Dynex DSX User manual

DSX™ Automated ELISA System
Service Manual
IMPORTANT: Please read this manual carefully before servicing
or adjusting the system.

Revision History
Revision Date:
July 2004
April 2005
Notice: The DSX™ Automated ELISA System is covered by a warranty (a copy of which is
enclosed in this manual). The customer is required to perform routine maintenance as
described in the user’s manual on a periodic basis to keep the warranty in effect.
DYNEX Technologies reserves the right to make technical improvements to this equipment
and documentation without notice as part of a continuous program of product development.
This manual supersedes all previous editions.
The material included in this manual is provided to assist service engineers in the
maintenance and repair of the DSX™ Automated ELISA System. It is assumed that the
individual using this manual has sufficient training in the service of analytical instrumentation
and is aware of the potential hazards including (but not limited to) electrical hazards, chemical
hazards and mechanical hazards.
If this manual is provided to an end user, it is with the understanding that the material
included herein is proprietary to DYNEX Technologies, Inc. The user may not provide this
material to a third party without the written permission of DYNEX Technologies.
Questions or comments regarding the content of this manual can be directed to:
DYNEX Technologies, Inc.
14340 Sullyfield Circle
Chantilly VA 20151-1683 USA
Phone: [phone] (USA only)
[phone]
Fax: [phone]
Part No. 91000090, Revision B
DSX™ Automated ELISA System is a trademark of DYNEX Technologies, Inc.
This manual is published by DYNEX Technologies, Inc.
2001, 2005 This document is the copyright of DYNEX Technologies, Inc. and must not be
copied or reproduced in any form without prior consent.
DYNEX Technologies reserves the right to make technical improvements to this equipment
and documentation without prior notice as part of a continuous program of product
development. This manual supersedes all previous editions.

Preface
Preface
The purpose of this manual is to enable a qualified field service engineer to carry out routine
maintenance and minor repairs on the DYNEX Technologies DSX™ Automated ELISA
System. In general, the service engineer is expected to make repairs, replace modules and
replace electromechanical subassemblies. Printed circuit boards and a few other components
are typically replaced as major subassemblies.
This manual is provided to complement the DSX™ Automated ELISA System Operator’s
Manual (Part No. 91000060). In some instances, references will be made to the Operator’s
Manual.
In most instances, the supplier of the reagent kit will install the unit. Detailed installation
information is provided in Chapter 2 of the Operator’s Manual.
Defective subassemblies may be returned to DYNEX Technologies or your DYNEX
Technologies distributor, where comprehensive repair facilities are available.
The service engineer should contact the local DYNEX Technologies service office for
additional information.
DSX™ System Service Manual i

Warnings and Safety Precautions
Warnings and Safety Precautions
The DYNEX Technologies DSX™ Automated ELISA System is designed to meet all relevant
safety codes. The service engineer should note the following points:
1 If any fluid contains an organic solvent, make sure that the laboratory is well
ventilated, so that a build-up of solvent cannot occur. In addition, avoid open
flames and sparks.
2 The system should be plugged into a power line that is connected to a true
ground. Make certain that all internal grounding cables are connected.
3 The reagents, wash solution etc., may contain compounds that may be
hazardous. Always wear safety glasses and protective clothing when working with
the washing solution or when the washer is operating (when testing the system, it
is recommended that deionized water be used).
4 The microplates and the waste solution may contain materials that present a
toxicological, radioactive or biological hazard. If the system is returned to a
DYNEX Technologies service facility, make certain that a "Certification of
Decontamination" is submitted before working on the unit.
5 Line voltage is present in the Power Supply printed circuit board and lower
voltages are present in other components. If the power must be on during testing,
take care to avoid contacting exposed components.
