Hygiena Autosampler III User manual

www.hygiena.com INS4088-REVA
Autosampler III User Manual

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About this guide
This manual should be used as a reference guide for the operators and technical staff who have
completed the user training. This manual provides the reader with detailed information about installation,
maintenance and service as well as the general use of the Autosampler III. Additional information about
specific applications can be made available by your supplier. Details about software installation and
protocol optimization may be provided with separate manuals. Images in this manual are intended to be
used generically and may not be representative of the (product) model. This manual should be treated
confidentially. The contents of this manual may not be reproduced without the permission of Hygiena®, nor
used in the wrong way, nor provided to third parties.
This document consists of the following parts:
• Internal/external transport
• Installation/adjustment
• Manual
• Instructions for operation
• Maintenance instructions
• Malfunctions and solutions
The different parts are intended for:
• Transport internal/external - Transport personnel
• Installation assembly/adjustment - Technical engineers
• Manual - Operators
• Repair manual - Service engineers
• Maintenance instructions - Service engineers
• Faults and solutions - Service engineers
Privacy statement
Hygiena is constantly working on the further development of its Autosampler III. The possibility of changes
in this document in terms of design, technical equipment and execution must therefore, be reserved. We
therefore inform the reader and owner of this manual that no claims can be assumed from the data in this
manual.
Safety symbols
The following aspects must be considered: before carrying out the work, this manual must first be carefully
examined. This prevents the Autosampler III from being used incorrectly. It is also advisable to keep this
manual with the Autosampler III so that the operator always has access to it.
The following symbols are used in the manual:

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Warning
Refer to the user manual
and pay attention
Warning
Dangerous voltage
Warning
Risk associated with chemicals
or biological material
Warning
Risk associated with
biological material
Warning
Warm surface
Warning
Optical radiation
Warning
Piercing hazard
Warning
Strong magnetic field
Warning
Trip hazard
Warning
Automatic starting machine
Warning
Beware of rotating parts
Warning
Beware of injuries to the hand
Note
Special explanation
Reserved for certified
engineers
Operations to be carried out
only by certified personnel
Tip
Interesting tips

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Table of Contents
1. Introduction ................................................................................................................................... 9
2. Technical specifications .............................................................................................................. 10
2.1. Mechanical ......................................................................................................................... 10
2.2. Electric................................................................................................................................ 10
2.3. Pneumatic........................................................................................................................... 11
2.4. Chemicals........................................................................................................................... 11
2.5. Sizes and weights............................................................................................................... 11
3. Transport and storage ................................................................................................................. 11
3.1. Transport ............................................................................................................................ 11
3.1.1. Internal transport ....................................................................................................... 11
3.1.2. External transport ...................................................................................................... 11
3.1.3. Lifting points.............................................................................................................. 11
3.2. Packaging........................................................................................................................... 13
3.2.1. Items included with Autosampler III .......................................................................... 13
3.2.2. Preparing for transport .............................................................................................. 14
3.2.3. Packaging exterior Autosampler III............................................................................ 14
3.3. Storage............................................................................................................................... 14
4. Assembly and installation............................................................................................................ 15
4.1. Installation .......................................................................................................................... 15
4.2. Commissioning................................................................................................................... 15
4.2.1. Commissioning instructions - general....................................................................... 16
4.2.2. Commissioning instructions - electrical components ............................................... 16
4.2.3. Commissioning instructions - pneumatic components............................................. 16
5. Machine functions ....................................................................................................................... 16
5.1. Workflow............................................................................................................................. 16
5.2. Load system....................................................................................................................... 16
5.3. Machine control.................................................................................................................. 18
5.4. Destacking and scanning ................................................................................................... 18
5.5. Smart vision camera........................................................................................................... 18
5.6. Pipetting ............................................................................................................................. 19
5.7. Sample dispensing and reagent addition........................................................................... 19
5.8. Shaking the sample............................................................................................................ 19
5.9. Plate output ........................................................................................................................ 20
5.10. Washing needles .............................................................................................................. 20
5.11. Carton box outfeed .......................................................................................................... 20
5.12. Stacklight.......................................................................................................................... 21
5.13. Emergency stop ............................................................................................................... 21
5.14. Doorlocks ......................................................................................................................... 21

