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VITEK•2® & VITEK•2® XL INTEGRATED SYSTEM SERVICE MANUAL

1. ds Z 2 Bg c Iz a O Fl 1 d Lor ZEE un LL fa ga S 2 un gt ww 3 ae e l l Lo oL l1 l1 bb bol Lt t 1l 1l b Lb Lb bob Lt 1b l1 Lb Lb Lb oL L saa 53 86 mol TZ oF x 7 SZRI ITT7 THTH7HHHHHHHIHHHHIHHHHCHHHHHHHC aSolee ZAKI pmi gt OCO ele 0O 0 0 0 0 0 0 0 ates 0 0 0 0 0 0 0 0 0 0 0 0 0 0 I g Z o a D E n Eo LL Z N X m O Z vn a fb VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Appendix E Alignment Procedures 1 Introduction This procedure covers the adjustments and alignments required on the Vitek 2 60 and Vitek 2XL 120 instruments Some adjustments are mechanical in nature some electrical but most will simply be software adjustments The software adjustments work by storing the required step count from a home sensor in non volatile memory Rather than adjust the physical position of a sensor the number of steps from the sensor to where the device needs to be is stored in memory 1 1 Procedure layout This alignment procedure is divided into multiple sections sub sections and steps The sections cover main functional parts of the instrument and are numbered with a single number followed by a period example 3 Pipettor The sub sections under a section each cover a separate adjustment which is required for that section and are
2. Figure 3 1 VITEK 2 60 Integrated System Instrument VITEK 2Z amp VITEK 2 XL System Service Manual oI Rev 0100 Chapter Three System Overview Figure 3 2 VITEK 20 120 Integrated System Instrument System Operation The VITEK 2 integrated system is a combination of several independent stations working together to optically scan test cards within a controlled temperature environment The major subsystem stations of the instrument are the load unload station cassette scan station dispenser pipettor station vacuum station card sealer station autoloader amp reader incubator station and waste collection station The LCD User Interface control panel located on the front of the instrument allows operator access through menu functions for normal setup and operation and specific menus for maintenance and troubleshooting The internal layout of the VITEK Z consists of several sample processing stations and a reader incubator Test cards tubes with patient isolates and empty tubes for susceptibilities will be loaded into cassettes by the operator Then the cassettes of cards will be placed into a carrier in the instrument called the Smart Carrier Boat Assembly The Transport System automatically moves the boat and cassette past several independent subsystem stations An operation description of each subsystem will be discussed in this chapter Component parts of each subsystem a
3. seeeeesususe 5 5 Power Switch Replaceruetit s eue testis mua Festo ca n bac ote Reb nUd S nee ueda da npud 5 5 Power Switch Fuse ReplacemieLit x t ordi ae ea Foam erase Fx nd usus Le ut Pos neon 5 7 Power Supply Drawer ASSeImbbly uie aesti oe Diete tona ua Unde Ro RC Lo Dao oes uL DER 5 8 Solid State Relay Replacement zac tore dere rb pora eae aere dr eie pegar ase oUbd 5 10 Bay Controller Board BCB Replacement cccccccssseesseecceeeecaeseeeeeceeeeeenaas 5 11 DC Power Supply Board Replacement ccccccccccssssseseeceeceeceeeesseeeeeeeeesaeeeeess 5 13 Head Control Board HCB Replacement cccccccsssssseeeeeeeeeeceaaeeeeeeceeseeenaas 5 14 Sample Prep Node SPN Board Replacement sees 5 15 Display Assembly Replace mentzea PRa tide E EU Den abe ERAT RO Dra Moda ie 5 18 Card Frannie SysteD seice P sin reed pater o ort code seta add brute e Bst Dad ou tesinss adus 5 19 Sici f 5 19 Palle GRE Fe T OTRO MNT 5 20 Paddle Pute y Motor neee ote Nugent erste iom Remus ru initum ete acutus 5 21 Transport Pulley MOOT 22 522 oet 1e hdta cu e us tide AUR a o etae tutes cop E E 5 23 Bilur Pulley Molo eers teogecb dibus eate a ids ed Une uU 5 23 Pipettor Vertical Pulley Motor zusuencee tiene beso tbe urea tee ees atu bia tocar E 5 25 Pipettor Pivoting Pulley Motor eeeeeeeeeeeeeeeeeeen nennen eene 5 26 Vacuum Assembly Vertic
4. Incubator Heater Solid State ncubato Heater Incubator mbar Carousel Rela Incubator auda Temperature RLY2 Cover Switch Bottom Sensor Top SW25 K2 MT16 TT J19 Blank Blank J8 J4 Een Carousel A J12 Blank SPN Board 530 04 Blank J15 J9 Blank TO Reader A SPN Board 120 x A6 60 Upper Fan i Right Transport SPN Bd 60 1 O A11 120 n ical amp B28 d Que Pi EN z Lower Fan _____ 0U TEU 5 W Incubator J6 B27 J5 J2 J16 J14 J3 Ejector Motor Carousel Motor B26 Ejector Home Switch SW23 Carousel Home Switch SW24 Carousel Index Top Sensor MT13 Carousel Index Bottom Sensor MT14 B25 Figure 4 59 Carousel SPN Board for VITEK 2 amp VITEKe2 XL Section A 4 60 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Four System Components Carousel B SPN Board 120 Only Incubator Heater Incubator Solid State inet Temperature Carousel Relay ncu ator S Temperature Cover Switch ensor RLY2 Sensor Top SW25 Bottom MT15 K2 MT16 J18 J11 J1 J19 Blank Blank J8 J4 one Carousel B SPN Board 530704 J12 Blank Blank J15 J9 Blank TO x Upper Fan Reader B SPN Board A12 120 J13 Heater oe C 120
5. BAR 1s not used to test the bar code reader This is for development purposes only By placing a card with a bar code in position typing BAR 2 and pressing ENTER the actual bar code card type IUO flag card expiration date and manufacturing information will be displayed If the bar code reader fails to detect or read the bar code it will display BAR CODE ERROR See Figure 6 11 BAR 2 VIRA Ao BAR 2 Rev 0100 Raw ASCI 0100 779000002592 Card Type 10 LOU Flag S 0 Exp Date 887846399 Wed Feb 18 23 59 59 1998 Line ID O0 Dash COC 9 Sequence 2592 Cand LOT x IOO 7 90 Figure 6 11 BAR 2 VITEK 2 amp VITEK 2 XL System Service Manual 6 13 Chapter Six Troubleshooting Button Memory Reader TOUCH RD BOAT TOUCH RD BOAT is performed by first placing a cassette with button memory in front of the button memory reader so contact is made Then type TOUCH RD BOAT and press ENTER This will display information previously programmed from the SCS such as the station name Boat ID SCS version Cassette Status O processed 1 not processed cards set up in cassette pipetting source etc See Figure 6 12 TOUCH RD BOAT E NOTE When a cassette is processed the instrument does not delete the data from the button memory Instead it changes the cassette status to processed 0 Only the SCS can delete the button memory VTK2 A gt touch_rd_boat Boat ID SCS Version SCS Touch Version BCB Touch Verison C
6. zZ DC Power Supply Bd c 6 J5 J2 J3 Left Front Front Paddle Paddle Paddle Motor Home Home B3 Switch Switch SW2 SW3 Left Front Boat Sensor MT3 Left Transport Home Switch SW4 44 J1 J12 Blank J9 Blank Cabinet Fan J13 B6 Cabinet Fan B5 J16 J14 Encoder Switch MT2 Left Lid Sensor MT1 Figure 4 53 Left Transport SPN Board 4 54 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Four System Components Right Transport SPN Board Loading Station Cassette Sensor MT6 Right Transport Motor B11 Right Transport Home Switch SW8 J8 J4 J11 J1 Rear Transport Motor B8 Blank Blank J19 J18 J12 Blank A Right Transport Ma nepor SPN Board Home Switch 530704 SW5 Right Lid Sensor MT5 J9 e R n cine E AE E TT Carousel SPN Bd A2 60 Only J13 Blank ee ee a ee ee ee DC Pwr Supply Bd 60 amp 120 Daten ee een eee eed uter ee tl J16 Encoder Sensor MT4 Figure 4 54 Right Transport SPN Board VITEK 2 amp VITEK 2 XL System Service Manual 4 55 Rev 0100 Chapter Four System Compon
7. BOOT SEQ TASK 60 is OK BOOT FLASH Data File Verified If this is a 120 ensure BOOT SEQ TASK 120 is OK 8 From the diagnostic prompt of the corresponding VITEK ZP type restore alignment and press ENTER This command downloads the saved alignments from the BCB board to the SPN boards 9 From the diagnostic prompt type fix spn params and press ENTER This updates the SPN parameters as determined by the BCB firmware 10 Verify alignments See Appendix E Alignment Procedure VITEK Z amp VITEK 2 XL System Service Manual 5 17 Rev 0100 Chapter Five Component Installation Display Assembly Replacement Refer to Figure 5 10 for the location of the display assembly Removal 1 Open the top and front access covers on the instrument 2 Disconnect the drain tube from the Diluter Cover and then unscrew and move the Diluter Cover including the saline bag to the side 3 Remove the screws and lock washers attaching the Display Assembly to the instrument cabinet 4 Remove the screw and lock washer to disconnect the ground wire from the frame Tag and disconnect the ribbon cable and backlight cable 6 Remove the Display Assembly a USER INTERFACE ASSEMBLY SALINE COMPARTMENT BOTTOM SCREWS Figure 5 10 Display Assembly Replacement Installation 1 Reconnect the display assembly cables 2 Reattach the ground wire to the frame 3 Place the Display Assembly into position on the instrumen
