................................................................1-5
1.4.1.3 Heater ............................................................................................1-5
1.4.1.4 Blower............................................................................................1-5
1.4.1.5 Step-5 Motor Assembly ...................................................................1-7
1.4.1.6 Fan ................................................................................................1-7
1.4.1.7 Quick Reference Card .....................................................................1-7
1.4.2 Communications Ports (Input / Output)...............................................................1-8
1.4.2.1 COMM Port.....................................................................................1-9
1.4.2.2 Printer Port .....................................................................................1-9
1.4.2.3 Internal Speaker w/external Speaker Jack ........................................1-9
1.4.2.4 Power Entry Module (PEM) / ON-OFF Switch ...................................1-9
1.4.2.5 Modem Port ....................................................................................1-9
1.4.2.6 LIS Port ..........................................................................................1-9
1.4.2.7 Monitor Port ....................................................................................1-9
1.4.2.8 UPS Port ........................................................................................1-9
1.4.2.9 UPS Serial Port...............................................................................1-9
1.4.2.10 Mouse Port .....................................................................................1-9
1.4.2.11 Keyboard Port.................................................................................1-9
1.4.2.12 Barcode Scanner Port .....................................................................1-9
1.4.3 Electronic Components....................................................................................1-10
1.4.3.1 CPU PCBA ...................................................................................1-11
1.4.3.2 ModSig PCBA...............................................................................1-11
1.4.3.3 Quad Serial PCBA.........................................................................1-11
1.4.3.4 Thermistor PCBA (Input/Output).....................................................1-11
1.4.3.5 CompactFlash Memory Disk ..........................................................1-13
1.4.3.6 CompactFlash Adapter PCBA........................................................1-13
1.4.3.7 Step-5 PCBA ................................................................................1-13
1.4.3.8 Incubator Chamber Components....................................................1-15
1.4.3.8.1 Rack...........................................................................1-15
1.4.3.8.2 Cell ............................................................................1-15
1.4.3.8.3 Cell Flag.....................................................................1-15
1.4.3.8.4 Cell Indicator Lamp .....................................................1-15

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Service Manual iii
1.4.4 Input / Output Devices .....................................................................................1-16
1.4.4.1 Operator Display Monitor ...............................................................1-17
1.4.4.2 Barcode Scanner ..........................................................................1-17
1.4.4.3 Keyboard......................................................................................1-17
1.4.4.4 Zip Drive.......................................................................................1-17
1.4.4.5 56K FAX Modem (Domestic)..........................................................1-19
1.4.4.6 56K Fax Modem (International)......................................................1-19
1.4.5 Uninterruptible Power Supply “UPS”.................................................................1-20
1.4.5.1 On/Off Switch................................................................................1-21
1.4.5.2 UPS Comm Port (Computer Interface Port).....................................1-21
1.4.5.3 Overload Reset Switch..................................................................1-21
1.4.5.4 Test (Check Battery/Alarm Disable) Switch.....................................1-21
1.4.5.5 120V Backup Receptacles .............................................................1-21
1.4.5.6 Accessory Surge Receptacles........................................................1-21
1.4.5.7 AC Power Cord.............................................................................1-21
1.5 OPERATOR DISPLAY CONFIGURATION SCREENS............................................1-24
1.5.1 Instrument Configuration Screen ......................................................................1-25
1.5.1.1 Accessing the Configuration Screen ...............................................1-25
1.5.1.2 Instrument Configuration Screen -Initial Entry.................................1-26
1.5.1.3 Configuration Screen [X Box] Buttons .............................................1-27
1.6 QUICK REFERENCE CARD......................................................................................1-29
2BACKGROUND INFORMATION ....................................................................................2-1
2.1 INTRODUCTION...........................................................................................................2-1
2.2 SYSTEM CONTROL -MODSIG PCBA.......................................................................2-2
2.3 THERMISTOR PCBA (INPUT/OUTPUT)....................................................................2-6
2.4 3D 60 POWER SUPPLY ASSEMBLY.........................................................................2-8
2.5 DC POWER SUPPLY.................................................................................................2-10
2.6 CPU PCBA.................................................................................................................2-12
2.7 COMPACTFLASH ADAPTER PCBA........................................................................2-14
2.8 QUAD SERIAL INTERFACE PCBA..........................................................................2-16