6 The cover interlock is provided as a safety feature so that the unit will not function
when the cover is in the upright (open position). If the interlock is disabled, there
is the possibility for bodily injury from rapid movements by the X, Y, and Z
assemblies. Care should be taken when operating the unit in this state.
ii DSX™ System Service Manual

Table of Contents
Table of Contents
Chapter 1 Introduction to the DSX™ Automated ELISA System ............................................. 1-1
1.1 Overview .............................................................................................................. 1-1
1.2 Functional Description and Features................................................................... 1-2
1.3 Steps in an Analysis ............................................................................................ 1-3
1.4 Major Components of the System ....................................................................... 1-4
1.4.1 Work Area................................................................................................ 1-4
1.4.2 Ambient Drawer and Plate Holders......................................................... 1-5
1.4.3 Pipette Module ........................................................................................ 1-6
1.4.4 Incubator Modules................................................................................... 1-7
1.4.5 Wash Module........................................................................................... 1-8
1.4.6 Wash Buffer Containers .......................................................................... 1-9
1.4.7 Waste Containers.................................................................................. 1-10
1.4.8 Absorbance Module .............................................................................. 1-11
1.4.9 System Cover ........................................................................................ 1-12
1.5 Application Software .......................................................................................... 1-13
1.6 Contents of this Manual ..................................................................................... 1-14
Chapter 2 Installation....................................................................................................................2-1
2.1 Overview .............................................................................................................. 2-1
2.2 Receipt of the System.......................................................................................... 2-1
2.3 Power Requirement ............................................................................................. 2-1
2.4 Locating the System in the Laboratory ................................................................ 2-1
2.5 Loading the Application ....................................................................................... 2-2
2.6 Initializing Communication ................................................................................... 2-4
2.7 Loading the Desired Assay.................................................................................. 2-8
Chapter 3 Maintenance and Introduction to Service................................................................. 3-1
3.1 Overview .............................................................................................................. 3-1
3.2 User Maintenance................................................................................................ 3-2
3.2.1 Maintenance Schedule............................................................................ 3-2
3.3 Cleaning and Decontamination............................................................................ 3-4
3.3.1 Cleaning the System ............................................................................... 3-4
3.4 Servicing the DSX Automated ELISA System..................................................... 3-5
3.4.1 Servicing Modules ................................................................................... 3-5
3.4.2 Servicing Non-Modular Components ...................................................... 3-5
3.5 Post-Service Checkout Protocol .......................................................................... 3-6
3.5.1 Role of the Post Service Checkout Protocol ........................................... 3-6
3.5.2 Power Down the System ......................................................................... 3-6
3.5.3 Workspace Calibration ............................................................................ 3-6
3.5.4 Module Calibration ................................................................................ 3-10
3.5.5 Drawer Calibration................................................................................. 3-11
3.5.6 Manual Adjustment of the Module Calibration ...................................... 3-12
3.5.7 Cycle Test.............................................................................................. 3-15
3.5.8 Tip Alignment Test ................................................................................ 3-15
3.5.9 Manual Wash Plate Test ....................................................................... 3-16
3.6 Returning Components...................................................................................... 3-18
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Table of Contents
Chapter 4 Troubleshooting ...........................................................................................................4-1
4.1 Overview...............................................................................................................4-1
4.2 Initialization ...........................................................................................................4-2
4.2.1 The Instrument Fails to Power up ............................................................4-2
4.2.2 The System Cannot Communicate with the Computer............................4-3
4.2.3 General Information..................................................................................4-3
4.2.4 Checking the Communication Link...........................................................4-4
4.2.5 Incorrect Password...................................................................................4-5
4.3 System Problems..................................................................................................4-6