8. BOARD i STANDOFFS Figure 5 21 Cam Motor Top View Installation S oo 11 Position the tray drive gear on the motor shaft to the distance measured during removal of the motor After appying thread locking adhesive place the set screws of the motor pulley over flat spots of the shaft and tighten set screws securely Mount the replacement motor onto the motor mount bracket in the same orientation as when removed When tightening the motor mounting screws make sure the drive gear engages the rack enough to remove backlash but not tight enough to produce binding Carefully place the cam motor assembly inside the reader head and while supporting the cam motor reinstall the assembly using two mounting screws Connect the motor wires to the Reader SPN board as previously noted Carefully snap the Reader SPN board back onto the standoff posts Re install the Diluter Cover including the saline bag and then re connect the drain tube Close the top access doors Ensure the instrument is ready to turn ON Verify the motor is operating properly and verify alignment See Appendix E Alignment Procedure See Table 5 4 for wiring information VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation Stacker Motor Replacement Refer to Figure 5 22 for the location of the auto loader motor Removal eee a 9 Open the top panel door and remove the side cover to expose
9. Figure 4 5 UPS and Workstation Computer Communication Port Locations 4 6 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Four System Components Work Station Computer The Work Station computer is a central diagnostic station It is connected to a 25 pin communication port located on the left rear corner of the instrument via an RS232 cable See Figure 4 5 Under normal conditions the instrument will send system status test card data and operational data to the workstation The Work Station serves as the instrument supervisory control test data storage system status information and data entry for the instrument Should the computer fail the VITEK 2 instrument is capable of sequentially buffering 2700 card hours before the oldest data begins dropping off Figure 4 6 shows the workstation computer Figure 4 6 Workstation Computer Card Transport System The VITEK 2 Card Transport System is made up of the following primary internal components Cassettes and Boats Cassette Load Unload Station Transport Assemblies VITEK 2 amp VITEK 2 XL System Service Manual 4 7 Rev 0100 Chapter Four System Components Cassettes and Boats The cassette is the main component of the transport system The cassettes are pre loaded external to the instrument with tubes of patient isolates tubes for susceptibility dilution and test cards The back portion of the cassette holds a maximum of 15
10. Figure B 16 Sealer Connection Board VITEK 2 amp VITEK 2 XL System Service Manual B 23 Rev 0100 Appendix B Schematics and Diagram User Interface I F Board bickderieua Wie s Ao mem Cit USER r MADE IN U S amp ascy ac Sap7ia L_ Figure B 17 User Interface I F Board Bar Code Board BARCODE BOARD MADE IN U S A eS eS L l E T Lk E U T gt ks L E ri D D ASSY 530726 HII Figure B 18 Bar Code Board S B 24 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Appendix B Schematics and Diagrams Fluorescence Optical Interrupt Board ASSY 530722 Figure B 19 Fluorescence Optical Interrupt Board Workstation Connector Board Figure B 20 Workstation Connector Board VITEK 2 amp VITEK 2 XL System Service Manual B 25 Rev 0100 iagrams d D ICS an Schemati Appendix B Cabinet Diagram Power Su T3A NHO 6 1Sd QNO SISSVHO 13 H3MVUG AlddNS H3MOd T3A NHD 9NI T3A NHO 9 Ld LHM 6 d SSANYVH AlddNS H3MOd OV LHM Zed M18 8 Zd M18 Ol cd M18 Zl zd LHM LL cd T3SA NHO I3 1d rcd NHH 9 zd LHM Scd Ma cd WNOS00rFooSgr THA NHO I3 LHM 2 d 1d L d Djo L2 N M L1 NuO O3S lL Gay 93S LL LSd MOVd 1V 1d HOIA Na IHd LL 84 XH I
11. J1 J19 J4 Jii J1 Autoloader Motor B19 Blank J18 Reader A SPN Board 530704 A4 60 A10 1 20 Loading Door Locking Solenoid L3 Carousel SPN Board A l 120 only DO Bower Supply Bd 60 amp 120 A H LLII Ie e w Network Optical Shuttle Home Switch SW16 Card Sensor 60 Front Slide Optical Shuttle Motor B20 Figure B 12a Reader A SPN Board B 18 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 S Appendix B Schematics and Diagrams Reader B SPN Board 120 Only Flourescence Optical Interrupt Stacker Tray Board 530722 Stacker Motor Stacker Cover Sensor 120 MT18 Stacker Home Switch SW19 Present Switch SW20 B22 J4 J1 J8 Autoloader Motor DE J12 Blank Header B SPN Board TA 530704 Lid Sensor MT17 TO A10 1 20 Loading Door Carousel SPN Board B Locking amp Solenoid L3 DC Power Supply Bd J6 J5 Optical Optical Shuttle Shuttle Card Sensor 60 Motor Home Front Slide B20 Switch SW16 Sensor 120 MT9 Figure B 12b Reader B SPN Board 120 only VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Appendix B Schem
12. AOv 4N000 L nid 91d T3A NHO 6 1Sd QNO SISSVHO 14 T3A NHD 191 T3A NHO 9 Ld NYS O23S Il qaa 93S LL Nd IHd LL M18 IHd LL LHM IHd LL NH8 lHd LL quvog ddMOd ov MId L Sd LHM Sd 1a Z LSd LHM 8 LSd m 0 z Zz Ss lt m r LHM td X18 L vd SS3NHVH AlddNS H3MOd 9G M18 8d LHM ZId M18 61d LHM Zb d 1d Ol td LHM_ h kd NH8 amp ld LHM cd 1d tid Nd tld 13A Lhd Gay Ol ld 1d 8 td X18 Ll td NYO Id H3MVHUG AlddNS H3MOd LHM 6 d LHM Z d 1d 8 d M18 Ol d M18 cL cd LHM LL cd TAA NYD I3 1d rcd NHH 9 ed LHM Scd Ma cd NUM USO ba RODS a9 Sse O2Z2GA4C OAs f Idd OVAOZI H3 NHOJSNVH L Ggiogor M1d 9L 1Sd Q3H 0L LSd bm X18 9L 1Sd 1d Scd 3H ced X18 9L 1Sd MI8 t d TAA Led Md 0L 1Sd NYO 9 d LHM 0IL ISd WVYSVIG L3NISVO AlddNS H3MOd Id LHM 8 Ld X18 Ltd aaaivug LHOddNS SISSVHO GND SISSVHO OL AN9 SISSVHO 24 T3A QND 9 Id TIHA QNO H4 aaaivag 1H5IH gunionuis uvau QNO SISSVHO OL 1VISOINH3H L 1VISOINH3H L LHM d LHM Z d X8 L d MI8 b LATY LHM td X18 L vd T3A NHO 23 x18 GEI NH8H O L14 LHM 8 F14 ma V V14 SS3NHVH H3MOd OV LHM h ld 1d Ob bd ZHO09 0S OVAOr2 00c OVAOZL 00L T3A NHD 24 einpoly 49 IJ osn4 fld ktd LHM cd 1VISOINH3H L NH8 d X18 vid 1VISOINH3H L indu ov 113 3LY1d dNNd QNO SISSVHO T3A NHO GNDSVHO ele HM 18 Z
13. Connect all wiring cables disconnected during removal of the power supply 4 Perform Steps 1 and 2 of the Fluorescence Lamp Cassette Assembly Replacement Installation Procedure 5 Re install the Diluter Cover including the saline bag and then re connect the drain tube Close the top access doors that were opened earlier Ensure the instrument is ready to be turned ON and verify the system operation 8 After turning the VITEK 2 instrument ON perform Fluorescence Optics Calibration Procedure See Appendix F UJ DU Reader Head Assembly Replacement Refer to Figure 5 40 for the location of the Reader Head Assembly captive screws Removal 1 Open the top covers of the instrument Disconnect the drain tube from the Diluter Cover and then unscrew and move the Diluter Cover including the saline bag to the side 2 Tag and disconnect all wires and cables from the Reader Assembly that are connected to the Head Controller Board 3 Tag and disconnect all wires and cables from the Reader SPN board that are going to another location 4 Carefully pry the Reader SPN board from the standoffs and push the board aside allowing access to the two captive screws 5 Perform the FL Lamp Cassette Assembly Replacement Removal Procedure Steps 2 4 and set the lamp assembly aside to install in new reader head assembly 6 Perform Lamp Power Supply Replacement Removal Procedure Steps 3 6 and set the power supply aside to install in new rea
14. If the belt was previously secured to the lead screw pulleys during the Removal process then release the hold from the belt keeping belt taught so phasing 1s not lost Tighten and secure the belt so it s tension 1s the same as noted earlier Rotate the motor shaft and pulley checking the force required Verify phasing If phasing has been lost position the belt so the vacuum chamber gasket just barely touches the boat s sealing surface equally around the periphery and tighten To verify phasing slowly turn the belt by hand right and then left Make sure when the vacuum chamber is lowered its gasket touches the boat at the same time If 1t does not loosen belt slightly and adjust by repositioning the notches of the belt respectively with the pulleys Once phasing has been verified and the belt tension is correct position and secure the vacuum belt drive plate to the upper bearing mount Reconnect all wires previously disconnected Close the doors 10 Ensure the instrument is ready to be turned ON and verify the system operation 11 After turning ON verify alignments See Appendix E Alignment Procedure VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation Incubator Motor Refer to Figure 5 17a for an example of the incubator motor Removal 1 Open the top panel door and remove left rear panel to expose the incubator assembly 2 Remove and set aside the incubator access cove