2.9 RACK CONTROLLER PCBA....................................................................................2-18
2.10 STEP-5 PCBA............................................................................................................2-24

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iv Service Manual
3INSTALLATION PROCEDURES....................................................................................3-1
3.1 INTRODUCTION...........................................................................................................3-1
3.2 BACT/ALERT 3D 60 INSTALLATION PROCEDURES..............................................3-3
3.2.1 Verification of Site Requirements........................................................................3-3
3.2.2 Record Line Noise.............................................................................................3-3
3.2.3 Unpacking ........................................................................................................3-3
3.2.4 Repacking ........................................................................................................3-3
3.2.4.1 Verification of Contents....................................................................3-6
3.2.4.1.1 3D 60 Instrument Parts..................................................3-6
3.2.5 Set AC Power...................................................................................................3-7
3.2.6 Instrument Placement........................................................................................3-9
3.2.7 Instrument UPS.................................................................................................3-9
3.2.8 Power Up .......................................................................................................3-11
3.2.9 Instrument Configuration..................................................................................3-11
3.2.10 Temperature ...................................................................................................3-11
3.2.11 Error Check ....................................................................................................3-11
3.2.12 Modem Functional Test ...................................................................................3-12
3.2.13 Barcode Reader Functional Test......................................................................3-13
3.2.14 UPS Functional Test (3D 60 Only, APC UPS 650).............................................3-13
3.2.15 Complete the Installation Checklist...................................................................3-13
3.3 RESTRAINT INSTALLATION....................................................................................3-14
3.3.1 Overview........................................................................................................3-14
3.3.2 Procedure.......................................................................................................3-14
3.4 SOFTWARE INSTALLATION....................................................................................3-17
3.5 SWITCHING ON.........................................................................................................3-17
3.5.1 Initialization.....................................................................................................3-17

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4SERVICING.........................................................................................................................4-1
4.1 INTRODUCTION...........................................................................................................4-1
4.2 SPECIFIC TOOLS AND REQUIRED...........................................................................4-3
4.3 POWER UP/DOWN PROCEDURES...........................................................................4-3
4.3.1 Introduction.......................................................................................................4-3
4.3.2 3D 60 Power Down ...........................................................................................4-3
4.3.3 3D 60 Power Up................................................................................................4-4
4.4MB CONVERSION PROCEDURE...............................................................................4-5
4.4.1 Overview..........................................................................................................4-5
4.4.2 Procedure.........................................................................................................4-5
4.5 DATA BACKUP/RESTORE PROCEDURES..............................................................4-9
4.5.1 BacT/ALERT 3D 60 -Data Backup Procedure ....................................................4-9
4.5.2 BacT/ALERT 3D 60 -Data Restore Procedure....................................................4-9
4.6 PREVENTIVE MAINTENANCE.................................................................................4-11
4.6.1 Overview........................................................................................................4-11
4.6.2 Perform Data Backup......................................................................................4-11
4.6.3 Barcode Reader Functional Test......................................................................4-11
4.6.4 Printer Maintenance ........................................................................................4-11
4.6.5 Temperature Verification..................................................................................4-11
4.6.6 Disabled Cell Check........................................................................................4-11
4.6.7 +5 DC Voltage Verification...............................................................................4-11
4.6.8 UPS Test........................................................................................................4-11
4.6.9 “Door Open” Test ............................................................................................4-12
4.6.10 Completing the Preventive Maintenance Card...................................................4-12
4.7 DIAGNOSTICS AND TROUBLESHOOTING............................................................4-13
4.7.1 Introduction.....................................................................................................4-13
