Thermo Scientific ALPS 3000 User manual

Thermo Scientific ALPS 3000™
Automated Laboratory
Plate Sealer
User Manual

Trademarks and Copyright
Thermo Fisher Scientific Inc. All rights reserved. All trademarks are the property of Thermo Fisher
Scientific Inc. and its subsidiaries.
No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by
any means, in whole or in part, without the prior written permission of Thermo Fisher Scientific Inc.
Third party products are registered trademarks of their respective companies in the United States and/or
other countries.
ALPS 3000™Heat Sealer

i
CONTENTS
1. Introduction ......................................................................................................................................1
2. Health & Safety Notes .....................................................................................................................2
3. Cautionary Notes ..............................................................................................................................3
4. Operating Environment & Footprint .................................................................................................4
5. Connecting the Air Supply ................................................................................................................5
6. Connecting the Voltage Supply ........................................................................................................6
7. Foil/Film Loading ..............................................................................................................................7
8. Operational Procedure and Optimization .........................................................................................8
9. Communication Protocol ................................................................................................................10
10. Cleaning the ALPS 3000 ...............................................................................................................14
11. Specification .................................................................................................................................15
12. Fault Finding .................................................................................................................................16
13. Declaration of Conformity ............................................................................................................18
14. Sealing Tapes................................................................................................................................20

1
Introduction
1. Introduction
The ALPS 3000 has been designed for robotic integration, or stand alone sealing, offering a fast effective
solution for the heat-sealing of microplates for experimentation, storage or transportation.
ALPS 3000
Heat sealing is now widely considered to be the most effective way of sealing plates for assays, thermal
cycling, storage and shipping. The extensive range of sealing materials available for our new instrument
offer permanent or peelable high integrity seals, for most plate material types.
The range of sealing materials includes ultra clear materials for colorimetric or fluorimetric assays, along
with solvent resistant seals with exceptional low temperature (-200 C) storage characteristics.
The ALPS 3000 has a compact footprint saving bench space. It features a serial port allowing RS232 and
external foot switch operation, for robotic control, plus a touch screen for manual operation.
Both seal time and temperature are fully adjustable and the unit has built-in sensors to monitor seal
presence and provide output error warning signals. The unit produces no waste material and seals plates of
different heights without the need for plate carriers.
ALPS 3000 is designed to be integrated into robotic platforms from all leading automation companies.
Procedure
The unsealed plate is placed on a shuttle which extends from the front of the sealer, allowing full access
with a robotic arm or stacking system. The shuttle is drawn into the unit automatically and the plate is
sealed in 6 to 12 seconds, depending on the sealing time. The shuttle then slides out, presenting the sealed
plate in its original position.
The sealer, as part of a fully automated plate handling system, is controlled by RS232 communication (see
page 14). Alternatively, the ALPS 3000 can be manually operated as a stand alone unit (see page 13).
Each roll of sealing film is sufficient for approximately five thousand plates. The cutting system cuts the film
to cover the entire plate surface but does not permit any overhang that would effect the plates handling, or
the visibility of barcodes.
The rolls of sealing film, either aluminium or clear laminates, are able to produce permanent, pierceable or
peelable seals with Polypropylene, Polystyrene or Polyethylene plates.
To keep the size and weight to a minimum, the unit uses laboratory compressed air and all parameters, such
as temperature and time are fully adjustable to ensure a perfect, even seal with different plate and film
formats. Should a compressor be needed if lab air is not available please contact Thermo Fisher Scientific.
User safety has been carefully considered during the design process, eliminating risk of contact with hot
surfaces or the internal mechanism during operation.

2
Health and Safety Notes
2. Health and Safety Notes
It is important that the ALPS 3000 is installed and operated in such a way that all applicable Health and
Safety requirements are met. It is the user’s responsibility to ensure that all relevant Health and Safety
regulations are identified and complied with. Failure to do so, may result in damage to the equipment and
could cause personal injury. In particular, the user should study the contents of this guide carefully before
handling or operating this equipment.
Under no circumstances will the supplier of this equipment be liable for any incidental, consequential or
any special damages of any kind whatsoever, including but not limited to lost profits arising from, or in
anyway connected with the use of this equipment or this instruction manual.
WARNING SYMBOLS Used In Accordance With IEC 417
RISK OF ELECTRIC SHOCK
WARNING!
Refer to accompanying documentation.
HOT SURFACE/HOT AREA
This instrument is fitted with an
internal heater with a maximum
temperature of 200° C when in use
PROTECTIVE CONDUCTOR TERMINAL
MAINS SWITCH SYMBOLS I - O
I = ON O = OFF
Environmental Requirements
Temperature Range Operating 15° C to 40° C
Storage 0° C to 40° C
Relative Humidity: Operating 10% to 80% Non-condensing
Storage 10% to 80% Non-condensing