15. Install the motor pulley on the motor shaft to the distance measured during removal of motor After applying threadlocking adhesive place set screws of motor pulley over flat spots of shaft and tighten set screws securely Mount the motor to the home bracket assembly using the four mounting screws in the same orientation as removed Install the drive belt on the pulleys Slide the motor to remove the slack in the drive belt Position and tighten the motor so the belt tension 1s the same as noted earlier Rotate the motor shaft and pulley checking the force required Reconnect the wires to the SPN board as tagged Install access doors or covers removed earlier Ensure the instrument is ready to be turned ON and verify the system operation After turning ON verify alignments See Appendix E Alignment Procedure VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation Transport Pulley Motor Refer to Figure 5 12 for an example of the transport pulley motor Removal 1 Open or remove the access cover s from the area that exposes the transport pulley motor you are replacing 2 Tag and disconnect the motor wires attached to the corresponding SPN board 3 Press on the middle of the timing belt and make a mental note of the tension Also turn the pulley and motor shaft and make a mental note of the force required to turn it by hand The belt will need to be adjusted accordingly after the rep
16. Lu L VACUUM TUBE 90 FITTING Figure 5 47 Filler Valve Assembly VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation Installation l dd ap cd 10 11 12 13 Connect the two large vacuum tubes onto the fittings of the valve assembly as noted from the removal Carefully place the assembly into the instrument and reinstall the hardware Connect all wiring cables disconnected during the removal Close the top access doors that were opened earlier Ensure the instrument is ready to be turned ON and verify the system operation After turning the VITEK 2 instrument ON and insuring the instrument status is OK open a diagnostic terminal From the diagnostic prompt type N_VAC and press ENTER The prompt should reappear From the prompt type sv 149 90 and press ENTER The prompt should reappear Position a boat underneath the vacuum chamber squarely up against the transport rails From the prompt type VAC_CYCLE and press ENTER A vacuum cycle should occur Perform another vac_cycle From the diagnostic terminal determine if any errors occurred If they did from the prompt type sv 149 120 press ENTER and perform two more vac_cycles Confirm no failures occurred Perform Alignments See Appendix E Alignment Procedure Vacuum Pump Replacement Refer to Figure 5 48 for the location of the vacuum pump Removal l is NT b Open the t
17. Previous Screen Key Message Key Undo Key Numeric Keys Arrow Keys Enter Key Figure 3 5 User Interface Keypad and Screen The user interface keypad and screen have the following components FUNCTION Buttons Use these buttons to select menu options or other specified functions HELP Key Press this key anytime to access the message queue PREVIOUS SCREEN Key Use this key to Exit this screen or function to its menu Return to a previous screen in a function Go from a sub menu to its previous menu Go from the Main Menu to the Status Screen UNDO Key Use it to cancel the last action performed ARROW Keys Use these keys to Scroll a screen or menu Move the cursor on some screen NOTE When ARROW keys are active there icons appear on the display ENTER Key Use this key to complete data entries or when instructed to do so on the screen NUMERIC Keys Use these keys to enter a number onto a screen 3 4 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Three System Overview Load Unload Station The Load Unload Station is where the operator loads Smart Carrier Cassettes to start the test card preparation process The cassettes are pre loaded outside of the instrument with tubes of patient isolates susceptibility dilution tubes if needed and 64 well test cards Loaded cassettes are placed into boats withi
18. Sensor J1 Diluter Pump Motor B23 Blank ae oe ae J4 PR J19 J18 J11 J8 J1 J12 Blank Diluter uis iR SPN Board Switch ul 530704 J9 Blank TO Pipetter SPN Bd amp DC Pwr Supply Bd A5 Diluter J13 Solenoid L4 Network J2 J14 J16 J3 J6 Blank Blank Blank Blank Diluter Tilt Diluter Tilt Home Switch SW22 Motor B24 Figure B 10 Diluter SPN Board VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Appendix B Schematics and Diagrams Pipettor SPN Board Pump Home Switch SW14 Vertical Blank Blank Blank Blank Blank Blank Motor B14 J19 J18 J11 J8 J4 J1 n J12 e Pipettor ertica H SPN Board Switch Pipettor SW10 930704 Snout Board a 530720 x TO O A3 Plat Diluter SPN Bd ats T 1 D L2 DC Pwr Supply Bd Z J14 J16 J3 J6 Blank Blank J3 J2 J4 Drum Home Rotor Home Switch Switch denk SW11 SW12 SW13 Figure B 11 Pipettor SPN Board VITEK 2Z amp VITEK 2 XL System Service Manual B 17 Rev 0100 Appendix B Schematics and Diagram Reader A SPN Board Flourescence Optical Interrupt Stacker Tray Board 530722 Stacker Motor Stacker Cover Sensor 120 MT18 Present Switch SW20 Stacker Home Switch SW19 B22
19. The DC Power Supply Board provides the DC power to the SPN Boards and to the Optics as shown in Figure B 5 DC POWER SUPPLY zen MO ee 5 IIe erste Ds bx Chen t T gf S ES Puto m Bieter x Vitak Connectors 1 R9 e TN BUT rn E re Figure B 5 DC Power Supply Board VITEK 2 amp VITEK 2 XL System Service Manual B 9 Rev 0100 Sample Prep Integrated Network Board The following charts shows the SPN board configuration jumpers to setup specific SPN board operation SPN BOARD P N 530704 1 soy Taub BD DESCRIPTION JUMPERS POSITION lt BCB gt JP2 JP9 Left Transport JP3 JP9 1 2 Right Transport JP4 JP9 1 2 Diluter JP5 JP9 2 3 NODE i i Pipettor Vacuum Sealer 1 2 Reader A 1 2 Carousel A J JP7 JP9 SPN BOARD P N 530704 2 NODE INSTALLED JUMPERS BOARDFUNCTION 1 lt BCB gt 2 JP2 Left Transport 3 JP3 Right Transport 4 JP4 Diluter 5 JP5 Pipettor 6 Vacuum Sealer 7 JP7 Reader A 8 JPS Carousel A B 10 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Appendix B Schematics and Diagrams SPN BOARD P N 530704 2 Ww N Un A oo NIA EN JP2 JP3 JP4 JP5 JP7 JP8 JP1 Left Transport Right Transport Diluter Pipettor Reader A Carousel A Reader B Carousel B Vacuum Sealer VIT
20. 11 2 1 Atthe Prompt type CARO INIT andhit Enter This will initialize the carousel and move it to slot 0 11 2 2 Remove the incubator access cover and install an empty blank 64 well card into the center most carousel slot of the exposed quad Straw port will be down and facing out towards front of instrument 11 2 3 Atthe Prompt type CT 52 andhit Enter This will move the card directly in front of the reader head 11 2 4 Atthe Prompt type ALIGN_CAM and hit Enter 11 2 5 Following the prompts on the screen move the Cam in or out as needed so the Cam just does touch the card The Cam should not apply any pressure to the card at all Note Press the H key when done to cycle the Cam and verify the proper position during this alignment Readjust if necessary 11 2 6 Press Enter when done to save the adjustment The Cam will cycle once 11 2 7 Atthe Prompt type CT 0 andhit Enter This will move the carousel so that you may remove the card easily Tip If you will be performing the Autoloader alignment next you may leave the test card in the carousel as it will be needed for that alignment as well VITEK 2Z amp VITEK 2 XL System Service Manual E 27 Rev 0100 Appendix E Alignment Procedures 12 Autoloader 12 1 Autoloader Selection If aligning a 60 then skip this sub section If aligning a 120 this sub section is required 12 1 1 For a 120 atthe Prom