4.3.1 Communication Problems ........................................................................4-6
4.3.2 Problems in a Specific Module.................................................................4-9
4.4 Application Problems..........................................................................................4-10
Chapter 5 Manual Operation of the System ................................................................................5-1
5.1 Overview...............................................................................................................5-1
5.2 Manual Control Operations...................................................................................5-2
5.2.1 Selecting the Desired Operation ..............................................................5-2
5.2.2 Performing the Operation.........................................................................5-3
5.2.3 Testing the Reader...................................................................................5-3
5.2.4 Testing the Drawer ...................................................................................5-4
5.2.5 Incubators.................................................................................................5-5
5.2.6 Washer .....................................................................................................5-6
5.2.7 Plate Movement .......................................................................................5-8
5.2.8 Arm...........................................................................................................5-9
5.2.9 Advanced ...............................................................................................5-11
5.2.10 Testing..................................................................................................5-12
5.3 Washing A Plate .................................................................................................5-13
Chapter 6 The Pipette Module/XYZ Drive ....................................................................................6-1
6.1 Overview...............................................................................................................6-1
6.2 The X-Drive and Y-Drive ......................................................................................6-3
6.2.1 General Design of the Drive Mechanisms ...............................................6-3
6.2.2 Command Types ......................................................................................6-7
6.2.3 Top Level Functional Design....................................................................6-8
6.2.4 Hardware Considerations.........................................................................6-9
6.3 The Z-Drive and the Pipette Module...................................................................6-11
6.3.1 General Design of the Drive Mechanisms .............................................6-11
6.3.2 Command Types ....................................................................................6-13
6.3.3 Top Level Functional Design..................................................................6-15
6.3.4 Hardware Considerations.......................................................................6-15
6.4 Serial Communication with the Controller ..........................................................6-16
Chapter 7 Replacing Components - Pipette/XYZ Axis Assemblies ..........................................7-1
7.1 Overview...............................................................................................................7-1
7.2 Troubleshooting ....................................................................................................7-2
7.3 Replacing the Pipette Assembly...........................................................................7-4
7.4 The Z-Drive Assembly ........................................................................................7-16
7.4.1 Removing the Z-Drive Assembly............................................................7-16
7.4.2 Replacing the Z-Drive Spring Assembly ................................................7-17
7.4.3 Removing and Replacing the Z-Drive Encoder......................................7-20
7.4.4 Replacing the Z-Drive Optointerrupter Assembly ..................................7-21
7.4.5 Replacing The Z-Drive Belt ....................................................................7-22
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Table of Contents
7.4.6 Replacing the Z Motor ........................................................................... 7-27
7.4.7 Replacing the Idler Assembly................................................................ 7-28
7.4.8 Replacing the Z Axis Transition Board.................................................. 7-30
7.5 The Y-Drive Assembly ....................................................................................... 7-31
7.5.1 Removing the Y-Drive Assembly .......................................................... 7-31
7.5.2 Removing the Y-Transition Printed Circuit Board ................................. 7-32
7.5.3 Replacing the Encoder .......................................................................... 7-33
7.5.4 Removing the Y-Axis Drive Belt ............................................................ 7-35
7.5.5 Removing the Y Optointerrupter............................................................ 7-40
7.5.6 Removing the Pulley ............................................................................. 7-41
7.5.7 Removing the Y Axis Motor................................................................... 7-41
7.5.8 Replacing the Idler Pulley...................................................................... 7-42
7.6 The X Axis Drive Assembly ............................................................................... 7-43
7.6.1 Replacing the Optointerrupter ............................................................... 7-43
7.6.2 X-Axis Motor.......................................................................................... 7-43
7.6.3 Replacing the Encoder .......................................................................... 7-44
7.6.4 Removing the Pulley from the X-Drive Motor........................................ 7-46
7.6.5 Replacing the X Idler Pulley Assembly ................................................. 7-47
7.6.6 Adjusting the X-, Y-, or Z- Motor Pulley and Idler Pulley....................... 7-50