4.7.2 Symptomatic Errors .........................................................................................4-13

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4.8 SOFTWARE DIAGNOSTICS.....................................................................................4-15
4.8.1 Button Legend ................................................................................................4-15
4.8.2 Purpose of the Section ....................................................................................4-16
4.8.3 Special Equipment ..........................................................................................4-16
4.8.4 Accessing the Diagnostics Screens ..................................................................4-17
4.8.5 Diagnostic Screens Overview...........................................................................4-18
4.9 ALIGNMENTS AND CALIBRATIONS.......................................................................4-69
4.9.1 Overview........................................................................................................4-69
4.9.2 System Power Supply......................................................................................4-69
4.9.3 Temperature ...................................................................................................4-69
4.9.4 Optics.............................................................................................................4-69
4.9.5 Rack –Single Cell Calibration ..........................................................................4-69
4.9.6 System Power Supply Check and Adjustments .................................................4-74
4.9.7 Door Micro Switch 1 & 2 Checks ......................................................................4-77
4.10 REMOVE AND REPLACE PROCEDURES..............................................................4-79
4.10.1 Introduction.....................................................................................................4-79
4.10.2 CPU PCBA Assembly (P/N 750-0070-01).........................................................4-81
4.10.3 Quad Serial Interface PCBA (P/N 750-0066-01) ................................................4-89
4.10.4 CompactFlash Adapter PCBA (P/N 957-0004-356)............................................4-91
4.10.5 Software Installation and CompactFlash Memory Card Replacement .................4-94
4.10.6 ModSig PCBA (P/N 48300-1) (Order Spare P/N 48300-901) ..............................4-95
4.10.7 ModSig PCBA Fuses (P/N 870-0008-14, -17, -22)...........................................4-105
4.10.8 Step-5 PCBA (P/N 48301-1) (Order Spare P/N 48301-901)..............................4-108
4.10.9 Step-5 Motor (P/N 48104-1)...........................................................................4-111
4.10.10 Outlet Thermistor PCBA (P/N 32300-1) ..........................................................4-117
4.10.11 Inlet Thermistor PCBA (P/N 32300-1) .............................................................4-119
4.10.12 Zip™ Drive (P/N 895-0004-38).......................................................................4-120
4.10.13 System Power Panel .....................................................................................4-124

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4.10.14 Power Supply Transformer (P/N 851-0015-01)................................................4-126
4.10.15 Power Supply MOV -Metal Oxide Varistor (P/N 43116-2)................................4-128
4.10.16 Power Panel Solid State Relays (P/N 845-0018-01) ........................................4-130
4.10.17 DC Power Supply (P/N 852-0010-01) .............................................................4-132
4.10.18 Power Entry Module (PEM) Fuses (P/N 870-0008-14, -17, -24, -25).................4-135
4.10.19 Fan (P/N 941-0009-07)..................................................................................4-138
4.10.20 Heater (P/N 847-0009-01)..............................................................................4-140
4.10.21 Blower Assembly (P/N 48411-1).....................................................................4-142
4.10.22 Blower Motor Capacitor (P/N 601-0001-02).....................................................4-143
4.10.23 Digital Reference Thermometer (P/N 848-0003-01) .........................................4-148
4.10.24 Rack Assembly (P/N 43147-921, -922, -923)...................................................4-149
4.10.25 Step-5 Drive Agitation Linkage Assembly (P/N 48418-1)..................................4-153
4.10.26 Gas Spring Assembly (P/N 926-0037-01)........................................................4-156
4.10.27 Magnetic Door Switches (P/N 841-0012-01)....................................................4-158
4.10.28 Keyboard (P/N 957-0004-373) .......................................................................4-160
4.10.29 Barcode Scanner (P/N 957-0004-291)............................................................4-161
4.10.30 Domestic 56K Fax Modem (P/N 957-0004-342) ..............................................4-162
4.10.31 International Fax Modem (P/N 957-0004-364).................................................4-163
4.10.32 APC Back-UPS Model 650 (Domestic Model) (P/N 957-0060-02).....................4-164
4.10.33 APC UPS (International Model) (P/N 957-0060-03) .........................................4-169
4.11 POST SERVICE VALIDATION................................................................................4-175
4.11.1 Overview......................................................................................................4-175
4.11.2 Required Materials ........................................................................................4-175
4.11.3 Procedures ...................................................................................................4-175

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0 F FR RO ON NT T M MA AT TT TE ER R
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0. .1 1 A AP PP PE EN ND DI IC CE ES S
Appendix A GLOSSARY.......................................................................................A.1
Appendix B PARTS LIST ......................................................................................B.1
Alphabetical Listing.................................................................................