21. 5 Install the access panels removed for replacement of the relay 6 Ensure instrument is ready to turn ON and verify operation See Table 5 1 for voltage test point information Bay Controller Board BCB Replacement Refer to Figure 5 6 for BCB Circuit Board Location Removal 1 Open the top left door of the instrument to access the BCB circuit board 2 Remove Bay Controller EMI Cover 3 Disconnect and tag all cables from the BCB circuit board 4 Note the mounting position of the BCB circuit board on the mounting plate 5 Using a flat tip screw drivers gently pry the board from the standoffs holding the board in place and remove the board from the instrument Be sure not to damage the board B TOP LEFT DOOR STANDOFFS STANDOFFS CABLES Figure 5 6 BCB Circuit Board Replacement cover removed VITEK 2 amp VITEK 2 XL System Service Manual 5 11 Rev 0100 Chapter Five Component Installation Installation l 5 12 Compare the replacement board with the old board for any jumper or switch configuration and make any adjustments Also confirm boot firmware has latest version Place the new BCB into the noted position from removal of the old board and gently press the board on the standoffs Reconnect the cables to the BCB circuit board connectors that were previously removed Ensure the instrument is ready to turn ON and verify board is working See Table 5 1 for voltage test point information
22. Card Transport System Failure The left paddle transport system failed the range of motion test during system boot Card Transport System Failure The right paddle transport system failed the range of motion test during system boot MESSAGE SEE MINORE MAJOR 181 Processing Warnings 182 Processing Incubator Temperature is LOW Warnings 183 Processing Internal Instrument Temperature Warnings is HIGH 184 Initialization Error Card Transport System Failure 185 Initialization Error 186 Initialization Error Card Transport System Failure 187 Initialization Error 188 Processing Can not unload cards waste tray Warnings is not functional Optical Controller Failure ISEQ 60 HCB analog test failure Optical Controller Failure ISEQ 120 HCB analog test failure DESCRIPTION OF ERROR SOURCE OF ERROR High get cassette info Incubator Temperature is Low get cassette info Inside Temperature is HIGH The front paddle transport system failed the range of motion test during system boot The back paddle transport system failed the range of motion test during system boot SEQ 60 unload card but the stacker installed 1 functional 0 DATATASK Failed to store a new wellmap into the Flash See Log for more details DATATASK Could not Flush the wellmaps DATATASK Could not Tagged Data as being Sent DATATASK Could not Remove the Target Command from the FCT DATATASK Could
23. Cleaning the Boats Cleaning the Carousel Cleaning the Cassettes Cleaning the Inside of the VITEK 2 Instrument and Cleaning the Drip Pan 4 Wipe down interior of all access doors and transport areas including the grooves 5 Remove any debris from inside the unit and dispose of it in a biohazard bag 6 Wipe down the base of the carousel making sure to clean all the way around 7 Wipe down the interior of the top access doors 8 Check the decontamination box on the MRA TAG VTK 777 Decontaminating Tools All tools used while servicing the VITEK 2 should be cleaned using a 10 bleach solution as follows 1 Moisten a foam or gauze sponge in the bleach solution and wipe all tool surfaces 2 Allow the bleach solution to react for a minimum of 10 minutes 3 Wipe off the bleach with water using a moistened foam or gauze sponge Be certain to rinse all areas thoroughly VITEK 2Z amp VITEK 2 XL System Service Manual A 1 Rev 0100 Appendix B Schematics and Diagrams Appendix B Schematics and Diagrams Figure B 1a shows a block diagram and location of the PC boards inside the VITEK 2 60 instrument Figure B 1b shows a block diagram and location of the PC Boards inside the VITEKe2 XL 120 instrument Vitek 2 PC Board Top Level 60 Unit Workstation Carousel A Bay Controller Board BCB SPN Board Head Control Board HCB Right Transport SPN Board Reader A Po
24. Head Control Board HCB A W15 24 Pin TP Ribbon Cable TX Detector 10 Pin TP W14 Ribbon Cable 4 Wire Harness Pin TP i Ribbon Cable Bardcode Reader J4 HCB A DC PS J6 rasta Board For 60 Only AMP 4 pin not 120 Flashlamp Figure 4 50 Head Control Board for VITEK 2 amp VITEK 2 XL Section A VITEK 2 amp VITEK 2 XL System Service Manual 4 49 Rev 0100 Chapter Four System Components Head Control Board B FL Optics TX Emitter Wie l optional J2 26 Pin TP 16 Pin TP Ribbon Cable W16 Ribbon Cable W17 Dallas Touch 2 Wire Memory s Harness Je Head Control BCB a Board TX Cable HCB Detector B W15 For 120 Only 24 Pin TP Ribbon Cable 4 Wire 10 Pin TP Harness W14 Ribbon Cable Head W2 Ribbon Cable Bardcode Motor EE gor Reader Cable DC PS Ele D is P Board AMP 4 pin Figure 4 51 Head Control Board for VITEK Z XL Section B 4 50 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Four System Components Sample Prep Node Board The Sample Prep Node SPN board is a slave controller to the BCB The SPN boards provide the remaining instrument interface and control functions The SPN board is networked to the BCB as a slave via a serial interface SPN board architecture includes a Motorola MC68HC11 single PLCC firmware chip based computer responsible for the remaining functions relative to instrument processing Each
25. PCB Printed Circuit Board Pipettor Transfers and mixes the appropriate inoculum volume pre determined by the card bar code 60 ul to 300 ul to adjacent susceptibility tubes The system includes a drum for pipette tips a displacement pump various tip mechanisms A segment of the carrousel that holds 15 cards and is removable for cleaning Radio Frequency Interference Quad Quadrant RFI Smart Carrier Station SCS Transmittance Optics A laptop computer like device used to aid in setting up the test and for entering test information A combination of light emitting diodes emitters and photodiodes receivers used to read the growth results in the card wells Transport System The transport system moves the cassette carriers by pulling them through each process station within the instrument Stacker The mechanism that pushes the cards into the waste tray User Interface UIF The keypad and screen located on the front of the Display Assembly VITEK 2 Used to send you messages about operation on board consumables and possible problems and let you control the instrument Vacuum System Fills the card with an inoculum using vacuum displacement principles similar to those used in the bioM rieux Vitek System Once testing 1s complete cards are stacked in a tray for disposal Waste Station Workstation Computer The workstation computer is the central diagnostic station
26. Q og j _f svi Lm f REMOTE STATION VITEK 2 2 CDNDI T 1 ONER 1Be1O0 4 X Figure 2 4 Cabling Diagram Four VITEK Z Instruments VITEK Z amp VITEK 2 XL System Service Manual Rev 0100 Chapter Two System Setu 4 Turn ON the VITEK 2 power VITEK 2 power switch is located on the lower left side Remove the shipping foam block from beneath the vacuum chamber and store it with the shipping container Clean the vacuum chamber seal and all top boat surfaces with a water dampened cloth or paper towel Clean the transmittance and fluorescence arrays with a lint free lens paper or an alcohol wipe with the excess alcohol squeezed out followed by lint free lens paper Install drum magazine assembly and motor shield If the cleaning window is not displayed on the User Interface screen from the Main Menu select Utilities Maintenance Cleaning and then Carousel Cleaning or Boat Cleaning Follow the directions on the User Interface screen to install all four carousel quadrants and all four boats Refer to VITEK 2 User s Manual for detailed information Install saline dispensing tube assembly and pipette tips Refer to VITEK 2 User s Manual for proper procedure Communication Configuration and Association The Work Station must be configured properly to communicate with the VITEK 2 instrument This includes setting up the logical tty device software for data as well as the dia
