Leica ASP300 S User manual

Leica ASP300 S
Advanced Smart Processor
Automated vacuum
tissue processor
Operating Manual
Leica ASP300S
V1.0 English - 07/2006
Always keep this manual together with the instrument.
Read this instruction manual carefully before working
with the instrument.

3
Leica ASP300 S
The information, numerical data, notes and value
judgments contained in this manual represent
the current state of scientific knowledge and
state-of-the-art technology as we understand it
following thorough investigation in this field.
We are under no obligation to update the present
manual according to the latest technical devel-
opments, nor to provide our customers with addi-
tional copies, updates etc. of this manual.
For erroneous statements, drawings, technical
illustrations etc. contained in this manual we
exclude liability as far as permissible according
to the national legal system applicable in each
individual case. In particular, no liability whatso-
ever is accepted for any financial loss or conse-
quential damage caused by or related to compli-
ance with statements or other information in this
manual.
Statements, drawings, illustrations and other
information as regards contents or technical
details of the present manual are not to be
considered as warranted characteristics of our
products.
These are determined only by the contract provi-
sions agreed between ourselves and our cus-
tomers.
Leica reserves the right to change technical
specifications as well as manufacturing process-
es without prior notice. Only in this way is it pos-
sible to continuously improve the technology and
manufacturing techniques used in our products.
This document is protected under copyright
laws. Any copyrights of this document are
retained by Leica Microsystems Nussloch GmbH.
Any reproduction of text and illustrations (or of
any parts thereof) by means of print, photocopy,
microfiche, web cam or other methods – including
any electronic systems and media – requires
express prior permission in writing by
Leica Microsystems Nussloch GmbH.
For the instrument serial number and year of
manufacture, please refer to the name plate at
the back of the instrument.
© Leica Microsystems Nussloch GmbH
NOTE
Published by:
Leica Microsystems Nussloch GmbH
Heidelberger Str. 17 - 19
D-69226 Nussloch
Germany
Telephone: [phone]
Fax: [phone]
Internet: http://www.histo-solutions.de

4Operating Manual V 1.0 – 07/2006
Table of Contents
1. Important information ................................................................................................................. 6
2. Safety .............................................................................................................................................. 7
2.1 Safety instructions .................................................................................................................................... 7
2.2 Warnings .................................................................................................................................................... 7
2.3 Integrated safety devices ...................................................................................................................... 11
3. Instrument components and specifications ......................................................................... 12
3.1 Overview - instrument components..................................................................................................... 12
3.2 Specific instrument options .................................................................................................................. 14
3.3 Standard delivery - packing list ............................................................................................................ 15
3.4 Technical Data ........................................................................................................................................ 16
3.5 Compatible reagents .............................................................................................................................. 19
4. Setting up the instrument ......................................................................................................... 20
4.1 Site requirements ................................................................................................................................... 20
4.2 Electrical connection ............................................................................................................................. 20
4.3 Installing the accessories ..................................................................................................................... 22
4.4 Setting up the data connections .......................................................................................................... 23
4.5 Alarm functions ....................................................................................................................................... 24
4.6 Switching the instrument on ................................................................................................................. 25
4.7 Touchscreen functions .......................................................................................................................... 27
4.8 Checklist for first operation ................................................................................................................... 28
5. Operation ..................................................................................................................................... 29
5.1 Setting up the instrument parameters ................................................................................................. 29
5.1.1 System setup ........................................................................................................................................... 29
5.1.2 Access levels .......................................................................................................................................... 32
5.1.3 INSTALLATION menu ............................................................................................................................. 34
5.1.4 Editing the reagent list ........................................................................................................................... 37
5.1.5 Viewing the program list ........................................................................................................................ 40
5.1.6 Adding and/or modifying programs ..................................................................................................... 41
5.1.7 Favorites ................................................................................................................................................... 44
5.1.8 Editing the stations ................................................................................................................................. 46
5.1.9 Reagent groups ....................................................................................................................................... 47
5.2 Reagent handling .................................................................................................................................... 48
5.2.1 Fill/drain reagents (other than wax) ..................................................................................................... 48
5.2.2 Changing the wax ................................................................................................................................... 50