Appendix C DISINFECTION ..................................................................................C.1
Introduction .......................................................................................C.1
Procedures........................................................................................C.1
Spills .............................................................................................C.1
Instrument Shipping...........................................................................C.1
Assembly Shipping ............................................................................C.1
Appendix D ERROR CODES .................................................................................D.1
Appendix E DIAGRAMS........................................................................................ E.1
INDEX .................................................................................................. Index-1

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0. .2 2 L LI IS ST T O OF F T TA AB BL LE ES S
Section 1
Table 1.2.1 Reference Data ........................................................................................1-2
Section 2
Table 2.2.1 Audio Frequency Selection (JP 23 through JP26) .......................................2-4
Table 2.5.1 Power Supply Data.................................................................................2-10
Section 3
Table 3.2.1 3D 60 instrument Parts List .......................................................................3-6
Table 3.2.2 Facility Power Rating and Conversion Chart ...............................................3-8
Table 3.2.3 Setup and Connections Table....................................................................3-9
Table 3.3.3 Restraint Hardware.................................................................................3-14
Table 3.3.4 Table of Equivalent Dimensions...............................................................3-15
Section 4
Table 4.2.1 Required Tools and Equipment..................................................................4-3
Table 4.7.1 Symptomatic Problems ...........................................................................4-13
Table 4.10.18 Facility Power Rating and Fuse Conversion Chart...................................4-135
Appendices
Table C 1.2 Disinfection Equipment.............................................................................C.1

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0. .3 3 L LI IS ST T O OF F I IL LL LU US ST TR RA AT TI IO ON NS S
CHAPTER 0 –FRONT MATTER
Fig. 1 -Text Box .........................................................................................................................................................................xxi
Fig. 2 -USA 115 VAC Standard............................................................................................................................................xxvi
Fig. 3 -European 230 VAC Standard..................................................................................................................................xxvi
CHAPTER 1 –GENERAL INFORMATION
Fig. 4 -BacT/ALERT 3D 60 Instrument................................................................................................................................1-3
Fig. 5 -3D 60 Power Panel Assembly ..................................................................................................................................1-4
Fig. 6 -Transformer..................................................................................................................................................................1-4
Fig. 7 -Blower & Heater...........................................................................................................................................................1-4
Fig. 8 -Step-5 Motor Assembly..............................................................................................................................................1-6
Fig. 9 -Fan Assembly...............................................................................................................................................................1-6
Fig. 10 -BacT/ALERT 3D 60 System Control (Rear View) w/Comm Ports.................................................................1-8
Fig. 11 -CPU PCBA................................................................................................................................................................1-10
Fig. 12 -ModSig PCBA..........................................................................................................................................................1-10
Fig. 13 -Quad Serial PCBA...................................................................................................................................................1-10
Fig. 14 -Thermistor PCBA....................................................................................................................................................1-10
Fig. 15 -CompactFlash Memory Disk................................................................................................................................1-12
Fig. 16 -CompactFlash Adapter PCBA.............................................................................................................................1-12
Fig. 17 -Step-5 PCBA.............................................................................................................................................................1-12
Fig. 18 -BacT 3D 60 Incubator Chamber..........................................................................................................................1-14
Fig. 19 -Rack Assembly........................................................................................................................................................1-14
Fig. 20 -Operator Display Monitor .....................................................................................................................................1-16
Fig. 21 -Barcode Scanner....................................................................................................................................................1-16
Fig. 22 -Keyboard...................................................................................................................................................................1-16
Fig. 23 -Zip Drive ....................................................................................................................................................................1-16
Fig. 24 -Uninterruptible Power Supply (UPS) Domestic Model–Front and Rear Views....................................1-20
Fig. 25 -Uninterruptible Power Supply (UPS) European Model –Front and Rear Views...................................1-22
Fig. 26 -Instrument Configuration Screen.......................................................................................................................1-24
Fig. 27 -Main Screen..............................................................................................................................................................1-25
Fig. 28 -Setup Screen w/Field Engineer Password Activation ..................................................................................1-26
Fig. 29 -Instrument Configuration Screen.......................................................................................................................1-26