27. SCREEN DUMP is a variable and is used to set the output of READWAVE or READROW to a specific format They are SCREEN_DUMP 0 No Dump SCREEN DUMP 1 RAW and Calculations SCREEN DUMP 2 SORTED and Calculations SCREEN DUMP 3 Calculations Only SCREEN_DUMP 4 Averages via Echo Port SCREEN_DUMP 5 Averages via DML CALWAVE The CALWAVE command calibrates and verifies the transmittance optics It is necessary to enter the optics number after this command For example CALWAVE 1 for Transmittance Optics 1 TX1 or CALWAVE 2 for Transmittance Optics 2 TX2 WARNING This command should only be used when cards are not processing or a SEQ PAUSE is invoked Typing CALWAVE 1 and pressing ENTER will display the calibration values for the transmittance 660nM optics TX1 and the pass fail result See Figure 6 19 CALWAVE 1 Ee NOTE Channel 1 is located closest to the optical interrupt VTK2 A gt CALWAVE 1 LOG 1722002 b4329 760 ALT ADC 3399 3400 3400 3400 3400 3400 2399 3399 LOGT 7s 500s L4229 760 CAET DAC 34995 S169 B0855 2176 3456 29290 2529 2687 LOG 17 00 14 29 760 CALT Transmittance Calibration PASSED Wavelength 1 Calibration PASSED Figure 6 19 CALWAVE 1 6 26 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Six Troubleshootin Typing CALWAVE 2 and pressing ENTER will display the calibration values for the Transmittance 568nM Optics TX2 and the pass fail result
28. UJ UJ UJ UU UJ UJ UJ UJ UU i m p Jg ggg ox Diluter Pipettor Vacuum Sealer Transport Touch Memory Bar Inside Host Power Low Code Temp Comm Fail Batt Installed Yes Yes Yes Yes Yes Yes No No No No No No No No No No No No Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Functional Yes Yes Yes Yes Yes Yes No No No No No No No No No No No No Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes 2 2 Error Codes 02 04 Figure 6 48 SYS STATUS VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Six Troubleshooting The following variables can be used to enable or disable the corresponding instrument component or section To enable the component or station type the variable followed by and press ENTER To disable the component or station type the variable followed by 0 and press ENTER Example VTK2 A gt DILUTER_EN 0 BARCODE_EN DILUTER_EN PIPETTER_EN VACUUM_EN SEALER_EN TX1_EN TX2_EN FLR_EN AUTOLOADER_EN STACKER_EN SERIAL_ NUMBER SERIAL_NUMBER will display the Bay Controller Board serial number Because this command begins with a it is a variable and has a value assigned to it To determine its value it is necessary to enter PR before the command Example VTK2 A gt PR SSERIAL NUMBER 000001FD4078 JUMPER JUMPER will display th
29. VITEK Z amp VITEK 2 XL System Service Manual Rev 0100 none none all none 1 2 3 4 7 8 None 11 12 13 14 speaker all none 2 3 2 3 none INSTALLED JUMPERS Chapter Four System Components HEADER INSTALLED JUMPERS HDR all HDR2 none HDR4 none HDR5 all HDR6 none HDR7 1 2 HDR8 3 4 7 8 HDRI11 none HDR12 11 12 HDR13 speaker HDRI6 all HDR19 none HDR20 2 3 HDR21 2 3 P12 none Figure 4 49 VITEK 2 XL BCB Jumper Configuration 4 48 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Four System Components Head Control Board The Head Control Board HCB connected to the BCB serves as a analog I O extension board for the reader drive belt motor laser bar code reader the button memory transmittance optics and fluorescence optics It also serves as the Analog to Digital ADC and Digital to Analog DAC converter for the transmittance optics The VITEKe2 includes one HCB and the VITEKe2 XL has two Head Control Boards Figure 4 50 and 4 51 shows block diagrams of the Head Control Board connections for the VITEK 2 amp the VITEK 2 XL Head Control Board A FL Optics TX Emitter J2 W12 26 Pin TP 16 Pin TP Ribbon Cable W16 Ribbon Cable For 60 Only not 120 c e w17 Dallas Touch BW 1 Memory Harness A unn nui e m E m e e qid edel mie MU ee Head CTRL A
30. 92 26 139 45 51 Sun Mar 07 23 05 49 1999 DAC Offset Calibration History Ref Pot Channel 2 Channel 3 Channel 4 Channel5 Channel6 Channel 7 Time Date pot dac pot off dac pot off dac pot off dac pot off dac pot off dac pot off 0 O 0 O O 0 O O 0 O O O O 0 00 O 0 Software Offset Calibration History Ref Pot Channel 2 Channel 3 Channel 4 Channel5 Channel6 Channel 7 Time Date pot dac pot off dac pot off dac pot off dac pot off dac pot off dac pot off 143 139 132 10 141 152 23 139 156 73 141 152 46 140 124 28 140 80 57 Thu Jul 01 11 40 15 1999 Figure 6 23 FL History HSHUTTLE amp ESHUTTLE HSHUTTLE homes the optical shuttle and ESHUTTLE extends the optical shuttle WARNING This command should only be used when cards are not processing or a SEQ PAUSE is invoked FL TOTAL FLASHES FL TOTAL FLASHES indicates the number of times the flash lamp has flashed Because this command begins with a it is a variable and has a value assigned to it To determine its value it is necessary to enter PR before the command When a lamp is changed this value should be reset to 0 by entering SFL TOTAL FLASHES O at the Diagnostics prompt See Figure 6 24 SFL TOTAL FLASHES VTK2 A gt PR SFL TOTAL FLASHES L2 7905 VTK2 A gt SFL TOTAL FLASHES 0 Figure 6 24 SFL TOTAL FLASHES 6 30 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter S
31. Get Cassette Info The BarCode reader and SCS both have Barcode info but the card type s are different Failure is not available is full is HIGH Call bioMerieux FLASH Memory Failure FLASH Memory Failure Slot conflict at Slot SCS and Bar Code Reader conflict at Slot Optical Controller Failure ITX 2 was detected without TX 1 Optical Controller Failure TX 3 was detected without TX 1 and or TX 2 Optical Controller Failure ITX 5 was detected without TX 4 Optical Controller Failure TX 6 was detected without TX 4 and or TX 5 Transmittance Calibration Can not unload cards waste tray Can not unload cards waste tray Internal Instrument Temperature ENV TASK The average inside temperature is Bar Code Reader failure at Slot Cassette button memory failure Get Cassette Info Could not successfully read the touch memory Inoculum source not available for SCS and Bar Code Reader General Tx Calibration Failure SEQ 60 Waste tray is not installed while attempting to unload a card SEQ 60 Waste tray is full while attempting to unload a card high with the exhaust fans ON Get Cassette Info Card sensor saw the card but the BarCode reader did not DATATASK could not store new wellmap into RAM DATATASK BOOT Failed Flash Verify of wellmaps Could not store the defaults to FLASH DATATASK BOOT Failed to verify the well
32. NEXT USED LTR DESCRIPTION DATE APPROVED ASSY ON SEE DCN PCN 199 0482 3 DAH 11 22 99 Standardized revision levels so all pages reflect revision level in the title block of document as stated D SEE DCN PCN 100 0037 1 SH omo 02 15 00 FILENAME 530600D DOC bioM rieux Inc proprietary rights are included in the information disclosed herein Recipient by accepting this document agrees that neither this document nor the information disclosed herein nor any part thereof shall be reproduced or transferred to other documents or used or disclosed to others for manufacturing or for any other purpose except as specifically authorized in writing by bioM rieux Inc DRAWN B FREINER 1 12 98 bioM rieux Inc CHECKED Joe Gruber 1 16 98 595 Anglum Road APPROVED P J Springer 1 19 98 Hazelwood MO 63042 2320 USA APPROVED Don Hellmann 1 19 98 TITLE APPROVED John L Bryant 1 19 98 VITEK 2 ALIGNMENT PROCEDURE APPROVED Mark Fanning 1 19 98 APPROVED SIZE DRAWING NO REV APPROVED HEC QU BE AN D APPROVED Ron Robinson 1 22 98 SCALE NONE DIST SHEET 2 OF 31 O Osmom E 2 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Appendix E Alignment Procedures IL H H H H DEDERE
33. The temperature is monitored and controlled by two remote precision thermistors monitored by an A D converter These inputs are compared to voltages produced by high precision resistors This will enable the temperature at the card to be held at an average temperature of 35 5 1 C 95 9 F 1 8 F Figure 3 24 shows the Heater Assembly CIRCULATING FAN r s i r me L a L a i T L 1 is THERMISTOR 5 E rr EL d Figure 3 24 Heater Assembly in molded incubator 3 18 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Three System Overview Reader System VITEK 2 60 consists of one reader system made up of a card drive belt system a fluorescence optical system and two transmittance optical systems VITEK 2 120 contains two reader systems Reader Section A which includes the same components as the 60 capacity instrument and Reader Section B which only includes one transmittance optical system 660 nM There will be an upgrade option allowing installation of a second fluorescence and a 568 nM transmittance to the 120 capacity instrument The optical systems are modular with each module independently controlled by a microprocessor This area is accessible to the user for maintenance functions See Figure 3 25 ACCESS READER OPTICS Figure 3 25 Reader System Accessibility The VITEK Z performs its identification and susceptibility an
