CAVRO XP 3000 User manual

Contents i
XP 3000 Modular Digital Pump
OPERATOR’SMANUAL
725730C
AUGUST, 1998
CAVRO
CAVRO SCIENTIFIC INSTRUMENTS, INC.
2450 ZANKER ROAD, SAN JOSE, CA 95131
TELEPHONE: [phone] •[phone] •FAX: [phone]
E-MAIL: [e-mail]
CAVRO

Contents ii
Copyright © 1998 Cavro Scientific Instruments, Inc.
Part number: 725730C
Copyright and Trademark Information
Teflonis a registered trademark of E.I. DuPont de Nemours & Co., Inc.
Kel-Fis a registered trademark of the 3M Company
CONTRADâis a registered trademark of Decon Laboratories, Inc.
Microsoft Windowsâ, Windows 3.1â, Windows 95â, and Windows NTâare registered trademarks of Microsoft
Corporation.
Product Warranty Information
Cavro warrants that instruments manufactured and sold by Cavro will be free from defects in materials and
workmanship for a period of twelve (12) months from the date of shipment to customer. Cavro’s liability for the
breach of the foregoing warranty is limited to the repair or replacement of the products found to be other than
warranted. Such products will be accepted for return only if customer returns them to Cavro’s factory or repair depot
within thirty (30) days from the time of discovery of the alleged defect, and prior to return, obtains a return
authorization number from Cavro, provides Cavro with the serial number of each instrument to be returned, and
prepays freight charges to the factory or a designated Cavro repair depot. No warranty is expressed or implied for:
•Breakage •Syringes
•Maltreatment •Syringe seals
•Unauthorized service •Tubing and tubing connections
•Units not returned in original or adequate packaging •Cavro Valves
•Units which are “life-cycled” •Cavro Probes
The foregoing warranties and limitations are customer’s exclusive remedies and are in lieu of all other warranties,
express or implied, including without limitation any warranty of merchantability or fitness for a particular purpose.
Product Documentation Warranty Information
The information contained in this document is subject to change without notice. Cavro makes no warranty of any
kind with regard to this material, including, but not limited to, the implied warranties of merchantability and fitness
for a particular purpose.
Cavro shall not be liable for errors contained in this document or for incidental or consequential damages in
connection with the furnishing, performance, or use of this material.

Contents iii
Contents
1 GETTING STARTED.............................................................................1-1
Regulatory Considerations..................................................................................1-1
CE.................................................................................................................1-1
Radio Interference ........................................................................................1-1
XP 3000 Features at-a-Glance............................................................................1-2
Unpacking the XP 3000.......................................................................................1-2
ESD Considerations......................................................................................1-2
Functional Description of the XP 3000................................................................1-3
Syringe and Syringe Drive............................................................................1-4
Valve and Valve Drive...................................................................................1-5
Printed Circuit Board.....................................................................................1-5
Communication Interfaces............................................................................1-6
Multi-Pump Configurations ...........................................................................1-7
Valve Sensor.................................................................................................1-7
Tips for Setting Up the XP 3000..........................................................................1-7
Mating Connector Suppliers................................................................................1-8
Power and Electrical Considerations ..................................................................1-9
Choosing a Power Supply.............................................................................1-9
Integrating a Power Supply...........................................................................1-9
Switching Power Supplies ..........................................................................1-10
2 HARDWARE SETUP ............................................................................2-1
Power ..................................................................................................................2-1
Cabling ................................................................................................................2-2
Communication Interfaces............................................................................2-3
Printed Circuit Board Settings and Options.........................................................2-8
Configuration Jumpers (JP1) for Standard Firmware...................................2-8
Configuration Jumpers (JP1) for Microstep-Enabled Firmware .................2-10
Address Switch Settings.............................................................................2-13
Self-Test......................................................................................................2-14
Inputs/Outputs.............................................................................................2-14
XP 3000 Without Valve .....................................................................................2-15
Installing Components.......................................................................................2-16
Installing the XP 3000 Valve.......................................................................2-16
Installing a Syringe......................................................................................2-18
Mounting the XP 3000.......................................................................................2-19