Fig. 30 -[X Box] Selection Checkbox ................................................................................................................................1-27
Fig. 31 -Quick Reference Card –Front Side ...................................................................................................................1-30
Fig. 32 -Quick Reference Card –Rear Side.....................................................................................................................1-31

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CHAPTER 2 –BACKGROUND INFORMATION
Fig. 33 -ModSig PCBA Diagram...........................................................................................................................................2-2
Fig. 34 -ModSig Block Diagram............................................................................................................................................2-5
Fig. 35 -Thermistor PCBA......................................................................................................................................................2-6
Fig. 36 -Power Distribution Block Diagram.......................................................................................................................2-8
Fig. 37 -CPU PCBA Diagram...............................................................................................................................................2-12
Fig. 38 -CompactFlash Adapter PCBA.............................................................................................................................2-14
Fig. 39 -Quad Serial Interface PCBA Diagram................................................................................................................2-16
Fig. 40 -Rack Controller PCBA Diagram..........................................................................................................................2-18
Fig. 41 -Rack Controller PCBA Block Diagram..............................................................................................................2-20
Fig. 42 -Rack Address Concept..........................................................................................................................................2-22
Fig. 43 -Step-5 PCBA Diagram............................................................................................................................................2-24
Fig. 44 -Step-5 PCBA Block Diagram................................................................................................................................2-28
CHAPTER 3 –INSTALLATION PROCEDURES
Fig. 45 -3D 60 Instrument Repacking Sequence .............................................................................................................3-4
Fig. 46 -3D 60 Instrument Repack–Web Strapping Diagrams...................................................................................3-5
Fig. 47 -Power Entry Module w. Fuse Holder Removed................................................................................................3-7
Fig. 48 -Fuse Holder w/Fuse..................................................................................................................................................3-7
Fig. 49 -PEM w/115 VAC Version .........................................................................................................................................3-8
Fig. 50 -PEM w/230 VAC Version .........................................................................................................................................3-8
Fig. 51 -Installation and Setup Diagram...........................................................................................................................3-10
Fig. 52 -Communications Panel Connection Diagram.................................................................................................3-12
Fig. 53 -Modem Configuration & Dip Switch Settings Diagram................................................................................3-12
Fig. 54 -Countertop/Surface Mounting Diagram............................................................................................................3-12
Fig. 55 -Mounting Surface Diagram..................................................................................................................................3-15
Fig. 56 -Mounting Surface (Drilling) Template...............................................................................................................3-16
Fig. 57 -Installation Checklist.............................................................................................................................................3-18
CHAPTER 4 -SERVICING
Fig. 58 -3D 60 Instrument –Power Switch........................................................................................................................4-3
Fig. 59 -Step-5 Motor PCBA Power Disconnect...............................................................................................................4-5
Fig. 60 -MB Conversion –Lock Screw Removal.............................................................................................................4-6
Fig. 61 -MB Conversion –Lock Screw Installation.........................................................................................................4-7
Fig. 62 -Backup Management Button .................................................................................................................................4-9
Fig. 63 -Cancel Button ............................................................................................................................................................4-9
Fig. 64 -ModSig PCBA LED 55 and 56 location..............................................................................................................4-12
Fig. 65 -Scanner Default Settings Barcode.....................................................................................................................4-13
Fig. 66 -Diagnostics Setup Screen Buttons....................................................................................................................4-15
Fig. 67 -Diagnostic Test Selection (Setup) Screen.......................................................................................................4-17
Fig. 68 -1.7 Inc Module/Flag Check...................................................................................................................................4-18
Fig. 69 -1.5 Inc Module 1/Temperature Log (Find Text String) ..................................................................................4-19

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Fig. 70 -1.5 Inc Module 1/Temperature Log (Text String Output)..............................................................................4-20
Fig. 71 -1.5 Inc Module 1/Temperature Log (Save Output to Zip) .............................................................................4-20
Fig. 72 -1.5 Inc Module 1/Temperature Log (Scroll/Anchor Buttons) ......................................................................4-21
Fig. 73 -1.5 Inc Module 1/Temperature Log (Slide Bar) ...............................................................................................4-22
Fig. 74 -1.1 Inc Module 1/Loopback Test Screen...........................................................................................................4-24