3
Cautionary Notes
3. Cautionary Notes
Statement: WARNING: Do not operate this instrument in an atmosphere containing explosive gases.
Statement: WARNING: Only approved, supplied mains cord must be used with this instrument.
Statement: WARNING: If it is required to use an extension lead, the lead MUST be grounded.
Statement: VOLTAGE: The ALPS 3000 is supplied for direct connection to normal 115VAC or 240VAC supply,
with a variation in supply that gives a voltage range of 108VAC to 250VAC
• Safety guards MUST be used at ALL times of operation of the unit.
• At no time should the sealing lm be in place while the unit is being transported.
• The ALPS 3000 is designed to be operated with a maximum sealing temperature of 200° C
• The ALPS 3000 should be switched on ten minutes prior to use, to enable the set temperature to be
reached.
• The unit should only be used in a suitably ventilated area. The use of solvents on the unit is not
recommended.
• Certain components become hot during the correct operation of the equipment. These components
are marked as described above. Due care should be taken to avoid personal injury.
• The Air Supply must be removed and the electrical supply disconnected, prior to the removal of any
safety guards.
• Thermo Fisher Scientic accepts no responsibility for the misuse of this equipment.
The Mains Plug supplied with the ALPS 3000 unit, is fitted with the following fuse:
Supply Fuses Fitted in Plug Fuses Fitted in Sealer
230VAC 13 Ampere T5AH 250V
115VAC No Fuses T5AH 250V
Only refit the correct type of Fuse. Must be IEC127 approved for use in EC Countries.
Must be C.S.A. or UL listed or recognized for use in Canada or the United States of America.

4
Operating Environment & Footprint
4. Operating Environment & Footprint
The ALPS 3000 should be operated in an environment with a temperature range of 15° C - 40° C and a non-
condensing relative humidity range of 10% - 80%.
The unit should be kept out of drafts and air currents as they will have an adverse effect on the temperature
stability of the sealing plate. Since the ALPS 3000 will not seal if the temperature is not at the set
temperature, if the sealing plate is cooled by drafts then the time between cycles may be increased.
The machine should be mounted on a sturdy bench to avoid any movement during operation. When locating
the machine there should be enough space allowed for the shuttle to move out without hitting anything
or anyone. The reduced weight compared to the previous model does make the ALPS 3000 much easier to
move into a suitable position.
Note: Allow 170mm at the front of the unit for the plate carrier to open and 100mm at the back and top for
the seal roll.
The ALPS 3000™should be operated in an environment with a temperature range of 15o C - 40o C and a non-
condensing relative humidity range of 10% - 80%.
The unit should be kept out of draughts and air currents as they will have an adverse effect on the
temperature stability of the sealing plate. Since the ALPS 3000™will not seal if the temperature is not
at the set temperature, if the sealing plate is cooled by draughts then the time between cycles may be
increased.
The machine should be mounted on a sturdy bench to avoid any movement during operation. When locating
the machine there should be enough space allowed for the shuttle to move out without hitting anything or
anyone. The reduced weight compared to the previous model does make the ALPS 3000™much easier to
move into a suitable position.
Note: Allow 170mm at the front of the unit for the plate carrier to open and 100mm at the back and top for
the seal roll.
5. Operating Environment & Footprint
6

5
Connecting the Air Supply
5. Connecting the Air Supply
All electrical and pneumatic connections are made to the lower rear of the unit, this is the only point of
interconnection to the sealer.
UK Europe and Asia supplied units.
The unit is supplied with a 6mm push-in connector to fit into the 1/4 BSP inlet.
USA supplied units.
The unit is supplied with a 1/4 inch push-in connector to fit into the Filter Regulator input.
When fitting an air connector to the ALPS 3000 always use 2 spanners, one to tighten the connector and
one to prevent the bulkhead fitting from turning. If the bulkhead fitting is allowed to rotate it may become
loose.
The air supply for the ALPS 3000 should be 80psi (5.5 bar) and a maximum of 87psi (6 bar).
The supply should be able to provide 50 litres/minute through a pressure regulator as there is no regulation
of the air within the ALPS 3000 Exceeding the maximum pressure may damage the unit. The air supplied
must be clean, dry and oil-free. Most air regulators include a water filter but not an oil filter; this may need
to be fitted separately.