Contents iv
3 SOFTWARE COMMUNICATION..........................................................3-1
XP 3000 Addressing Scheme .............................................................................3-1
Communication Protocols ...................................................................................3-3
OEM Communication Protocol .....................................................................3-4
Data Terminal (DT) Protocol.........................................................................3-8
Using DT Protocol with Microsoft Windows................................................3-10
CAN Interface Communications .................................................................3-12
Using the XP 3000 Command Set ....................................................................3-21
Command Execution Guidelines ................................................................3-21
Control Commands.....................................................................................3-23
Initialization Commands..............................................................................3-27
Plunger Movement Commands..................................................................3-29
Valve Commands........................................................................................3-31
Valve Leakage Detection Commands ........................................................3-33
Set Commands (Velocity and Acceleration)...............................................3-34
Report Commands......................................................................................3-39
XP 3000 Microstep-Enabled Firmware Commands ...................................3-41
Error Codes and Query Status ...................................................................3-43
4 SETTING UP THE XP 3000 FOR YOUR APPLICATION......................4-1
Glossary ..............................................................................................................4-1
Optimizing XP 3000 Performance.......................................................................4-3
Helpful Hints........................................................................................................4-8
5 MAINTENANCE....................................................................................5-1
Daily Maintenance...............................................................................................5-1
Weekly Maintenance...........................................................................................5-1
Weak Detergent Cleaning.............................................................................5-2
Weak Acid-Base-Sequence Cleaning...........................................................5-2
10% Bleach Cleaning....................................................................................5-3
Periodic Maintenance..........................................................................................5-3
Quality Control Assurance............................................................................5-3
Replacing Dispense or Reagent Tubing.......................................................5-4
Replacing a Syringe......................................................................................5-5
Replacing the Reagent Syringe Seals..........................................................5-6
Replacing the XP 3000 Valve.......................................................................5-7
On-Site Replacements ........................................................................................5-8
Replacing the Printed Circuit Board (PCB)...................................................5-8
Replacing the EPROM..................................................................................5-8
6 TECHNICAL SERVICE .........................................................................6-1

Contents v
A ORDERING INFORMATION.................................................................... 1
Available Configurations.........................................................................................1
XP 3000 Spare Parts..............................................................................................2
Syringes...........................................................................................................3
Syringe Seals...................................................................................................3
Syringe “O”-Rings............................................................................................3
Valves ..............................................................................................................4
Printed Circuit Board........................................................................................4
Interconnect Tubing.........................................................................................5
Pump Evaluation Accessories.........................................................................6
Miscellaneous Parts.........................................................................................6
Other Cavro Products.............................................................................................7
RSP 9000 Robotic Sample Processor.............................................................7
MSP 9000/9500 Mini Sample Processors.......................................................7
XL Series Smart Valve.....................................................................................8
XL Series Smart Peristaltic Pump....................................................................8
XL 3000 Series Multi-Channel Pumps.............................................................8
XL 3000 Modular Digital Pumps......................................................................8
XE 1000 Pump.................................................................................................8
Smart I/O Board...............................................................................................9
Cavro MiniWash...............................................................................................9
Accessories......................................................................................................9
B PLUNGER INFORMATION ..................................................................... 1
Plunger Force.........................................................................................................1
Plunger Time Calculations .....................................................................................2
Symbol Definitions...........................................................................................2
Move Calculations............................................................................................3
C ASCII CHART OF CODES FOR U.S. CHARACTERS ............................ 1
D CHEMICAL RESISTANCE CHART......................................................... 1
E XP 3000 PHYSICAL SPECIFICATIONS.................................................. 1
F CAN COMMUNICATION COMMANDS ................................................... 1
G COMMAND QUICK REFERENCE .......................................................... 1
Control Commands ................................................................................................1
Initialization Commands for 3-Port Valve and T-Valve...........................................1
Initialization Commands for 3-Port Distribution Valve............................................1
Plunger Movement Commands/Status Bit Reports................................................2
Valve Commands...................................................................................................2
Valve Leakage Detection Commands....................................................................2

Contents vi
Set Commands.......................................................................................................2
Microstep-Enabled Firmware Commands..............................................................3
Report Commands .................................................................................................3
Error Codes............................................................................................................3
Error Codes and Status Byte..................................................................................4
DB-15 Connector Pin Assignments........................................................................4
Figures
Figure 1-1. XP 3000 Modular Digital Pump.............................................................................................. 1-3
Figure 1-2. Syringe Components ............................................................................................................. 1-4
Figure 1-3. 3-Port Valve Components...................................................................................................... 1-5
Figure 1-4. XP 3000 Printed Circuit Board External Connectors.............................................................. 1-6
Figure 2-1. DB-15 Connector Pins ........................................................................................................... 2-3
Figure 2-2. Termination Jumpers............................................................................................................. 2-4
Figure 2-3. RS-232 Multi-Pump Cabling .................................................................................................. 2-5
Figure 2-4. RS-485 Multi-Pump Cabling ................................................................................................... 2-6
Figure 2-5. CAN Multi-Pump Cabling........................................................................................................ 2-7
Figure 2-6. Configuration Jumpers........................................................................................................... 2-8
Figure 2-7. JP4 Jumper Settings Per Mode........................................................................................... 2-10
Figure 2-8. Printed Circuit Board Settings for Microstep-Enabled Firmware......................................... 2-12
Figure 2-9. Address Switch .................................................................................................................... 2-13
Figure 2-10. XP 3000 Valve Installation (3-Port Valve Shown).............................................................. 2-16
Figure 2-11. Syringe Installation............................................................................................................. 2-18
Figure 2-12. XP 3000 Threaded Mount Holes........................................................................................ 2-20
Figure 3-1. Valve Positions for all Valve Types...................................................................................... 3-32
Figure 4-1. Syringe Speed........................................................................................................................ 4-2
Figure 5-1. Syringe Replacement............................................................................................................. 5-5
Figure 5-2. Syringe Seal Assembly.......................................................................................................... 5-6
Figure 5-3. XP 3000 Valve Replacement (3-Port Valve Shown).............................................................. 5-7
Figure B-1. Plunger Force Curve .................................................................................................................1