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5.15. Conditions of use ............................................................................................................. 22
5.16. Description of the operator's workplace .......................................................................... 22
5.17. Personal protective equipment ........................................................................................ 22
5.18. Restrictions on the use of the Autosampler III ................................................................. 22
6. Standard operating procedure - Autosampler III......................................................................... 23
6.1. Prepare the compressor for use:........................................................................................ 23
6.1.1. Starting up the compressor:...................................................................................... 23
6.1.2. Shutting down of the compressor:............................................................................ 25
6.2. Starting up the Autosampler III........................................................................................... 25
6.3. Initializing the Autosampler III............................................................................................. 27
6.3.1. Checklist prior to starting Autosampler III initialization ............................................. 27
6.4. Starting Autosampler III initialization .................................................................................. 32
6.5. Priming the pumps ............................................................................................................. 33
6.5.1. Checklist prior to start priming the pumps................................................................ 33
6.5.2. Start priming method................................................................................................. 34
6.6. Loading plates.................................................................................................................... 34
6.7. Pre-Run .............................................................................................................................. 36
6.8. Lock/Unlock doors ............................................................................................................. 36
6.9. Starting a run...................................................................................................................... 37
6.10. Main run............................................................................................................................ 38
6.11. Dummies .......................................................................................................................... 39
6.12. Manual PO........................................................................................................................ 40
6.13. Exchange of liquids procedure......................................................................................... 42
6.13.1. Pumps ..................................................................................................................... 42
6.13.2. Chemical containers................................................................................................ 43
6.14. End of day procedure....................................................................................................... 48
7. Daily validation procedure........................................................................................................... 49
7.1. Autosampler III checks prior to starting daily validation..................................................... 49
7.2. Starting the daily validation ................................................................................................ 49
8. Replacing needle(s) ..................................................................................................................... 50
9. Cleaning the Autosampler III ....................................................................................................... 52
9.1. Outside of the Autosampler III............................................................................................ 52
9.1.1. See-through parts such as doors, windows and covers........................................... 52
9.1.2. Trespa panels (white)................................................................................................. 52
9.1.3. Frame parts ............................................................................................................... 52
9.1.4. Pipetting cabin (powder coated white)...................................................................... 52
9.1.5. Deck/stainless steel................................................................................................... 53
9.1.6. Barcode camera ........................................................................................................ 53
9.1.7. HMI ............................................................................................................................ 53

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9.2. Destacker unit .................................................................................................................... 53
9.3. Pipetting cabin.................................................................................................................... 53
9.3.1. Washing station ......................................................................................................... 53
9.3.2. Reagent dispenser..................................................................................................... 53
9.3.3. Downholders.............................................................................................................. 53
9.4. Shaker ................................................................................................................................ 54
9.5. Tubing................................................................................................................................. 54
9.6. Needles............................................................................................................................... 54
9.6.1. Regular cleaning of needles ...................................................................................... 54
9.6.2. Deep cleaning of needles .......................................................................................... 54
9.7. Pumps (syringes) ................................................................................................................ 55
9.8. Conveyor belt ..................................................................................................................... 56
9.8.1. Belt ............................................................................................................................ 56
9.8.2. Scraper ...................................................................................................................... 56
10. HMI / Xperimate operation panel .............................................................................................. 56
10.1. Login................................................................................................................................. 56
10.2. Sidebar ............................................................................................................................. 57
10.3. Recipe manager ............................................................................................................... 58
10.4. Top bar.............................................................................................................................. 59
10.5. General overview.............................................................................................................. 59
10.6. Plate detail overview......................................................................................................... 61
10.7. Alarm manager overview.................................................................................................. 62
10.8. Status overview ................................................................................................................ 62
10.9. User manager................................................................................................................... 63
10.10. Settings .......................................................................................................................... 64
11. Maintenance.............................................................................................................................. 64
11.1. Preparation maintenance ................................................................................................. 64
11.2. Maintenance instructions electrical components............................................................. 65
11.2.1. Barcode scanners and camera................................................................................ 65
11.2.2. Cables...................................................................................................................... 65
11.2.3. Switch cabinets ....................................................................................................... 65
11.3. Maintenance Instructions pneumatic components .......................................................... 66
11.3.1. Cylinder.................................................................................................................... 66
11.3.2. Air service unit ......................................................................................................... 66
11.3.3. Couplings and valves .............................................................................................. 66
11.3.4. Air tubing ................................................................................................................. 66
12. Maintenance service panel visualizations ................................................................................. 67
12.1. Introduction ...................................................................................................................... 67