6
Connecting the Voltage Supply
6. Connecting the Voltage Supply
The ALPS 3000 utilizes a standard IEC inlet, which is fused and switched.
Plug the IEC Lead in the inlet and switch on the Rocker I.O. Switch. The display that is mounted on the front
of the unit should illuminate.
NOTE: The system is self regulated to sense voltage differences between 100 and 240 VAC.
Standard ¼ BSP to 6mm pneumatic connection
Standard IEC inlet for mains connection

7
Foil/Film Loading
7. Foil/Film Loading
Loading the ALPS 3000 with heat sealing film:
We recommend the unit be cold when loading the film to minimize the possibility of personal injury. To
allow the film to be threaded through the system, the air and electrical supply must be connected and
turned on to open the foil gripper and foil clamp assembly, .
The electrical power must be connected to load the foil/film.
• 7.1 - Ensure the power is on the unit, enter the setup menu, which will then display an option to
load foil.
• 7.2 - Press the load foil button, this will open the foil gripper and foil clamp allowing you to insert
the foil loading tool through the plate shuttle access to machine.
• 7.3 - Slide the tool through the foil gripper, then through the cutting section and nally bring the tool
out to the rear of the machine, this is best carried out by placing the foil loading tool flat on the plate
shuttle, with no plate present, then sliding the foil loading tool carefully through the machine.
• 7.4 - Allow one turn of the roll as slack, to feed through the unit.
• 7.5 - Fold the foil end into a point, alternatively the foil may also be cut to a point.
• 7.6 - Insert folded point into the slot in the loading tool, ensuring that the foil is not twisted, with
the sealing surface facing away from the machine.
• 7.7 - Carefully pull the foil loading tool through the machine and ensure that it is sitting at and
central.
• 7.8 - Remove foil from the loading tool.
• 7.9 - Keeping a rm hold of the foil, press the trim foil button on the display and slowly pull the foil
away from the machine, keeping your hand out of the machine.

8
Operational Procedure
8. Operational Procedure
The ALPS 3000 has been designed to reliably seal plates of different heights and different plastics, using a
variety of films. These components will require different sealing conditions.
The quality and strength of the seal created between the sealing film will vary with different conditions. In
general, increasing either the sealing temperature or duration of seal, gives a stronger, more complete seal;
however over-sealing on a regular basis can cause damage to the plate being sealed. This in turn, reduces
the number of times a particular plate can be resealed. Therefore a balance has to be achieved that gives
an acceptable seal with the minimal plate damage or distortion.
Another optimization factor to be taken into account is the surface area of the plate.
Plate with thin raised rims around each tube, have a reduced surface area compared to a plate with wide
raised rims. Therefore less heat is needed to seal the thin rim plate in comparison to the wide rim.
The pressure that the heater plate exerts during sealing is pre-set and cannot be adjusted. Plates without
raised seals are not considered suitable for heat sealing.
8.1 - Temperature and Time Setting:
The following table gives a guide as to the sealing time and temperature for different materials.
Plate Material Temperature Setting Time Setting
Polystyrene 145° C - 165° C 3 Seconds - 5 Seconds
Polypropylene 150° C - 175° C 3 Seconds - 5 Seconds
Polyethylene 150° C - 170° C 3 Seconds - 5 Seconds
8.2 - Commands, Indications and warnings:
The ALPS 3000 is software controlled, employing micro-controllers. All commands, indications and
warnings are effected via the touch sensitive LCD display panel located on the front of the unit.
The sequence of events is as follows:
8.3 - Setting the sealing operation:
With a plate in position on the Shuttle, the SEAL segment is pressed to start the sealing operation.
If the sealing plate is not up to temperature, the display will indicate it is heating, and the actual
temperature compared to the set temperature. The display flashes ‘Sealing’ during the operation and then
returns to the seal screen, ready for another operation.