7.6.7 Replacing the X Transition Printed Circuit Board.................................. 7-51
7.6.8 Replacing the X-Drive Belt .................................................................... 7-53
7.7 Spare Parts and Jigs ......................................................................................... 7-57
7.7.1 Z-Drive Assembly (13001440)............................................................... 7-57
7.7.2 Y-Drive Assembly (13001430) .............................................................. 7-58
7.7.3 X-Drive Assembly (13001420) .............................................................. 7-59
7.7.4 Jigs ........................................................................................................ 7-59
Chapter 8 The Incubator Module ................................................................................................. 8-1
8.1 Overview .............................................................................................................. 8-1
8.2 Design of the Incubator Module........................................................................... 8-1
8.3 Electrical/Control Considerations......................................................................... 8-2
8.4 Operational Activities for the Incubator Module................................................... 8-4
Chapter 9 Servicing the Incubator Module................................................................................. 9-1
9.1 Routine Maintenance/Service Procedures .......................................................... 9-1
9.2 General Troubleshooting ..................................................................................... 9-1
9.3 Removing External Components......................................................................... 9-3
9.3.1 The Top Cover......................................................................................... 9-3
9.3.2 The Bottom Cover ................................................................................... 9-4
9.3.3 The Front Bezel....................................................................................... 9-5
9.3.4 Removal/Replacement of the Plate Carrier Door.................................... 9-6
9.4 Repairing/Replacing Internal Components.......................................................... 9-9
9.4.1 Removal/Replacement of the Main Circuit Board ................................... 9-9
9.4.2 Replacing the Top Heater Plate Assembly ........................................... 9-11
9.4.3 Removal of the Eject Sensor................................................................. 9-13
9.4.4 Removing the Position Sensor .............................................................. 9-14
9.4.5 Removal/Replacement of the Drive Belt ............................................... 9-15
9.4.6 Removing the Plate Carrier Motor......................................................... 9-17
9.4.7 Removal/Replacement of the Plate Carrier Assembly.......................... 9-19
9.4.8 Replacement of Lower Heater Assembly.............................................. 9-21
9.4.9 Removal/Replacement of Locking Lever/Pivot/Spring.......................... 9-23
9.4.10 Removal/Replacement of the Plate Carrier Bearings ......................... 9-25
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Table of Contents
9.5 Spare Parts.........................................................................................................9-26
9.6 Jigs......................................................................................................................9-26
Chapter 10 The Reader Module ....................................................................................................10-1
10.1 Overview .........................................................................................................10-1
10.2 Design of the Optical Module ..........................................................................10-1
10.2.1 General Characteristics........................................................................10-1
10.2.2 Optical Considerations .........................................................................10-2
10.2.3 Electrical/Control Considerations .........................................................10-3
Chapter 11 Servicing the Reader Module....................................................................................11-1
11.1 Routine Maintenance/Service Procedures......................................................11-1
11.1.1 Replacing the Lamp .............................................................................11-1
11.1.2 Removing and/or Installing a Filter.......................................................11-2
11.2 Troubleshooting the Reader Module...............................................................11-4
11.2.1 Error Messages upon Power up...........................................................11-4
11.2.2 General Troubleshooting......................................................................11-6
11.2.3 Measurement Errors.............................................................................11-9
11.3 Removing External Components ..................................................................11-11
11.3.1 The Top Cover ...................................................................................11-11
11.3.2 The Bottom Cover ..............................................................................11-12
11.3.3 The Front Bezel..................................................................................11-13
11.3.4 Removal/Replacement of the Plate Carrier Door...............................11-14
11.4 Repairing/Replacing Internal Components ...................................................11-17
11.4.1 Removal/Replacement of the Main Board .........................................11-17
11.4.2 Removal/Replacement of the Plate Carrier Motor .............................11-18
11.4.3 Removal/Replacement of the Drive Belt ............................................11-21
11.4.4 Removal/Replacement of the Plate Carrier Assembly.......................11-22
11.4.5 Removal/Replacement of Locking Lever/Pivot/Spring.......................11-23
11.4.6 Removal/Replacement of the Plate Carrier Bearings ........................11-24
11.4.7 Installing the Plate Carrier..................................................................11-25