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12.2. Main.................................................................................................................................. 67
12.2.1. Login........................................................................................................................ 67
12.2.2. Logout ..................................................................................................................... 68
12.3. Actuators .......................................................................................................................... 68
12.4. Sensors............................................................................................................................. 68
12.4.1. Safety....................................................................................................................... 68
12.4.2. Sensors.................................................................................................................... 69
12.4.3. Status light............................................................................................................... 69
12.5. Cylinders........................................................................................................................... 69
12.5.1. Cylinder control ....................................................................................................... 70
12.5.2. Stacker pins............................................................................................................. 70
12.6. Pumps .............................................................................................................................. 71
12.6.1. Wash pump ............................................................................................................. 71
12.6.2. Waste Valve ............................................................................................................. 71
12.7. Pipetting arm channel movements................................................................................... 71
12.7.1. General .................................................................................................................... 71
12.7.2. Control word............................................................................................................ 71
12.7.3. Status word ............................................................................................................. 71
12.7.4. Network ................................................................................................................... 72
12.8. Channel 1-4...................................................................................................................... 72
12.8.1. Single channel ......................................................................................................... 72
12.8.2. All............................................................................................................................. 73
12.9. Motors .............................................................................................................................. 74
12.9.1. Transport belt........................................................................................................... 74
12.9.2. Lift stacker............................................................................................................... 75
12.9.3. Pusher input ............................................................................................................ 75
12.9.4. Snare belt ................................................................................................................ 76
12.9.5. Pipetting arm ........................................................................................................... 76
12.10. Routines ......................................................................................................................... 76
12.10.1. Box handling.......................................................................................................... 77
12.10.2. Shaker.................................................................................................................... 77
12.10.3. Plate input.............................................................................................................. 77
12.10.4. Plate output ........................................................................................................... 78
12.10.5. Pipetting arm ......................................................................................................... 78
13. Camera jobs .............................................................................................................................. 78
13.1. Create new camera job .................................................................................................... 78
13.2. Modify existing camera job .............................................................................................. 86
13.3. Parameter overview.......................................................................................................... 88

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14. Errors and warnings .................................................................................................................. 89
15. Lockout tagout .......................................................................................................................... 94
15.1. Definitions......................................................................................................................... 94
15.2. Lockout rules.................................................................................................................... 95
15.3. Sequence to lockout or tagout......................................................................................... 95
15.4. Sequence to restore the Autosampler III to normal production operations ..................... 96
16. Patch management ................................................................................................................... 97
16.1. Xperimate ......................................................................................................................... 97
16.2. HMI................................................................................................................................... 97
16.3. Windows updates............................................................................................................. 97
16.4. Installing software............................................................................................................. 97
16.5. List of drivers.................................................................................................................... 98
17. Spare parts list .......................................................................................................................... 98
18. Tools .......................................................................................................................................... 98
19. Decommissioning and disposal ................................................................................................ 99
19.1. Disassemble ..................................................................................................................... 99
19.2. Environment...................................................................................................................... 99
19.3. Disposing.......................................................................................................................... 99
Appendix I: Camera flow including barcode processing............................................................... 100

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1. Introduction
The Autosampler III aims to move liquid samples quickly, accurately and consistently from customer products
to microtiter plates.
The Autosampler III is made from high quality, durable components. The surface of the Autosampler III is
made from stainless steel 304 which makes for an anti-corrosive surface that is made to last. The anodized
aluminum frame allows for quick and easy manufacturing and allows for adjustments when necessary. The
outside of the framework is closed to minimize cleaning efforts.
The pipetting cabin is the heart of the Autosampler III. In the pipetting cabin, the samples are aspirated
from the products and dispensed into microtiter plates. The pipetting cabin can be safely entered by the
operator to perform cleaning and daily maintenance tasks by means of interlocks. This prevents the user from
entering the Autosampler III while the system is running and forces the user to make a controlled stop of the
Autosampler III. Besides the main lockable access door on the front, the user can also access the pipetting
cabinet from the side and from the back.
Because of this three-point access, the user has
many options to enter the Autosampler III in a
comfortable manner.
The electrical cabinets are not accessible for
the user, they utilize special keys to only allow
certified personnel to access the electrical
Autosampler III. However, the user can easily
power up the Autosampler III with the main
electrical switch on the front of the system.
A closed conveyor feeds carton boxes
containing samples into the Autosampler III. Transparent covers are implemented to shield the user from
hazards, but still provide a means to visually inspect the process. If access to the conveyor is required, the
access hatch on top or the several doors of the pipetting cabinet can be used. These access points should
allow the user to clean the Autosampler III after a day's work.
Stacklight Cognex camera
Air service unit (behind panel)
IO Cabinet A
Waste connection to drain (behind panel)
Diaphragm pump
Cooler peltierFluid container (2x)
Syringe pumps (6x)