9
Operational Procedure
8.4 - To set Sealing Time:
Press Settings > Time > Increment Up/Down > Save
8.5 - To set Sealing Temp:
Press Settings > Temp > Increment Up/Down > Save
8.6 - To Load Foil:
Press Settings > Load Foil >remove and load new foil > Whilst holding surplus foil pulled through with foil
loader, centre foil on shuttle and Press Trim. Whilst trimming pull gently on foil until fully removed from
machine.
8.7 - To set Remote Mode:
Press Settings > Next > Remote Mode > Next
8.8 - To set Local Mode:
Press Settings > Next > Local Mode > Next
8.9 - To Park the Machine:
NOTE: Remove foil before setting machine in park
Press Settings > Next > Park > Remove Foil > OK > Turn off machine

10
Communication Protocol
9. Communication Protocol
ALPS 3000 Host Communications Protocol 19/02/06
9.1 - Serial Port Setup:
Baud rate 9600 Data bits 8
Parity none Stop bits 1
Flow control none
All communications via ASCII.
9.2 - Cable:
Connection is via a straight cable – not a modem cable.
PC (9 way female) ALPS (9 way female)
Pin 2 <------------------------------> Pin 2
Pin 3 <------------------------------> Pin 3
Pin 5 <------------------------------> Pin 5
9.3 - Message Response time:
The unit responds to each message within 100 msec.
9.4 - Configuring for remote operation:
On the touch-screen use the advanced menu to set the following:
9.5 - “Remote” to “Local”:
This sets the unit into remote mode and ignores commands issued from the touch screen. This is strongly
recommended when controlling the unit from a host computer.
9.6 - System Initialization:
The system automatically initializes on power up. While initializing the system status is reported as “busy.”

11
Communication Protocol
ALPS 3000 Host Communication Protocol - Continued
9.7 - Status Message:
PC sends: ?<cr>
ALPS 3000 replies: <status byte><cr>
The status byte is a hexadecimal value represented in ASCII, i.e. the characters “ff” means 0xff hex.
9.8 - Bit values:
Bit 0 No Foil
Bit 1 Error
Bit 2 Busy
Bit 3 Waiting For Seal Temperature
Bit 4 Plate Not Present
Bit 5 Low Air
Bit 6 Foil Load Mode After Park
Bit 7 Park Mode
When checking the communication using, for example Hyper-terminal, the responses to the status message
enquiry are hexadecimal values which when converted to binary values allow the status to be interpreted.
For example, when the unit is heating or cooling and so not at the sealing temperature, the response is 08.
In binary this is 1000. Taking the bit values from 0-7 from the right bits 3 is at 1. The status is ‘not at seal
temperature’ as listed above.
9.9 - Seal Plate Command:
PC sends: S<cr>
ALPS 3000 replies: ok<cr>
If the sealing operation has commenced
Or: err<cr>
If it is unable to seal the plate.
9.10 - The ALPS 3000 will not seal the plate if the following conditions exist:
Status:
Bit 0 No Foil
Bit 1 Error
Bit 2 Busy
Bit 3 Not at seal temperature

12
Communication Protocol
9.11 - Error Message:
PC sends: E<cr>
ALPS 3000 replies: ##<cr>
Where ## is a decimal value represented in ASCII, i.e. the characters “01” means error
9.12 - Error numbers:
ERROR DOWN 1
ERROR UP 2
ERROR SHUTTLE_IN 3
ERROR SHUTTLE_OUT 4
ERROR MAINS_AIR 13
ERROR THERMOCOUPLE 7
ERROR OVERHEATING 9
ERROR NO_FOIL 10
9.13 - Sealing Temperature message:
PC sends: A###<cr>
ALPS 3000 replies: ok<cr>
Where ### is a 3 digit decimal number represented in ASCII, i.e. the string A180<cr> sets the sealing
temperature to 180° C.
9.14 - Sealing Time message:
PC sends: B##<cr>
ALPS 3000 replies: ok<cr>
Where ## is a 2 digit decimal number represented in ASCII, i.e. the string B25<cr> sets the sealing time to
2.5 seconds.
9.15 - To read back sealing temperature set point:
PC sends: C<cr>
ALPS 3000 replies: ###<cr>
Where ### is a 3 digit decimal number represented in ASCII, i.e. the string 170<cr> means the current set
point is 170° C.