5
Leica ASP300 S
Table of Contents
5.3 Running programs .................................................................................................................................. 53
5.3.1 Editing a selected program ................................................................................................................... 54
5.3.2 Starting a program .................................................................................................................................. 56
5.4 Reagent status ........................................................................................................................................ 57
5.5 System Monitor ....................................................................................................................................... 58
5.6 On-line help .............................................................................................................................................. 59
6. Solutions ...................................................................................................................................... 60
6.1 General ..................................................................................................................................................... 60
6.2 Power failure ........................................................................................................................................... 60
6.3 Troubleshooting ...................................................................................................................................... 61
6.4 Typical fill or drain problems................................................................................................................. 62
7. Cleaning and Maintenance ..................................................................................................... 63
7.1 Clean programs ....................................................................................................................................... 63
7.1.1 Retort clean programs ........................................................................................................................... 63
7.1.2 Wax clean program ................................................................................................................................ 65
7.1.3 Smart Clean ............................................................................................................................................. 66
7.2 General cleaning steps .......................................................................................................................... 67
7.2.1 Daily cleaning and maintenance .......................................................................................................... 69
7.2.2 Periodic cleaning and maintenance .................................................................................................... 71
7.3 Preventative maintenance schedule ................................................................................................... 72
8. Warranty and Service ............................................................................................................... 74

6Operating Manual V 1.0 – 07/2006
Symbols used in this manual
Warnings
appear in a gray box and are
marked by a warning triangle .
Notes,
i.e. important user information ap-
pear in a gray box and are marked
by an information symbol .
Flammable solvents and reagents
are marked with this symbol.
Instrument surfaces which become
hot during operation are marked
with this symbol.
Avoid direct contact with these sur-
faces - they may cause burns.
Figures in brackets refer to item
nos. in drawings.
Function keys to be pressed on the
instrument touch screen are written
in bold-print capital letters.
1. Important information
Designated use
The instrument has been designed so that it is
safe to use by the operator as well as for pro-
cessing specimens – provided that it is operated
according to the present instruction manual.
The Leica ASP300S is a modular automated
tissue processor designed for the following labo-
ratory applications:
• fixation,
• dehydration
• paraffin wax infiltration of histological
tissue specimens.
The Leica ASP300 S must be operated exclusively
with the reagents listed
in chapter 3.5 - "Compatible reagents" .
(5)
ENTER
Qualification of personnel
• The Leica ASP300 S may be operated only by
trained laboratory personnel.
•
The instrument may be operated only accord-
ing to the instructions contained in this manual.
Instrument type
All information provided in this manual applies
only to the instrument type indicated on the title
page.
Fig. 1
A name plate
indicating the
instrument
serial number
is attached to
the back of the
instrument.
Any other use of the instrument is
considered improper!
Failure to adhere to these instruc-
tions may result in an accident,
personal injury, damage to the
instrument or accessory equipment.

7
Leica ASP300 S
2. Safety
2.1 Safety instructions
This instruction manual includes important infor-
mation related to the operating safety and main-
tenance of the instrument and it is an important
part of the product.
If additional requirements on acci-
dent prevention and environmental
protection exist in the country of op-
eration, this instruction manual
must be supplemented by appropri-
ate instructions to ensure compli-
ance with such requirements.
Make sure to comply with the safety instructions and warnings in this chapter.
Make sure to read these instructions, even if you are already familiar with the operation
and use of other Leica products.
The protective devices on both instrument and accessories may neither be removed nor
modified. Only authorized and qualified service personnel may repair the instrument and
access the instrument’s internal components.
2.2 Warnings
The safety devices installed in this instrument by the manufacturer only constitute the basis for
accident prevention. Primarily responsible for accident-free operation is above all the institution
which owns the instrument and, in addition, the designated personnel who operates, services or
repairs the instrument.
To ensure trouble-free operation of the instrument, make sure to comply with the following
instructions and warnings.
This instrument has been built and tested in ac-
cordance with the safety regulations on electri-
cal measuring, control, regulating and laboratory
devices.
In order to maintain this condition and to ensure
safe operation the operator must comply with the
instructions and warning contained in this
instruction manual.
For current information on applicable
standards, please refer to the instru-
ment’s CE declaration and visit:
http://www.histo-solutions.com