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The user can load all necessary fluids
from one central place in the front
of the Autosampler III. On top of this
so-called fluid bay, the user loads
the necessary number of plates to be
processed by the Autosampler III into
an automated stacker. The stacker is
covered by a cover plate to ensure
cleanliness of the top plate even if the
stack is not emptied completely.
The user controls and receives
feedback using a touch panel. Having
one point of system control allows for
easy and understandable workflows
on the lab.
After the Autosampler III finishes the
sample preparations, the finished
product exits the system allowing
the user to pick up the samples and
place them into an Innovate for ATP
testing. The whole process of sample
preparation is done autonomously
including the linking to the local LIMS
as well as the innovates.
2. Technical specifications
The Autosampler III needs two power utilities: compressed air and electricity. In addition, for proper
functioning of the Autosampler III, the system's various liquid reservoirs must be filled. Both power
connections can be found on the back of the Autosampler III and are connected by means of a power plug
and a pressure fitting. For correct functioning of the Autosampler III the drain of the system needs to be
attached to the sewage at floor level. For alternatives to a floor level sewage please contact your supplier.
2.1. Mechanical
The Autosampler III is intended to be used in a lab or otherwise clean environment. Room temperature
(0-40 °C), Humidity levels (theoretical) max 80%.
The Autosampler III is intended to be connected to an infeed supply of products and an outfeed such as roller
conveyors. It is expected that products are presented at the infeed of the Autosampler III and that products
once pushed out of the Autosampler III are removed.
Room temperature (0-40 °C), Humidity levels max 80%
2.2. Electric
Electrical energy supply requirements for the Autosampler III:
Rated voltage: 400 V
Rated frequency: 50 Hz
1 x CEE plug 400V 16A 5P 6H (3 Phase + N + PE) separate group.
Pipetting arm:
- Pierce needle (4x)
- Varispan
Box output
Wash station
LED bar (2x)
Alignment bar
Emergency buttonEmergency button
Box separation
Box input
Box alignment
Box barcode readerShaking conveyor
Regent dispenser (2x)
Plate input stacker
(capacity: 40 shallow well MTP)
HMI
IO Cabinet B IO Cabinet C Belt scraper and capture tray (behind panel)

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2.3. Pneumatic
The required air quality class is 4 or 5.
The amount of air that the product uses in normal liters per unit of time is estimated at 20 L/min.
The minimum pressure is rated at 5 Bar and optimal pressure is rated at 7 Bar.
2.4. Chemicals
The Autosampler III is made to pipette liquids. Additional information about specific applications and their
chemicals can be made available by your supplier. You can also request the corresponding MSDS Material
safety data sheets.
• INS4003 en-US-ATX-200-SDS-2051000 Ver 3.0.pdf
• INS4045 en-US-Microwash-SDS-321410175 Ver 2.0.pdf
• INS4048 en-US-Microwash-SDS-321410500 Ver 2.0.pdf
• INS4074 ATP Buffer-atp-SDS Rev 2.0.pdf
The Autosampler III is designed to allow proper cleaning. The working surface is closed off as much as
possible and can therefore, be cleaned properly. Connections on the worktop are resistant to alcoholic
cleaning products. The Autosampler III is equipped with anodized aluminum and stainless steel. Chlorinated
agents can affect these areas with prolonged use. When the Autosampler III is cleaned using wet, dry and or
chemical means, the system must always be switched off by means of the main switch. Cleaning of the
Autosampler III is addressed in Chapter 9 Cleaning the Autosampler III.
2.5. Sizes and weights
The Autosampler III has the following
physical properties:
• Dimensions:
– Depth: 138 cm
– Width: 246 cm
– Height: 175 cm
• Weight: 800 kg
• Sound level
– Measured average: 68 dB
3. Transport and storage
This section contains important information about how to transport and move the Autosampler III correctly. It
describes which measures should be taken during transport as well as the necessary lifting tools necessary
to pick up/place the Autosampler III on and from a truck. This chapter distinguishes between internal and
external transport. Internal transport refers to transport within buildings and external transport refers to
transport outside buildings, for example when the Autosampler III is transported by truck.
3.1. Transport
Before any kind of transport, the product must be packed in accordance with the procedure described in
3.2.3 Packaging Exterior Autosampler III.
1900
2210
3126 1379