34. at the completion of the return to atmospheric pressure and held open while the vacuum chamber is raised from the cassette 9 The proportional valve is closed and the system 1s ready to run again Throughout the entire cycle the air pressure inside the vacuum chamber is monitored This is to ensure that the rate of change of pressure and the maximum vacuum value is maintained without boiling the sample Figure 4 29 shows the theoretical vacuum cycle chart followed for vacuum chamber operation 18 17 16 DEPENDS ON THE AMOUNT OF CARDS LOADED IN THE CASSETTE 15 14 13 12 11 10 PRESSURE PSIA N OO A O10 OC CO VARIABLE _ 5 10 15 20 25 30 35 40 45 50 55 60 65 TIME SECONDS VACUUM CYLCE Figure 4 29 Theoretical Vacuum Cycle Chart Reference only VITEK 2 amp VITEK 2 XL System Service Manual 4 27 Rev 0100 Chapter Four System Components Card Sealer Station The card sealer station completes the function inside the instrument that prepares the test cards for incubation and reading Before a test card can be incubated and read the wells must be sealed off from the outside environment The card sealer station melts and seals the transfer tube that delivered the inoculum to the card from the test tube During the last part of the vacuuming process a hot wire from the sealer station drops down and begins heating As the boat and cassette move through the sealer station the hot wire comes in contact wi
35. current documentation or compare it to the circuit board being removed When servicing instrument take caution not to contaminate disposables such as saline pipette tips and diluter tubes VITEK 2 amp VITEK 2 XL System Service Manual 5 3 Rev 0100 Chapter Five Component Installation Voltage Test Points Supplied voltages shown in Table 5 1 should be tested at the listed test points for each of the circuit boards as indicated Table 5 1 Supplied Voltages CIRCUIT BOARD TEST POINT DATA Test Signal Voltage Comments Point Bay Controller Board BCB OV 5V TP3 GND 5V GND TP7 Fia lov o TP8 DACOUT OV to 45V Variable output voltage can be set by SHCB DAC Ha ao pee eo nT HERD variable User I F Board as K i tpi vcc 5V TP2 GND OV T GND OV TP4 ES 24V 24V o TP5 GND pov TP6 RS232 7 8V Typical 7 8V no specification on min max TP7 RS232 86V 8 6V Typical 8 6V no specification on min max TP8 MGND OV DC Power Supply Board TP1 GND OV TP2 24V 24V Po TP3 12MOT 12V Po TP4 12V 12V oO O Ol TPS 12V PHM fs TP6 GND ov PO e TP 5V 5V LLLA Head Control Board HCB TPI 12V 12V TP2 12V 12V ooo 5V GND o ot TP4 mn V2 LCD_BIA LL 12V to 24V Variable this voltage is set to V1 x 2 TP5 H VLLCD BIA OV to 12V Vari
36. enter the test tube at the same relative point then the rotor 1s vertical If the top of a tip appears to move to the left or right of where the bottom of the tip entered the tube then the rotor is not vertical This can also be caused by improper Rotor home and Vertical home alignments 7 6 3 Press Enter when done to save the adjustment This will drop a straw 1f one was picked up 7 6 4 To check that you are stopping at the correct position type ALIGN ROTOR DOWN andhit Enter atthe Prompt gt If not readjust as needed by following the instructions above in this sub section VITEK 2Z amp VITEK 2 XL System Service Manual E 17 Rev 0100 Appendix E Alignment Procedures 7 7 Pump home The pump bellofram should be at a relaxed neutral state when the pump is setting at home and should have 340 steps of free travel 7 7 1 Atthe Prompt type ALIGN PIP PUMP andhit Enter This starts the pipettor pump alignment routine 7 7 2 Following the prompts on the screen insert 3 mm pin when instructed by screen Adjust the pump home position out slowly using the O key as instructed until the pin just drops out of the pump Note Itis important that you be in one step mode when making the last outward movement where the 3 mm pin drops If not reinsert the tool and manually step back in until the tool 1s held in place again so you can switch to one step mode 7 1 3 Press Enter when done to save
37. key when done to verify the proper position during this alignment Readjust if necessary Tip You may use a small pencil or screwdriver to move card to check for excess pressure from Autoloader 12 2 6 Press Enter when done to save the adjustment The Autoloader will cycle once 12 2 7 Atthe Prompt type CT 0 andhit Enter This will move the carousel so that you may remove the card easily E 28 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Appendix E Alignment Procedures 13 Optical Shuttle 13 1 Shuttle Selection If aligning a 60 then skip this sub section If aligning a 120 this sub section is required 13 1 1 For a 120 atthe Prompt type CAROUSEL A and hit Enter This will redirect all shuttle alignment commands to Shuttle A You may complete the rest of this section to align Shuttle A then return back to this point 13 1 2 For a 120 after Shuttle A has been aligned type CAROUSEL B and hit Enter to redirect all shuttle alignment commands to Shuttle B You may complete the rest of this section to align Shuttle B 13 2 Shuttle Home Offset and Stroke The shuttle is properly aligned when the reflector glass dark glass is centered with the interrupt LED when the shuttle is home The shuttle must also center the solid reference standard glass mirrored glass with the interrupt LED when the shuttle is extended Caution Be careful not to get fingerprints or
38. optical modules can be used in the instrument The system scans across the well in 16 steps and takes 3 readings per step The readings are smoothed and the peak value is chosen It ignores any readings resulting from air bubbles The TX optics calibration is verified before each reading and then electronically re calibrated if necessary Figure 4 38 shows a cross section of the TX optical system Emitter Emitter Ceramic Substrate Eg Emitter Aperature M Sample Well TOP VIEW d Detector Aperature Asos te Detector Photodiode Detector Ceramic Substrate Emitter Output SIDE VIEW Sample Well Figure 4 38 TX Optical System Cross Section 4 36 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Four System Components Fluorescence Optical System DANGER Do not remove the fluorescence power supply cover with system turned on The fluorescence power supply casing contains a 600V Power Supply and an ultraviolet flashlamp The fluorescence FL optics detect the growth of organisms indirectly It detects a chemical byproduct of their growth rather than the organisms themselves This chemical called a fluorophore absorbs light at a wavelength of 365 nM and immediately re emits the light at a different wavelength of 445 nM The FL optical system 1s comprised of a hinge mounted motorized
39. 1 9 Now gently press on the left side of the boat to the right to remove any play from the transport relative to the boat then remove the pressure 4 1 10 Press the X key to activate the bar code scanner 4 11 Loosen the two screws holding the bar code reader bracket and move it until the center of the laser beam is hitting a point 20mm Imm from the inner side of the boat measured from the bump out for the right paddle pocket Tighten the bar code bracket mounting screws verifying the beam position has not moved after tightening 4 1 12 Press the Space Bar to stop the bar code reader from firing and get the Prompt back 4 1 13 Press Enter when done to save the bar code separator adjustment E 12 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Appendix E Alignment Procedures 5 Touch Memory Contacts Two types of touch memory contacts are in use One is adjustable and one is not If you have the non adjustable type of contacts contact block mounting hole is not slotted then skip the Touch memory contact position sub section below 5 1 Touch memory contact position The touch memory contacts are correctly positioned when they apply light pressure to the touch memory contacts on the cassette even when the cassette is positioned as far forward in a boat as possible 5 1 1 Loosen the screw holding the mounting block for the touch memory contacts just enough so the block can be moved forward or
40. 120 a DC Power Supply Bd 3 Lower Fan J6 Incubator B27 J5 J16 J14 Ejector Motor Carousel Motor B26 Ejector Home Switch SW23 Carousel Index Top Sensor MT13 B25 Carousel Index Bottom Sensor MT14 Figure B 13b Carousel B SPN Board 120 only VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 B 21 Vacuum Sealer Board Vacuum Pump Solid State Relay RLY1 c N TO Left Transport SPN Bd amp DC Power Supply Bd Network Vacuum Solenoid L1 4 way Valve J8 Appendix B Schematics and Diagram Hot Wire Sealer Up Down Motor B13 Blank J3 Vacuum Sealer Board 530724 J4 Hot Wire Sealer Up Down Home Switch SW8 Vacuum Chamber Home Switch SW9 Encoder Vacuum Servo Switch Vacuum Valve MT7 did Proportional Valve otor B12 Figure B 14 Vacuum Sealer SPN Board B 22 J3 Blank Blank J2 J1 Sealer Connector VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 S Appendix B Schematics and Diagrams F2 3A biaMerieux Vitek VACLILIM SEALER AOF IM UA ASSY 539724 SERIAL 31 F1 3A Figure B 15 Vacuum Sealer Board Sealer Connection Board bioMerieux Vitek MADE IN USA ASSY NO 530744