8Operating Manual V 1.0 – 07/2006
2. Safety
Transport and Installation
The instrument may only be transported in an upright position.
Follow the unpacking instructions carefully to avoid damage to the instrument!
A cleaning must be performed prior to each transport, during which the instrument may
be shaken, tilted or lifted. Severe internal damage may otherwise occur.
The instrument MUST be connected to an earthed mains power outlet socket. The instru-
ment must not be connected to an extension cord without protective earth conductor.
Ensure uniform current supply according the to set voltage!
The set voltage CANNOT be changed by the user.
Severe damage may occur if the instrument is connected to a power supply voltage other
than that to which it was originally set.
The instrument must be set up in a well ventilated area, free from any ignition sources.
The chemicals to be used in the Leica ASP300 S are both flammable and noxious.
Do not operate the instrument in rooms with explosion hazard.
If there is a significant difference in temperature between the warehousing and the in-
stallation site of the instrument and if at the same time there is a high air humidity level,
condensation water may form. In this case, a waiting period of at least two hours must be
observed before the instrument is switched on. Failure to adhere to this waiting period
may result in damage to the instrument. Failure to adhere to this waiting period may re-
sult in damage to the instrument.
Warnings - Markings on the instrument itself
Markings on the instrument showing the warning triangle indicate that the correct
operating instructions (as defined in this manual) must be followed when operating or
replacing the item marked. Failure to adhere to these instructions may result in an acci-
dent, personal injury, damage to the instrument or accessory equipment.
Some instrument surfaces become hot during operation.
They are marked with this warning label. Touching these surfaces may cause
burns.

9
Leica ASP300 S
Warnings - Operating the instrument
The Leica ASP300S may only be operated by trained laboratory personnel, according to
its designated use and per the present instruction manual.
The ON/STOP switch at the side of the instrument may be used in an emergency to stop
the instrument during operation.
Always press PAUSE before opening the retort lid during processing to allow the retort to
vent.
Do not remove the wax drain hose or the remote fill/drain hose until the fill or drain has
been completed, as pressurized air is used to clear the hose after each fill / drain.
After refilling / replacing the reagent bottles ensure that the lids are tight.
The bottles must be properly pushed home into the connection manifolds at the rear inner
wall of the reagent module.
Failure to correctly plug the reagent bottles into the manifold will cause an interruption
to the processing run and may result in spilling of reagents.
Fixatives containing mercuric salts, acetic or picric acid will corrode metallic compo-
nents in the instrument.
After each paraffin step a retort clean cycle must be run.
2. Safety
Material safety data sheets can be obtained from the supplier of the chemicals.
They are also available on the Internet:
http://www.msdsonline.com

10 Operating Manual V 1.0 – 07/2006
Warnings -handling reagents
Be careful when handling solvents!
Always wear rubber gloves and safety goggles when handling the chemicals used in this
instrument.
Reagents used for tissue infiltration can be both toxic and/or flammable.
To avoid damaging the instrument only use those reagents that are listed in chapter 3.5!
Do not use acetone, benzene or trichlorethane in the instrument!
Use caution when handling paraffin wax or removing baskets – molten paraffin is hot and
may cause burns.
Also, avoid personal contact with paraffin stations and retort walls – they can be very hot
as well.
Dispose of waste solvents with care according to local regulations and the waste man-
agement policy of the company or institution.
Do not clean reagent bottles in an automatic dishwasher – they are NOT dishwasher-
proof.
2. Safety
Warnings - Cleaning and maintenance
Prior to each maintenance and/or cleaning, switch the instrument off and disconnect
mains power.
Do not clean the instrument with solvents containing acetone or xylene. No liquid may be
spilled into the internal components of the instrument – neither during operation nor
during cleaning.
When working with cleaning detergents, comply with all safety instructions by the manu-
facturer of the product and the laboratory management policy.
The condensate bottle should be inspected at least once every week and, if necessary,
emptied.