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3.1.1. Internal transport
A pallet lift can be used to move the Autosampler III within a building. Please note the sizes specified in
this user manual. If the Autosampler III is to be moved through doors or narrow and/or low passages, this
should be done at appropriate speed to avoid damage. Follow additional instructions on the packaging of the
Autosampler III.
3.1.2. External transport
When the Autosampler III needs to be transported outside, the necessary measures must be taken.
Transportation should always follow local laws and regulations.
• Transport, loading and unloading of the Autosampler III may only be carried out by authorized,
skilled personnel.
• The device can only be lifted from below (no lifting anchors are available). When lifting the
Autosampler III utmost care must be taken to prevent injuries.
• The device must not be tilted.
• When using a forklift truck or pallet truck to move the Autosampler III it must be ensured that
non-load-bearing parts cannot be damaged.
• When using pallets or other forms of formwork, these must be properly secured, and the associated
safety precautions should be considered.
3.1.3. Lifting points
There are two options available for lifting the
Autosampler III. The Autosampler III can either be
lifted from the rear side using a single pallet truck,
or the Autosampler III can be lifted from both
sides, which requires two pallet trucks.
The lifting points of the Autosampler III are based
on a pallet truck with the following dimensions:
• Total width: 550 mm
• Fork width: 160 mm
• Fork length: 1150 mm
When lifting the Autosampler III, the forks of the pallet lift should be placed below the arrows, where the arrow
is pointing towards the middle of the fork.
3.1.3.1. Lifting points rear side
Lifting the Autosampler III from the rear side can be done with a
single pallet truck positioned at the lifting points on the rear side.
Position the forks below the machine at 1150 mm depth to lift
the machine.
Fork placement when lifting the Autosampler III
Lifting points rear side Autosampler III

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3.1.3.2. Lifting points sides
The Autosampler III can also be lifted from the left and right side, which requires two pallet trucks. Position
the forks of the pallet truck below the lifting points on both the left and right side of the Autosampler III. The
forks of the pallet truck on the left side need to be placed at a depth of 550-650 mm. Do not exceed this
depth, since this can damage the tubing and connectors below the system. The forks on the right side can be
moved to a depth of 1150 mm.
Lifting points, left side Autosampler III Lifting points, right side Autosampler III
3.2. Packaging
In order to ensure safe transport, both for the transporter and the Autosampler III, the packaging instructions
must be observed. When moving the Autosampler III, remove all loose or demountable (without tool) items
from the system. If chemical/biological material has been used on the Autosampler III, it must be cleaned
in accordance with applicable guidelines to protect the transporter. Products that are damaged must be
documented before packaging.
3.2.1. Included items with Autosampler III
The Autosampler III has several parts that are removable and supplied separately. See table below.
Article Quantity Image
Needles 4
SBS cover 1
Compressor Where applicable
User manual 1
CE declaration 1
Keep the original packaging in order to move the
Autosampler III correctly.

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3.2.2. Preparing for transport
The moving parts in the Autosampler III must be fixed before movement to prevent damage during transport.
The following steps must be followed:
1. Make sure that the machine is clean. Further guidance in doing so is described in Chapter 9.
2. The Autosampler III must be shut down as described in Chapter 6.1.2.
3. Shut down the compressed air source and bleed it down.
4. Disconnect the air supply.
5. Make sure all loose parts are removed from the Autosampler III.
6. Remove the samples and plates from the Autosampler III.
7. Remove all parts that can be dismantled without using tools.
3.2.3. Packaging Exterior Autosampler III
To prevent damage to the outside of the Autosampler III, it should be packed with the following materials.
Material Image
Protective edge covers
Protection strap
(Transparent) stretch film
The packaged Autosampler III shall be fitted with the standard packing slip.
3.3. Storage
The Autosampler III must always be stored indoors. For the proper functioning of the Autosampler III and
optimal maintenance of the service life, the following environmental conditions are prescribed:
Condition Specification
Temperature during use 0 to 40 °C
Temperature during transport -10 to 60 °C (make sure no liquids are within the
Autosampler III)
Humidity when used 20 to 80% relative humidity (no condensation allowed)
Storage environment Cool and dry environment