41. 1997 5 Pipetter ENABLED 103 109 108 0 O 01 61 18 11 1997 6 VacuSealer ENABLED 82 101 103 0 O 01 58 23 10 1997 7 Reader A ENABLED 103 150 157 0 0 01 61 18 11 1997 8 Carousel A ENABLED 103 238 237 3 0 O 01 61 18 11 1997 9 Reader B DISABLED D 1 0 0 0 unknown 10 Carousel B DISABLED 0 L 4 0 0 0 unknown 11 unused DISABLED 0 3 I 0 0 0 unknown Figure 6 33 NODE STATUS CUR NODE CUR_NODE indicates the current node for specific commands to apply such as SPN_SENSORS and SPNVAR_SHOW Because this command begins with a it is a variable and has a value assigned to it To determine its value and therefore the current node it is necessary to enter PR before the command The value of CUR_NODE can be changed by first entering NODE STATUS to reference the node numbers Then assign the desired value to SCUR NODE For example if it was desired to make the Diluter SPN Board the current node type CUR_NODE 4 and press ENTER Note A short command is NODE X where X equals the node to address Another means of performing the same function as the SCUR NODE command is to enter one of the following commands from Table 6 2 Table 6 2 Node Addressing N FTRANS Front Left Transport SPN board N LTRANS Front Left Transport SPN board N BTRANS Back Right Transport SPN board N RTRANS Back Right Transport SPN board N DIL Diluter SPN board N PIP Pipetto
42. 24 Pipettor Pump Assembly When the instrument is set in automatic mode and a identification card is positioned under the pipettor system by the front transport the pipettor pump assembly initializes to its home position Next the fingers inside the drum begin to rotate allowing a pipette tip to drop onto the horizontal slide between the drum slot The tapered pin motor assembly extends the hollow tapered pin into the pipette tip and presses it against the straw sensor pad The vacuum sensor verifies the tip is attached The solenoid for the horizontal slide activates and the slide retracts allowing the pipettor pivoting motor to rotate the pipette tip down vertical With the pipette tip directly over the test tube the pipettor vertical motor lowers the pipette tip into the test tube a preprogrammed distance The pipettor pump motor assembly draws a preprogrammed amount of bacterial suspension solution from the identification tube into the pipette tip The vertical column raises the pipette tip from the tube The transport system moves the cassette to position the adjacent susceptibility test tube under the pipette tip The pipette tip containing the bacterial suspension is lowered into the test tube The pipettor pump motor assembly first verifies there is saline and then works to deliver the suspension into the test tube where it mixes with the saline A volume of air is then slowly bubbled through the tip to mix the solution The tapered pin
43. 4 Transport Home Switch Assy Qty 4 Transport Encoder Switch Assy Qty 2 Front amp Back for counting steps Pipettor Vertical Home Switch Assembly Pipettor Rotor Home Switch Assembly Diluter Tilt Home Switch Assembly Diluter Pump Home Switch Assembly Vacuum Home Switch Assembly Vacuum Encoder Switch Assembly Sealer Home Switch Assembly Carousel Home Switch A amp B Auto Loader Home Switch A amp B Ejector Home Switch A amp B Stacker Push Plate Home Switch A amp B Auto Cal Home Switch Fluorescence Cam Home Switch VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 5 41 Chapter Five Component Installation Wide Optical Switch Assembly Sensors Carousel Index Top Sensor p n 530154 1 Carousel Index Bottom Sensor p n 530154 1 Incubator Cover Switch p n 530154 1 Stacker Empty Switch Sensors p n 530154 2 Left amp Right Lid Sensors Qty 2 p n 530157 1 Front Slide Sensor Qty 1 120 only p n 530157 1 Other Optical Switch Assembly Sensors Diluter Sensor Assy Wide sensor on PCB p n 530738 Pipettor Pump Home Switch Assembly p n 530160 1 Pipettor Tip Pine Home Switch Assembly p n 530159 1 Card Separator Switch Assembly p n 531114 1 Pipettor Diluter Cover Sensor Assembly Front Door p n 531110 1 Pipettor Hall Effect proximity Sensor The VITEK 2 has only one Hall Effect sensor The sensor is located on the base that holds the drum Refer to Figure 5 25 for loca
44. 5 Remove the timing belt and the pipettor pulley motor 6 Measure and note the distance of the drive pulley mounted on the motor drive shaft 7 Loosen the pulley set screws and remove from the motor shaft 8 Discard the motor Figure 5 14 Pipettor Vertical Pulley Motor Installation 1 Install the motor pulley on the motor shaft to the distance measured during removal of motor After applying threadlocking adhesive place set screws of motor pulley over flat spot of shaft and tighten set screws securely 2 Install the four mounting screws attaching the motor to the vertical motor mount in the same orientation as removed VITEK 2 amp VITEK 2 XL System Service Manual 5 25 Rev 0100 Chapter Five Component Installation 3 Install the drive belt on the pulleys Slide the motor to remove the slack in the drive belt Position and tighten the motor so the belt tension 1s the same as noted earlier Rotate the motor shaft and pulley checking the force required Reconnect the wires to the pipettor SPN board as tagged Close large access door Ensure the instrument is ready to be turned ON and verify the system operation After turning ON verify alignments See Appendix E Alignment Procedure imu Pipettor Pivoting Pulley Motor Refer to Figure 5 15 for an example of the pipettor pivoting pulley motor Removal 1 Open the large access door to expose the pipettor system assembly 2 Remove the display assembly and s
45. ARE EXCLUSIVE AND IN LIEU OF ALL OTHER REMEDIES OR WARRANTIES EXPRESS OR IMPLIED ARISING BY LAW OR OTHERWISE WITH RESPECT TO THE PRODUCT DELIVERED THEREUNDER INCLUDING WITHOUT LIMITATION ANY OBLIGATION WITH RESPECT TO MERCHANT ABILITY FITNESS FOR A PARTICULAR PURPOSE AND CONSEQUENTIAL DAMAGES AND WHETHER OR NOT OCCASIONED BY BIOM RIEUX INC S NEGLIGENCE This warranty shall not be extended or altered except by written instrument duly approved and signed by bioM rieux Inc VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 PREFACE This manual is for use by bioM rieux Field Service Engineers and Factory trained Biomedical Engineers to assist in the troubleshooting and repair of the VITEK 2 integrated system Every effort has been made to ensure that the information contained in this manual is complete and accurate All calibration and adjustment procedures used in this manual are adapted directly from current Engineering documentation Information in this document is subject to change without notice Should a change to this manual become necessary revision will be performed in accordance with bioM rieux General Procedure DO 07 00 or the latest revision and will take place at the Chapter level No part of this manual may be reproduced or transmitted in any form or by any means electronic or mechanical including photocopying and recording for any purpose without express written permission of bioM rieux Inc VI
46. Alarms Messages LOG 00 00 00 00 063 BOOT Touch Serial Number Verifies LOG 00 00 00 00 087 FBOOT Time Fri Jul 16 14 33 51 1999 Pilot49 x LOG 00 00 00 00 102 NSB Firmware BCB 4 Version BCB 02 27 Jun 30 1999 LOG 00 00 00 00 528 BOOT FLASH WellMaps Verified with 40 Well Maps LOG 00 00 00 01 207 NWK Node Left Transport was AutoDetected LOG 00 00 00 01 332 NWK Node Right Transport was AutoDetected LOG 00 00 00 01 458 NWK Node Diluter was AutoDetected LOG 00 00 00 01 583 NWK Node Pipetter was AutoDetected 0 0 j 3 E j o0 00070 0 0 0 0 LOG 00 00 00 01 707 NWK Node VacuSealer was AutoDetected LOG 00 00 00 01 831 NWK Node Reader A was AutoDetected LOG 00 00 00 01 923 BOOT FLASH Log File Verified with 809 Logs and 20 Alarms Messages LOG 00 00 00 02 956 NWK Node 8 Carousel A was AutoDetected LOG 00 00 00 02 571 NWK 7 Nodes were AutoDetected YA OB W NH Figure 6 31 FLASH LOG BOOT FLASH LOG GHEP FLASH LOG GREP will search for specific text from the flash log and display the corresponding lines found The text being searched should follow the FLASH LOG GREP command and is case sensitive For example FLASH LOG GREP PIP will list all logged messages containing PIP in its text and FLASH LOG GREP Pip will list all logged messages containing Pip A line number is displayed at the beginning logged message foun