11
Leica ASP300 S
2.3 Integrated safety devices
In the case of power failures or other processing problems the Leica
ASP300S incorporates specimen protection features such as a fluid level
sensor and sophisticated software controls which ensure that processing
can be completed successfully without damage to the tissue specimens.
Overpressure protection
• When power is off the air pump and air valves default to a safe condition
(retort vented, no pressure generation).
• If the microprocessor control fails to stop the air pump at the right
moment during retort pressurizing, a separate electronic hardware
circuit will cut pump power.
• In addition, there is a safety relief valve that vents all excess air pump
output to atmosphere.
Overcurrent protection
• Overcurrent conditions are protected against by both the mains fuse and
the separate heating power fuses.
Overheating protection
An error is indicated and all heating is stopped by the microprocessor
control if the instrument detects any of the following conditions:
• abnormally high temperature (>75 °C)
• contradictory results of the temperature sensors
• failure of one or more heating power control components
• If the microprocessor fails to interrupt heating power, independent
temperature limiting hardware circuits limit the temperature rise to a
safe level.
• If the temperature limiting circuits malfunction, an independent hard-
ware thermal fuse circuit cuts power to the heating elements.
Over vacuum protection
• The vacuum system is not capable of generating a dangerous vacuum
condition.
Overcurrent protection
• Overcurrent conditions are protected against by both the mains fuse and
the separate heating power fuses.
2. Safety

12 Operating Manual V 1.0 – 07/2006
3.1 Overview - instrument components
3. Instrument components and specifications
Fig. 2
2
34
5
13
6
7
14
15
16
17 18
19
20
21
22
12 11 8
10 9
1
23

13
Leica ASP300 S
Overview - instrument components
1 - Basic instrument - processor module
2 - Basic instrument - reagent module
3 - Wax bath lids
4 - Retort lid
5 - Touch screen
6 - Cover flap of the instrument console
7 - Instrument console comprising:
8 - Printer port
9 - Local alarm connection
10 - Remote alarm connection
11 - Floppy disk drive
12 - Serial port
13 - Activated carbon filter
14 - Condensate bottle
15 - Reagent bottle (13 units)
16 - Drip tray
17 - Wax drain connection
18 - Remote drain connection
19 - Retort
20 - Wax baths
21 - Specimen basket
22 - Lid for specimen basket
23 - Splash protection
3. Instrument components and specifications
Instrument components and accessories
The processor module contains three paraffin
wax baths, a processing retort, and also a touch
screen with integrated key symbols as well as
the electronic components.
The cassettes are held in three baskets (21), each
of which has a capacity of up to 100 cassettes.
All processing occurs in the stainless steel retort
under the pressure, vacuum and temperature
conditions selected.
The quick-connect reagent bottles are stored in
the reagent cabinet.

14 Operating Manual V 1.0 – 07/2006
3. Instrument components and specifications
3.2 Specific instrument options
•Reagent Management System option (RMS) that displays the usage
(length and frequency of use) of each reagent and also allows automatic
ordering of reagent sequence, thus eliminating the need to physically
move reagent bottles. After renewal of one or more reagents in a se-
quence, the RMS automatically uses the reagents in order of increasing
cleanliness.
• In-process fluid recirculation ("tidal agitation") for continuous and
efficient mixing of fluids.
• Remote fill/drain system – can drain and refill reagent bottles from bulk
containers via the retort and a hose plugged into the processor module
while the user is fully protected against coming into contact with
reagents.
• Remote wax bath fill/drain feature.
• Optical fluid level sensor.
• Active paraffin wax solvent removal feature that increases the life of the
wax by extracting and condensing contaminating solvents.
• Magnetic stirrer – to gently circulate reagents, ensuring uniform reagent
temperature.
• Programmable finish time for processing programs.
• Three-step retort drain feature (adjustable) minimizes reagent carryover.
• Specimen processing under pressure, vacuum, alternating pressure /
vacuum cycles or under ambient pressure.
• Four user-programmable clean programs. The clean programs
automatically skip any steps not required to complete the clean.