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4. Assembly and installation
This chapter explains how the assembly and installation should be carried out. Please refer to this chapter
when the Autosampler III has been moved.
The assembly and installation of the Autosampler III is carried out by personnel of Hygiena Partners or by
an external body that has been authorized to do so by Hygiena. The final check is carried out by Hygiena
Partners. The assembly and installation is carried out by qualified and experienced technicians. This chapter
is written for the technicians who assemble, install and test the Autosampler III. The user of the Autosampler
III can use this chapter as an information tool to verify that the installation was done properly.
The following conditions must be met before both assembly and installation:
• Assembly and installation of the Autosampler III should only be carried out by qualified,
skilled personnel.
• Only correct, undamaged and sturdy tools should be used.
4.1. Installation
Before installing the Autosampler III, clearly identify where it should be installed and how the system should
get to its destination. The Autosampler III must be placed in a clean and dust-free location. Before the
Autosampler III can be installed, all packaging material must be removed from the Autosampler III with care.
Some tools maybe required to install the Autosampler III, see tool overview in Chapter 18. Before unpacking
and installing, it is recommended to take a photo of the Autosampler III. After unpacking, a photo must also
be taken. The photos are archived and taken by both the sending and receiving party. This is done to ensure
the proper state upon receipt. In order to install the product, the following power sources must be provided:
• Voltage according to connection value
• Air pressure according to connection value
4.2. Commissioning
This chapter describes the steps to follow, before using the Autosampler III.
• Before starting the Autosampler III, check that all removed parts are properly mounted and secured.
It is also necessary to check that there are no loose parts, such as tools and cleaning cloths, in the
Autosampler III.
• There should be no personnel inside the Autosampler III when it is switched on.
• Only correct products must be used according to the specifications. If a different product needs to be
processed, consult your supplier.
• Do not access a running Autosampler III with (cleaning) tools.
• While operating the Autosampler III, pay attention to unusual noises and take appropriate action
if necessary.
• Before commissioning the Autosampler III, all defects must be corrected.
Watch out! In addition to the precautions and safety instructions described on
page 3, there are specific safety instructions and warnings regarding transport,
loading and unloading, assembly and installation, and commissioning.
Reserved for certified engineers.
Operations to be carried out only by certified personnel.
Reserved for certified engineers.
Operations to be carried out only by certified personnel.

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4.2.1. Commissioning instructions General
• Make sure the Autosampler III is matched to the correct products.
• In order to ensure the safe operation of the Autosampler III, the protective devices, such as the door
locks and emergency stop, must be checked.
• The fixed guards such as windows and panels must be properly mounted or installed before
commissioning.
4.2.2. Commissioning instructions Electrical Components
• The safety devices, barcode scanners, camera and control panel must be undamaged and clean.
• The barcode scanners and control camera must be set to the correct height.
• When starting the Autosampler III, take into consideration that certain electrical components can start
to move.
4.2.3. Commissioning instructions Pneumatic Components
• The valve of the compressed air unit should be opened.
• The air service unit must be set to the correct pressure,
as indicated in the technical specification: 7 bar.
• Please note the nominal working pressure of 7 bar. A higher
working pressure will adversely affect the life of the pneumatic
components.
• The water separator should be empty.
• When starting up the Autosampler III, keep in mind that certain
pneumatic components can move.
5. Machine functions
Chapters 6 to 10 describe how to operate the Autosampler III.
This chapter provides the user with information about what functions are provided in the machine to get
familiar with the subsystems before usage. It is important that the user familiarizes themself with these
instructions before using the Autosampler III.
5.1. Workflow
The Autosampler III has several operating modes that can be started from the HMI interface. The sampling
and manipulating procedure can differ depending on the operating mode such as sampling without adding
reagents and or shaking. The machine can also just perform the manipulating tasks, reagents adding and
shaking, without sampling. The daily ATP validation routine is performed the same way but has a (software)
sample limitation.
5.2. Load system
The user loads the system with microtiter plates into the destacker. The destacker has a capacity of up to 40
plates. To protect the plates in the system from external influences, the user must add the closing plate on
the top of the stack. This closing plate cannot enter the machine and therefore also functions as a closing
mechanism for the destacker itself. The closing plate has an edge on the sides which makes the closing plate
larger than the destacker access hole.
Compressed air valve in open state
Warning
Dangerous voltage