Fig. 75 -1.2 Inc Module 1/Port Stats Test Screen...........................................................................................................4-25
Fig. 76 -1.3 Inc Module 1/Message Stats Test Screen..................................................................................................4-26
Fig. 77 -1.4 Inc Module 1/Message Log Test Screen....................................................................................................4-27
Fig. 78 -1.5 Inc Module 1/Temperature Log Test Screen.............................................................................................4-28
Fig. 79 -1.6 Inc Module 1/Reading Log Test Screen.....................................................................................................4-29
Fig. 80 -1.7 Inc Module 1/Flag Check Screen.................................................................................................................4-30
Fig. 81 -1.7 Inc Module 1/Flag Check Test Screen........................................................................................................4-31
Fig. 82 -1.7 Inc Module 1/Flag Check (Calibration Screen..........................................................................................4-31
Fig. 83 -1.8 Inc Module 1/Heater Screen..........................................................................................................................4-32
Fig. 84 -1.9 Inc Module 1/LED Check................................................................................................................................4-33
Fig. 85 -1.9 Inc Module 1/LED Check (Walking).............................................................................................................4-33
Fig. 86 -7.1 Instrument Cntrl/ZIP Drive Test Screen.....................................................................................................4-35
Fig. 87 -7.2 Instrument Cntrl/Barcode Loopback Test Screen...................................................................................4-36
Fig. 88 -7.4 Instrument Cntrl/Power Event Log Screen...............................................................................................4-39
Fig. 89 -7.6 Instrument Cntrl/Software Test Screen –Scan........................................................................................4-62
Fig. 90 -7.6 Instrument Cntrl/Software Test Screen –Misc........................................................................................4-66
Fig. 91 -Diagnostic Test Selection Screen –Flag Check............................................................................................4-70
Fig. 92 -Incubator Flag Check –Cell Differences Screen...........................................................................................4-71
Fig. 93 -Flag Check –Cell Calibration Screen................................................................................................................4-72
Fig. 94 -System Power Panel and DC Supply.................................................................................................................4-74
Fig. 95 -Step-5 PCBA at Connector J4.............................................................................................................................4-75
Fig. 96 -ModSig PCBA with +5 VDC Test Points ...........................................................................................................4-75
Fig. 97 -DC Power Supply....................................................................................................................................................4-75
Fig. 98 -Door Micro Switches and Magnets....................................................................................................................4-77
Fig. 99 -Top Panel Screw Locations (Removal).............................................................................................................4-81
Fig. 100 -CPU PCBA w/Quad Serial PCBA pluggedin.................................................................................................4-82
Fig. 101 -CPU PCBA -Screw Removal.............................................................................................................................4-83
Fig. 102 -CPU PCBA –J27 and J7 Cable Routing.........................................................................................................4-84
Fig. 103 -Quad Serial PCBA Removed from CPU PCBA.............................................................................................4-85
Fig. 104 -CPU PCBA Cable Connections.........................................................................................................................4-86
Fig. 105 -WinSystems®CPU Connector Locations.......................................................................................................4-87
Fig. 106 -Quad Serial PCBA................................................................................................................................................4-89
Fig. 107 -Quad Serial PCBA Cable Connections ...........................................................................................................4-90
Fig. 108 -EMC –CompactFlash PCBA..............................................................................................................................4-91
Fig. 109 -CompactFlash Adapter & ZIP Drive Installed...............................................................................................4-92
Fig. 110 -CompactFlash Adapter w/WinSystems Computer......................................................................................4-92
Fig. 111 -CompactFlash Card (Memory Removal) ........................................................................................................4-93
Fig. 112 -CompactFlash Adapter (Removal)...................................................................................................................4-93
Fig. 113 -ModSig PCBA –Connector Location..............................................................................................................4-95
Fig. 114 -ModSig PCBA........................................................................................................................................................4-96
Fig. 115 -ModSig PCBA –Tie Wrap Removal.................................................................................................................4-97
Fig. 116 -ModSig PCBA –Bundled Cable Disconnection...........................................................................................4-98
Fig. 117 -ModSig PCBA –JP19 Cable Removal.............................................................................................................4-99
Fig. 118 -ModSig PCBA –JP21, MS-JP11, JP12, &JP31 Cable Removal................................................................4-99
Fig. 119 -ModSig PCBA –MS-JP1 Cable Removal....................................................................................................4-100

TABLE OF CONTENTS BacT/ALERT® 3D 60
xvi Service Manual
Fig. 120 -ModSig –Rear Panel Screw Removal..........................................................................................................4-100
Fig. 121 -ModSig PCBA –Mounting Screw Locations..............................................................................................4-101