15
Leica ASP300 S
3. Instrument components and specifications
3.3 Standard delivery - packing list
The basic version of the Leica ASP300 S includes the following parts: Part no.
1 Leica ASP300 Basic Instrument
1 Set of power cords
230-240 V version:
1 Mains cable "D" 0411 13558
1 Mains cable "UK" ST-BU F-5A 0411 27822
100-120 V version:
1 Mains cable "USA-C-J" 0411 13559
1 Jumper cable - mains 0411 34604
1 Basket hook 0476 34713
3 Specimen baskets, assy. including lid,dividers, springs and handle 0476 34193
1 Remote fill/drain hose 0476 34716
1 Paraffin drain hose 0476 34721
1 Funnel 0476 43631
1 Lubricant, Molykote 111, for valves and O-rings 0336 35460
2 Activated carbon filters, assy. 0476 34150
1 Magnetic stirrer, complete 0476 34202
1 Paraffin wax scraper 0476 35923
14 Reagent bottles, plastic (13 in instrument) 0476 34274
1 Condensate collector, plastic (in instrument) 0476 34278
1 Drip tray (in instrument) 0476 34145
1 Splash protection 0476 34770
1 Maintenance kit (2 replacement lids, 9 o-rings) 0476 35921
1 Maintenance kit for pump (in instrument) 0476 35922
2 Sets of labels for reagent bottles, set of 15 each 0476 35792
1 Remote alarm plug 6844 01005
1 Operating manual for Leica ASP300 S, multi-language 0476 34712
1 3,5" HD-diskette, blank, DOS-formatted, (on rear of console cover)
1 Demo-Program, CD-ROM
Please check all delivered parts against the packing list and against your order to
verify whether the delivery is complete! If there is any difference, please contact your
local Leica Sales Office immediately.

16 Operating Manual V 1.0 – 07/2006
3. Instrument components and specifications
3.4 Technical Data
Nominal voltage: Two factory-preset voltages (not user-adjustable):
100 to 120 V or
230 to 240 V
Nominal frequency: 50 to 60 V
Main fuses: Two fast-blowing melting fuses, 20 x 5 mm, UL-approved
• for 100 to 120 V ; F 10 A 250 VAC
• for 230 to 240 V ; F 5 A 250 VAC
Nominal power: 1000 VA
Dimensions, (W x D x H), in mm: 595 x 680 x 1,325
Dry weight, unpacked: approx. 160 kg
Weight, packed: 220 kg
Operating temperature range: 15 °C to 35 °C
Relative humidity: 10 % to 80 %, non-condensing
IEC 1010 classifications: Protective class 1
Pollution degree 2
Overvoltage installation category II:
• 800 V impulse (120 V systems)
• 1500 V impulse (240 V systems)
Altitude: 2500 m maximum
Local / remote alarm relays: 30 V DC, maximum 2 A
2 connections:
Both single voltage-free, changeover contacts
(both Normally-Open and Normally-Closed
connections available)
Paraffin wax baths
Number of baths: 3
Volume (liters): 4.3 l per bath
Melt time: approx. 10 hrs
Temperature: 40 to 65 °C
Temperature accuracy: + 1 K

17
Leica ASP300 S
3. Instrument components and specifications
Retort
Capacity: max. 300 cassettes
Reagent volume: 4.3 l
Temperature (paraffin): 40 to 65 °C
Temperature (processing reagents): ambient or 35 to 55°C
Temperature (cleaning reagents): 50 to 65 °C
Temperature accuracy: + 1 K
Filling time: approx. 90 sec
Drain time: approx. 80, 120, 140 sec (adjustable)
Impregnation vacuum: -70 kPa (g)
Impregnation pressure: 35 kPa (g)
Fill vacuum: -70 kPa (g)
Drain pressure: 35 kPa (g)
General
Reagent bottles: 10
Cleaning solution bottles: 3
Maximum bottle volume: 5.0 l
Printer: Optional accessory
Pretest check: ON/OFF
Fluid level sensor: ON/OFF
Recirculation (pump in/out): ON/OFF
(a) Time before 1st cycle: 16 min
(b) Time between cycles: 20 min
System setup
Password status: Supervisor / User
Type of password: alphanumeric, freely selectable
Reagent Management Status: ON/OFF
Software access control (lock mode): ON/OFF