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The Autosampler III has a dedicated pump bay from which all fluids used in the system originate. The fluid bay
houses the pumps, fluid containers and the cooling block. From the fluid bay, the liquids are distributed within
the system. The fluid bay has a raised edge to prevent any accidental spillage from falling on the floor. The
bottom of the bay has a drain plug that can be connected to the waste connection. The layout of the fluid bay
can be seen in the figure below.
Samples enter the machine from an external rolling conveyor. The system separates the carton boxes from each
other and aligns the box to the side rail (green) with a push bar (blue). This allows the Autosampler III to work
with various box and sample sizes. As the cardboard box is slightly tilted at an angle, filling of the partially filled
boxes with material to keep them in place may be needed. Products that are not aligned in some form may not
be recognized for sampling.

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5.3. Machine control
The HMI is used to control the system and is
connected to the main computer. The user can
initialize, start, pause and stop the machine
using the HMI. The HMI is used to start the
various operation modes that the software
offers such as normal operation, validation
routines, but also maintenance tasks. The user
gets feedback from the HMI in case actions are
required but also allows the user to follow the
progress of the machine. The HMI is also used
in case user input is required, such as the input
of barcodes. The HMI is based on an industrial
touch panel. Next to the panel, an emergency
stop is available as well as a button to reset the
safety network.
5.4. Destacking and scanning
The microtiter plates are fed into the system one
by one by the destacking module. When a plate
is destacked, the plate is located at the barcode
scanning position, where the integrated barcode
scanning camera scans the barcode of the plate.
When the barcode is correct it is coupled to the
box/sample LIMS ID.
5.5. Smart vision camera
The Autosampler III is equipped with a Cognex smart camera. The camera is used to detect the piercing
positions and the grid layout of a box.
A barcode camera is placed outside the pipetting cabin to read the barcodes on the boxes containing the
products. The barcodes provide the system with information on what product is being processed. Using this
information presets can be loaded for various functions of the system. The barcode of the box is matched
with the barcode of the microtiter plate.

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5.6. Pipetting
Samples are pipetted by the pipetting arm.
The variable pitch allows for sampling of different
products with different diameters and heights.
A push off mechanism is integrated to remove the
products from the needles to prevent products from
getting stuck. The pipetting arm transfers the sample
from the product to the microtiter plate and performs
the washing steps. The conveyor aligns the new
products to be sampled and the reagent dispensers
add the reagents. In term of motion: the pipetting
arm does the Y-Z movements and the conveyor
does the X movements.
5.7. Sample dispense and reagent addition
The samples are dispensed into the microtiter plate
per column. When a column is filled the plate is moved one column further for the next 8 samples.
After the samples are filled in the microtiter plates, the two reagents, ATX and buffer, are dispensed on top of
the sample. this is done by two 8-channel dispensers. The dispensers both add 25 microliters to the sample
in the well.
5.8. Shaking the sample
After the samples and the reagents have been added
to the microtiter plate, the samples are homogenized
in a shaking routine of five minutes. The shaker
conveyor belt allows for each sample to have nearly
the exact same chemical reaction time.

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5.9. Plate output
When the shaking has been completed the plate is pushed out of the system so that the user can bring the
final product to the analyzer for analysis. A push mechanism removes the plate from the shaker and pushes
it out onto the plate output buffer.
The Autosampler III has an output buffer to enable continuous processing of products. The output buffer
is filled one by one with the push mechanism described above. The buffer is accessible by opening the
transparent panels that close off the output buffer. The panels are used to minimize the introduction of
external particles such as dust. The panels are transparent so the user can see what panel to open in order
to remove a plate.
A fixed sensor is positioned at the tenth plate position to alert the user and stop the machine once the output
buffer reaches 10 plates.
5.10. Washing needles
The pipetting needles are washed in a washing module
to prevent contamination between samples. The
washing module washes both the external part of the
needle as well as the inside.
5.11. Carton box outfeed
The outfeed of the system has two rollers to connect
to an external conveyor. The system detects a correct
outfeed, otherwise the system stops.