13
Communication Protocol
9.16 - To read back sealing time:
PC sends: D<cr>
ALPS 3000 replies: ##<cr>
Where ## is a 2 digit decimal number represented in ASCII in units of 10ths of a second i.e. the string
25<cr> means the current sealing time is 2.5 seconds.
9.17 - To read back sealing temperature actual value:
PC sends: F<cr>
ALPS 3000 replies: ###<cr>
Where ### is a 3 digit decimal number represented in ASCII, i.e. the string 170<cr> means the actual value
is 170° C.

14
Cleaning the ALPS 3000
10. Cleaning the ALPS 3000
Before using any cleaning or decontamination method, other
than that recommended by the manufacturer, users should
check with the manufacturer that the proposed method will
not damage the unit.
Always remove the power and pneumatic supplies before
cleaning the unit.
Never turn on power and pneumatic supplies before the unit
is fully dry.
DO NOT USE ACETONE OR ABRASIVE CLEANERS.

15
Specications
11. Specifications
Specifications of ALPS 3000
Power Supply: 115 - 240 - V AC 50/60Hz
Power Consumption: 600 Watts Nominal
Fuse Rating: 5 Amp anti-surge (T5AH 250V)
Internal Heaters: 4 x 100 Watts (Sealing Plate)
Dimensions: 185 x 350 x 414mm (W x H x D)
Weight: 12Kg
Air Input: 1/4 BSP Female Thread
Air Requirement: 50 Litres per minute
Air Input Pressure: 5.5 Bar (80 PSI)
Minimum Operating Pressure: 5.5 Bar (80 PSI)
Minimum Operating Ambient Temperature: 15° C
Maximum Working Temperature Ambient: 40° C
Minimum Sealing Plate Height: 8mm
Maximum Sealing Plate Height: 46mm
Maximum Sealing Temperature: 200° C
Protection: IP20
Fire Retardancy: Plastic Case & Trays ECCEN 6073
Cycle Time Minimum: 5 Seconds

16
Fault Finding
12. Fault Finding
NOTE: THIS EQUIPMENT SHOULD ONLY BE DISMANTLED BY PROPERLY TRAINED PERSONNEL.
REMOVING THE MAIN COVER EXPOSES POTENTIALLY LETHAL MAINS VOLTAGES.
The ALPS 3000 System has been designed to give long term reliability with the minimum of maintenance.
Annual maintenance is recommended to maintain instrument integrity and optimal performance. Should
a problem occur with the sealing, an initial inspection may identify its cause and the necessary corrective
action. The following list highlights potential faults and the course of action to take.
If you are continuing to have problems with your ALPS 3000 or are interested in one of our maintenance
contracts please contact us:
North America:
Thermo Fisher Scientific
Hudson, NH 03051 USA
Tel: [phone]
Europe:
Thermo Fisher Scientific
Chesire, U.K
Tel: [phone]

17
Fault Finding
FAULT ACTION
Foil loading tool will not pass through the rear
clamp.
Air supply not connected. Connect air to open
clamp.
Foil will not pull through. Pulling the foil loading tool too fast or insufficient
slack fed off the roll.
Foil not transported across in clean-up cut. Foil not trimmed square after pulling through.
Remove waste and reset under front clamp.
Failure of any air operated part to move properly
or stops during operation.
Check air supply is at the correct pressure and
that there is sufficient volume. If no improvement
call for service.
Fails to respond to an input. Check air as above.
Doesn’t cut properly. Tool setting problem – call for service.
Foil not picked up. Check display for vacuum error. Check air supply.
If no improvement call for service.
Vacuum error. Check air supply.
Doesn’t seal properly. Time or temperature setting incorrect.
Poor seal. Unsuitable plate. No plate support or incorrect
plate support.
Punch hits plate support with 384 PCR plate or
no plate. Check and, if necessary, reset rear shuttle stop.
External fuse blows. Replace and if it fails again call for service.
No power. Check fuses. If OK, call for service.
The display shows ‘thermocouple error’ The ambient temperature is too low for the unit
to operate.