18 Operating Manual V 1.0 – 07/2006
3. Instrument components and specifications
3.4 Technical Data (continued)
Hardware and Software:
• Large color Liquid Crystal Display (LCD) and touchscreen.
• User-friendly, intelligent software.
• 3,5" floppy drive and printer port.
• Alarm system with two remote alarm sockets.
• Password-protected instrument supervisor mode.
• Multiple specimen protection system.
Capacities:
• 15 programs that consist of up to 10 reagent and 3 paraffin wax steps.
• Time per program step: 0 to 99 hours, 59 minutes.
• Delay time: max. 7 days.
• Up to 300 cassettes can be processed simultaneously.
• Four user-programmable retort clean programs.
• Wax clean program.
• 10 reagent bottles.
• 3 wax baths.
• 3 cleaning solution bottles.
• 1 condensate bottle.
• Reagent temperature adjustable from 35 °C to 55 °C
or ambient.
• Paraffin temperature adjustable from 40 °C to 65 °C.
• Choice of three retort drain rates of
80, 120 and 140 seconds.
• Up to 100 reagent names in memory.

19
Leica ASP300 S
3. Instrument components and specifications
3.5 Compatible reagents
The following reagents may be used in the Leica ASP300S:
Fixatives
1. Formalin, buffered or unbuffered
2. Formalin saline
Dehydration
1. Ethanol 4. Butanol
2. Isopropanol 5. Industrial Methylated Spirits
3. Methanol
Clearing
1. Xylene
2. Toluol *
3. Chloroform *
Paraffin wax
1. Paraffin
Caution:
Reagents other than those listed here may damage some com-
ponents of the instrument.
Do not use acetone, benzene or trichlorethane in the instru-
ment.
Fixatives containing mercuric salts, acetic or picric acid will
corrode metallic components in the instrument and shorten
instrument life.
If you choose to work with such fixatives, it is essential to
perform a clean cycle which contains multiple water rinses
each time after use, to minimize damage.
In addition, we recommend frequent and regular preventive
maintenance by the Leica Technical Service.
* Prior to using these reagents, contact your
Leica representative or Leica directly for in-
formation on necessary protective measures.

20 Operating Manual V 1.0 – 07/2006
4. Setting up the instrument
Attention!
Follow the instructions below care-
fully to avoid damage to the instru-
ment.
4.2 Electrical connection • Check the voltage label (Fig. 3) on the rear of
the instrument to ensure that the instrument
delivered is set to the correct voltage range.
Caution!
Severe damage may occur if the in-
strument is connected to a power
supply voltage other than that to
which it was originally set.
The power supply voltage for the in-
strument is factory preset, and CAN-
NOT be altered by the user.
Moving the instrument
After the instrument has been unpacked (see un-
packing instructions attached to outside of trans-
port crate) it must be touched only at the points
marked with dots ‘ ‘ for transport to its final site
of installation.
Once the instrument has been installed there, the
brakes on the instrument rollers (24) must be
locked.
4.1 Site requirements
• The instrument needs approx. 650 x 700 mm
floor space.
• Practically vibration-free floor.
• Room temperature constantly between +10 °C
and +35 °C.
• Relative humidity maximum 80%, non-con-
densing.
• Avoid vibrations, direct sunlight and heavy
variation in temperature.
The chemicals to be used in the Lei-
ca ASP300S are both flammable and
noxious. The Leica ASP300S must
be set up in a well ventilated area
free from any ignition sources.
Do not operate the instrument in
rooms with explosion hazard.
Fig. 3
The instrument must be installed
such that the mains switch at the
rear of the instrument (item no. 42 in
Fig. 4) can easily be accessed at any
time.
24