Fig. 122 -ModSig –Step-5 MCJ4 Connection..............................................................................................................4-102
Fig. 123 -ModSig –Rear Panel Hex Nut & Knurled Nut Removal..........................................................................4-103
Fig. 124 -ModSig PCBA –JP10, JP1 and Ground Cable ..........................................................................................4-103
Fig. 125 -ModSig PCBA Fuse Locations.......................................................................................................................4-105
Fig. 126 -ModSig PCBA –Fuse Locations 1 ................................................................................................................4-106
Fig. 127 -ModSig PCBA (Installed) -Fuse Locations 2.............................................................................................4-107
Fig. 128 -Step-5 PCBA Location......................................................................................................................................4-108
Fig. 129 -Step-5 PCBA Connector and Wiring Locations ........................................................................................4-109
Fig. 130 -Step-5 Motor Windings ....................................................................................................................................4-111
Fig. 131 -Step-5 Motor Removal –MCJ3 Disconnection..........................................................................................4-112
Fig. 132 -Step-5 Motor Removal –Set-Screw Removal............................................................................................4-113
Fig. 133 -Step-5 Motor Removal –Mounting Screw Removal.................................................................................4-114
Fig. 134 -Step-5 Motor Removal......................................................................................................................................4-114
Fig. 135 -Step-5 Motor Removal –Reinstalling Mounting Screws........................................................................4-115
Fig. 136 -Outlet Thermistor PCBA Removal................................................................................................................4-117
Fig. 137 -Inlet Thermistor PCBA Removal....................................................................................................................4-119
Fig. 138 -Zip™Drive Removal.........................................................................................................................................4-120
Fig. 139 -Zip Drive –Flash Adapter PCBA Removal.................................................................................................4-120
Fig. 140 -Zip Drive Screw Removal................................................................................................................................4-121
Fig. 141 -Zip Drive Removal –Cutout Hole ..................................................................................................................4-121
Fig. 142 -Zip Drive Sled Removal (Side Screws)........................................................................................................4-122
Fig. 143 -Zip Drive Sled Removal (Bottom Screws)...................................................................................................4-122
Fig. 144 -Zip Drive –Reconnecting IDE Cable and Power Connector..................................................................4-122
Fig. 145 -Power Panel Assembly –Screw Removal..................................................................................................4-124
Fig. 146 -Power Panel Assembly....................................................................................................................................4-125
Fig. 147 -Power Panel Assembly –Installed...............................................................................................................4-125
Fig. 148 -Power Supply Transformer–Power Supply Panel Removed...............................................................4-126
Fig. 149 -Power Panel with Transformer Installed.....................................................................................................4-127
Fig. 150 -Transformer –PEM Connections ..................................................................................................................4-127
Fig. 151 -Power Supply –Simplified Schematic.........................................................................................................4-128
Fig. 152 -Term Board 1 (TB1)...........................................................................................................................................4-128
Fig. 153 -Power Panel Solid State Relay Layout ........................................................................................................4-130
Fig. 154 -Power Supply Assembly w/DC Power Supply...........................................................................................4-132
Fig. 155 -DC Power Supply –J1 and J2 Disconnection ...........................................................................................4-133
Fig. 156 -Power Panel Assembly –DC Supply Screw Removal.............................................................................4-134
Fig. 157 -Power Entry Module w/Fuse Holder Removed..........................................................................................4-135
Fig. 158 -Fuse Holder Fuse Installation ........................................................................................................................4-135
Fig. 159 -PEM Fuse Removal w/ Screwdriver..............................................................................................................4-136
Fig. 160 -PEM Fuse Holder Removal.............................................................................................................................4-136
Fig. 161 -PEM Fuse Holder Pulled Out..........................................................................................................................4-136
Fig. 162 -PEM w/115 VAC Version..................................................................................................................................4-137
Fig. 163 -PEM w/230 VAC Version..................................................................................................................................4-137
Fig. 164 -Fan –Inside View...............................................................................................................................................4-138
Fig. 165 -Fan Wiring Connections ..................................................................................................................................4-138
Fig. 166 -Heater Terminal Connectors..........................................................................................................................4-140
Fig. 167 -Heater Removal..................................................................................................................................................4-141
Fig. 168 -Blower Motor ......................................................................................................................................................4-142
Fig. 169 -Blower Motor Capacitor...................................................................................................................................4-143