11.4.8 Removal/Replacement of the Idler Bearings .....................................11-26
11.4.9 Removal/Replacement of the Fiber Optic Bundle..............................11-28
11.4.10 Removal/Replacement of the Optics Cube......................................11-29
11.4.11 Removal/Replacement of the Lens Holder ......................................11-30
11.4.12 Removal/Replacement of the Optics in the Lens Bracket ...............11-31
11.4.13 Removal/Replacement of the Lamp Holder .....................................11-32
11.4.14 Removal/Replacement of the Optics Cube Fan...............................11-33
11.4.15 Removal/Replacement of the Filter Wheel ......................................11-34
11.4.16 Removal/Replacement of the Filter Motor .......................................11-35
11.4.17 Removal/Replacement of the Filter Switch ......................................11-36
11.4.18 Removal/Replacement of the Slide Blocks ......................................11-37
11.4.19 Removal/Replacement of the Plate In and Out Sensors .................11-38
11.4.20 Removal of the Eject Sensor............................................................11-39
11.4.21 Removal/Replacement of the Upper Optic Block.............................11-40
11.4.22 Separating the Upper Block Components........................................11-41
11.4.23 Removing/Replacing the Lower Optic Block....................................11-42
11.4.24 Separating the Lower Block Components........................................11-44
11.4.25 Rebuilding the Lower Optic Block ....................................................11-45
11.5 Spare Parts ...................................................................................................11-49
11.6 AM Module Jigs and Fixtures........................................................................11-51
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Table of Contents
Chapter 12 The Washer Module .................................................................................................. 12-1
12.1 Overview ........................................................................................................ 12-1
12.2 The Wash Delivery System and Waste Delivery System .............................. 12-1
12.3 The Drive Assemblies .................................................................................... 12-2
12.4 Basic Operations of the Plate Washer ........................................................... 12-4
12.4.1 Initialization.......................................................................................... 12-4
12.4.2 Purge ................................................................................................... 12-5
12.4.3 Dispense.............................................................................................. 12-5
12.4.4 Aspirate ............................................................................................... 12-6
12.4.5 Soak .................................................................................................... 12-6
12.4.6 Fill ........................................................................................................ 12-7
12.4.7 Bottom Wash....................................................................................... 12-7
12.4.8 Sweep.................................................................................................. 12-8
12.4.9 Move to Strips...................................................................................... 12-8
12.4.10 Terminate .......................................................................................... 12-9
12.4.11 Clean ................................................................................................. 12-9
12.5 Control of the Washer Module ..................................................................... 12-10
12.5.1 Block Diagrams ................................................................................. 12-10
12.5.2 Components of the Washer Module Electronics ............................... 12-12
12.6 Printed Circuit Boards .................................................................................. 12-14
12.6.1 Main Board ........................................................................................ 12-14
12.6.2 Daughter Board ................................................................................. 12-15
Chapter 13 Replacing Washer Module Components ................................................................ 13-1
13.1 Overview ........................................................................................................ 13-1
13.2 Troubleshooting.............................................................................................. 13-1
13.3 Replacing External Components.................................................................... 13-7
13.3.1 Dispense Bottle Assembly................................................................... 13-7
13.3.2 Waste Bottle Assembly ..................................................................... 13-11
13.3.3 Replacing The Aspirate Pump Assembly.......................................... 13-13
13.3.4 The Plate Carrier Assembly and Wash Head ................................... 13-14
13.3.5 Replacing the Vacuum Switch........................................................... 13-15
13.4 Repairing/Replacing Internal Components .................................................. 13-17
13.4.1 Accessing Internal Components........................................................ 13-17
13.4.2 Replacing the Pinch Valve ................................................................ 13-18
13.4.3 Replacing the Printed Circuit Board Assembly ................................. 13-20
13.4.4 Mounting the X/Z Subassembly ........................................................ 13-21
13.4.5 Mounting the Y Subassembly............................................................ 13-22
13.5 Replacing Components - Wash X/Z Subassembly ...................................... 13-23
13.5.1 Removing the Lower Front Panel...................................................... 13-23
13.5.2 Removing the Wash X-Drive Motor................................................... 13-24
13.5.3 Replacing the Wash X-Drive Timing Belt .......................................... 13-26
13.5.4 Replacing the X-Drive Microswitch ................................................... 13-27