Getting Started 1-1
1 - Getting Started
Congratulations on your purchase of the Model XP 3000 Modular Digital Pump from
Cavro Scientific Instruments, Inc.
The XP 3000 is a compact OEM pump module designed to handle precision liquid
handling applications in the 5 µL to 5 mL range. It is controlled by an external computer
or microprocessor and automates pipetting, diluting, and dispensing functions.
This chapter includes these topics:
•Regulatory Considerations
•XP 3000 Features at-a-Glance
•Unpacking the XP 3000
•Functional Description of the XP 3000
•Tips for Setting Up the XP 3000
•Mating Connector Suppliers
•Power and Electrical Considerations
•Choosing a Power Supply
Regulatory Considerations
The XP 3000 is a general laboratory module. Since it is not a medical device, it is not
subject to FDA regulatory approval. The XP 3000 uses UL-approved components
wherever possible.
CE
Wherever possible, UL-approved components have been used in the design and
manufacturing of the XP 3000. As a module designed for incorporation into larger
systems which require independent testing and certification, the XP 3000 does not carry
its own CE mark. Compliance with EMC Directive 89/336 EEC may be inferred from
testing of the Cavro MSP 9000 Mini Sample Processor, including the XP 3000, which
meets all requirements of the EMC Directive.
Radio Interference
The XP 3000 generates, uses, and can radiate radio frequency energy which may cause
interference to radio and television communications. Follow standard good engineering
practices relating to radio frequency interference when integrating the XP 3000 into
electronic laboratory systems.

Getting Started 1-2
XP 3000 Features at-a-Glance
The XP 3000 is a compact syringe pump that is designed for OEM precision liquid
handling applications. It has the following standard features and functions:
•Small and lightweight
•Syringe sizes from 50 µL to 5 mL
•Accuracy <1.0% at full stroke
•Precision ≤0.05% at full stroke
•Standard dispense/aspirate resolution of 3,000 steps
•Microstep dispense/aspirate resolution of 24,000 steps
•3-port-, 3-port distribution-, and T- valves, or Y-block
•Borosilicate glass, Kel-Fand Teflonfluid contact
•Optional RS-232/RS-485 or CAN/RS-485 interface
•Programmable plunger speeds from 1.2 sec/stroke to 20 min/stroke, with ramps
and on-the-fly speed changes
•Valve leak detection
•Rack and pinion drive with lost-step detection
•Manually movable syringe drive (power off)
•Pump diagnostics, self-test, and error reporting
•5K programmable EEPROM
•Auxiliary inputs and outputs
•Operates using a single 24VDC power supply
Unpacking the XP 3000
To unpack the module, follow these steps:
1 Remove the pump module(s) and accessories from the shipping cartons.
2 Check the contents against the packing slip to make sure that all the components are
present.
ESD Considerations
The XP 3000 is an electronic device that is sensitive to electrostatic discharge (ESD).
Static discharge from clothing or other fixtures can damage these components. To
prevent premature failure of pump components, the XP 3000 should be handled using
good ESD practices. These include, but are not limited to:
•Using wrist or ankle straps
•ESD mats or worktables
•ESD wax on the floor
Prepare an ESD-free work area before the chassis is grounded.

Getting Started 1-3
Functional Description of the XP 3000
The XP 3000 uses a stepper-motor driven syringe and valve design to aspirate and
dispense measured quantities of liquid. Both the syringe and the valve are replaceable.
Functional descriptions and illustrations of each major XP 3000 component are provided
in the sections that follow.
Figure 1-1. XP 3000 Modular Digital Pump

Getting Started 1-4
Syringe and Syringe Drive
The syringe plunger is moved within the syringe barrel by a rack and pinion drive that
incorporates a 1.8°stepper motor and quadrature encoder to detect lost steps.
The syringe drive has a 30 mm travel length and resolution of 3000 steps (3000 or 24000
steps for microstep-enabled firmware). When power is not applied to the pump, the
syringe drive can be moved by pushing up or down firmly on the plunger holder
assembly. This facilitates syringe removal.
The base of the syringe plunger is held to the drive by a knurled screw. The top of the
syringe barrel attaches to the pump valve by a 1/4-28" fitting.
Figure 1-2 shows the components of a typical syringe.
Figure 1-2. Syringe Components
Syringes are available in these sizes: 50 µL, 100 µL, 250 µL, 500 mL, 1.0 mL, 2.5 mL,
and 5.0 mL. For ordering information, see Appendix A, “Ordering Information.”