13.5.5 Replacing the Z-Drive Motor ............................................................. 13-28
13.5.6 The Wash Z-Drive Belt ...................................................................... 13-30
13.5.7 The Wash Z Microswitch ................................................................... 13-31
13.6 Replacing Components - Y-Drive Assembly ................................................ 13-32
13.6.1 Replacing the Drive Belt.................................................................... 13-32
13.6.2 Removing the Moving Base Assembly.............................................. 13-34
13.6.3 Replacing the Y Sensor Assemblies ................................................. 13-35
13.6.4 Replacing the Bearings ..................................................................... 13-35
13.6.5 Replacing the Motor Assembly.......................................................... 13-36
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Table of Contents
13.6.6 Replacing the Motor Pulley ................................................................13-36
13.7 Spare Parts ...................................................................................................13-37
13.7.1 Dispense and Aspirate Bottle Assembly ............................................13-37
13.7.2 X-Drive and Z-Drive Assembly (13001571) .......................................13-37
13.7.3 Y – Drive Assembly (13001800) ........................................................13-38
13.7.4 Electronics Components ....................................................................13-38
13.7.5 Miscellaneous Items...........................................................................13-38
13.7.6 Jigs .....................................................................................................13-39
Chapter 14 The Ambient Drawer ..................................................................................................14-1
14.1 Overview .........................................................................................................14-1
14.2 General Electronics Design.............................................................................14-1
14.3 Hardware Considerations................................................................................14-3
14.3.1 Motor Drivers........................................................................................14-3
14.3.2 Voltage Generation and Regulation.....................................................14-3
14.3.3 Microcomputer......................................................................................14-3
14.3.4 Serial Communications with Controller ................................................14-4
Chapter 15 Servicing the Ambient Drawer/Bar Code Scanner..................................................15-1
15.1 Overview .........................................................................................................15-1
15.2 General Troubleshooting.................................................................................15-2
15.3 Accessing Internal Components .....................................................................15-3
15.4 Servicing Internal Components.......................................................................15-4
15.4.1 The Drive Mechanism ..........................................................................15-4
15.4.2 Replacing the Motor .............................................................................15-8
15.4.3 Replacing Idler Subassemblies............................................................15-9
15.4.4 Replacing the Main Circuit Board.......................................................15-10
15.4.5 Replacing the Optical Sensors...........................................................15-11
15.4.6 Replacing the Temperature Sensor ...................................................15-12
15.4.7 Replacing the Actuating Levers .........................................................15-13
15.5 Sample ID Module.........................................................................................15-14
15.5.1 Overview ............................................................................................15-14
15.5.2 Manual Testing of the Scan Module...................................................15-14
15.5.3 Replacing the Module ........................................................................15-15
15.5.4 Testing the Scan Module ...................................................................15-16
15.5.5 Setting the Barcode Options ..............................................................15-17
15.5.6 Spare Parts and Jigs..........................................................................15-18
15.5.7 Ambient Drawer Assembly.................................................................15-18
15.5.8 Jigs .....................................................................................................15-18
Chapter 16 Mechanical System Components .............................................................................16-1
16.1 Overview .........................................................................................................16-1
16.2 Accessing Internal Components .....................................................................16-1
16.2.1 Removing the Top Cover .....................................................................16-1
16.2.2 Removing the Rear Cover....................................................................16-2
16.2.3 Replacing the Cover Assembly ............................................................16-3
16.2.4 Removing the Right Side Panel ...........................................................16-4
16.2.5 Removing the Left Side Panel..............................................................16-6
16.3 Replacing the Interlock Switch ........................................................................16-8
16.4 Replacing a Gas Damping Spring...................................................................16-9
16.5 Replacing the Left Hinge...............................................................................16-10
16.6 Spare Parts ...................................................................................................16-11
16.7 Jigs ................................................................................................................16-11
viii DSX™ System Service Manual