47. Appendix E VITEK 2 Alignment Procedure Run ejector cycle to verify proper operation of the carousel ejector Run cam cycle to verify proper operation of the carousel cam Note To view the sensor status first initialize the corresponding node and then run spn sensors Q to quit Verify proper functioning of power supply 24 VDC Replace SPN board for carousel Run incu stat to verify carousel temperatures Verify integrity and connection of thermistor assembly located inside lower carousel stack Verify integrity and connection of thermistor assembly located below the heater assembly Verify integrity of heater assembly located beneath the carousel fan assembly Verify replace carousel fans Verify power supply voltages Check solid state relay for proper functioning Replace SPN board affecting control of the incubator VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Six Troubleshooting Table 6 4 General Instrument Troubleshooting Information con t MALFUNCTION 11 Ambient temperature out of range 12 Drive motor s will not operate 13 Instrument not communicating messages GENERAL TROUBLESHOOTING ACTIONS Check lab for excessively high ambient temperature Verify replace fans To check fan run fan 100 and then fan O Check the integrity of the fan rotation when it stops Check for obstructions on the outside of the instrument verify proper clearances around
48. BAR CODE SCANNER LASER BEAM Figure 3 8 Laser Bar Code Scanner As the transported cassette and cards enter the Cassette Scan Station area a spring loaded cam shaped card separator makes contact and positions the card to be scanned Figure 3 8 When the card approaches the card separator cam moves into the path of a sensor detecting that the card 1s present The scanner triggers to read or look for the bar code information on a card for each slot of the cassette Each card 1s positioned and read as the cassette moves through this station See Figure 3 9 CARD IN SCAN POSITION 2 CARD SEPARATOR CAM SHAPED To SENSOR Figure 3 9 Card Separator VITEK 2Z amp VITEK 2 XL System Service Manual 52 Rev 0100 Chapter Three System Overview Cassette Memory As the last card in the cassette is scanned the cassette is positioned at the button memory device Figure 3 10 If the VITEK 2 was previously set up in Smart Carrier Cassette Mode and the button memory device was programmed at the Smart Carrier Station the Cassette Scan Station will read the memory This non volatile memory device contains the patient test and carrier specific information for the system BUTTON MEMORY DEVICE READER E L Figure 3 10 Button Memory Device Reader Information is read from the cassette memory and transferred to the computer workstation Figure 3 11 The information is used by the instrument to deter
49. D Error Code Text MESSAGE MAJOR 18 Processing Error 19 Processing Error 20 Processing Error 2 Processing Error 22 Processing Warnings 23 Processing Errors 24 Processing Errors 25 Host Communication Errors 26 Host Communication Errors Processing Warnings Processing Warnings Processing Warnings Processing Warnings 27 28 29 30 32 Optical Error 39 Optical Error 4 Optical Error _ _ D NO 31 Optical Error 33 Optical Error 34 Optical Error 35 Hardware Errors 36 Optical Error 37 Optical Error 38 Optical Error 40 lOptical Error ALARM MESSAGE DESCRIPTION OF ERROR SOURCE OF MINOR ERROR During pipettor diluter processing if the pipettor SPN board fails the pipettor prep command up to 5 retries attempts will be made to prep the system If the retries fail to prep the system an error message will be generated The diluter SPN board has failed to execute diluter empty command during cassette processing Pipettor Failure The pipettor SPN board has failed to execute Pipettor Failure Dispenser Failure pipettor get command during cassette processing Pipettor Failure The pipettor SPN board has failed to execute pipettor put command during cassette processing Stacker tray can not hold the SEQ The stacker try can not hold the number number of cards currently in the of card that ar
50. ENTER Verify that there are no Error Codes and that all the required components for the VITEK Z are Installed amp Functional See Figures 2 10 and 2 11 for an example VITEK 2Z amp VITEK 2 XL System Service Manual 2 13 Rev 0100 Chapter Two System Setu VTK2 A gt sys_status Component Installed Functional Error Codes Reader A Yes Yes Stacker A Yes Yes Autoloader A Yes Yes Incubator A Yes Yes HCB Head A Yes Yes TX 1 Head A Yes Yes TX 2 Head A Yes Yes TX 3 Head A No No FL Head A Yes Yes Reader B No No Stacker B No No Autoloader B No No Incubator B No No HCB Head B No No TX 1 Head B No No TX 2 Head B No No TX 3 Head B No No FL Head B No No Diluter Yes Yes Pipettor Yes Yes Vacuum Yes Yes Sealer Yes Yes Transport Yes Yes Touch Memory Yes Yes Bar Code Yes Yes Inside Temp Yes Yes Host Comm Yes Yes Power Fail Yes Yes Low Batt Yes Yes Figure 2 10 VITEK 2 With TX1 TX2 amp Fluorescence Installed VTK2 A gt sys_status Component Installed Functional Error Codes Reader A Yes Yes Stacker A Yes Yes Autoloader A Yes Yes Incubator A Yes Yes HCB Head A Yes Yes TX 1 Head A Yes Yes TX 2 Head A Yes Yes TX 3 Head A No No FL Head A Yes Yes Reader B Yes No Stacker B Yes Yes Autoloader B Yes Yes Incubator B Yes Yes HCB Head B Yes Yes TX 1 Head B Yes Yes TX 2 Head B No No TX 3 Head B No No FL Head B No No Diluter Yes Yes Pipettor Yes Yes Vacuum Yes Yes Sealer Yes Yes Transport Ye
51. Fluorescence Optics power supply is a High Voltage source The Optics is an Ultraviolet radiation source All shields and filters must be in place prior to operation The Fluorescence Optics has a high pressure flashlamp To prevent injury wear suitable protective devices such as safety glasses and gloves during disassembly The Fluorescence Optics power supply is a High Voltage source The Optics is an Ultraviolet radiation source All shields and filters must be in place prior to operation The Sealer Station contains a wire that is heated during the sealing operation The proper precautions should be taken VITEK 2 amp VITEK 2 XL System Service Manual 5 1 Rev 0100 Chapter Five Component Installation Laser Bar Code Scanner Cautions and Warnings The VITEK 2 contains a laser bar code scanner component to read the bar codes on the cards Ensure you read and understand the following warning information prior to performing and maintenance or entry into the instrument Caution Labels Located on the top right side of the front access door and on the top right access door behind the Waste Collection Tray s The VITEK 2 60 has a third label behind the front access door CAUTION Laser light when open DO NOT STARE INTO BEAM oo 530520 1 Laser Radiation Specifications 660 680 nm 1 milliwatt maximum output Caution Statements Use of controls or adjustments of performance or procedures other than
52. From the diagnostic terminal confirm the following are displayed during the instrument initialization NOTE If the instrument has completed initialization before the screen could be reviewed use FLASH LOG BOOT command BOOT Boat Management System is OK BOOT SEQ TASK 60 is OK BOOT FLASH Data File Verified If this is a 120 ensure BOOT SEQ TASK 120 is OK From the diagnostic terminal type save_alignment This command uploads the current alignments from the SPN boards to the BCB board From the Command Terminal of the Work Station at the dms gt prompt type vt2setup and press ENTER a In VITEK 2 Setup type 2 and press ENTER for Instrument Association Instrument Association has 4 columns The first column header is labeled This label is the identification for the buttons on the VITEK Z User Interface The second column is labeled Instrument This is the corresponding internal serial number of the Bay Controller Board on each VITEK Z The third is labeled Name This is the instrument name given to the VITEK 2 by the operator The last is labeled Device This is referencing which serial port the data cables are hooked b First type the internal serial number of the removed Bay Controller Board and press ENTER This can be identified by the Name that the VITEK 2Z has been given Note the corresponding and the old internal BCB serial number c Type 0 and press ENTER so the old BCB serial number become
53. LATH zjz xa LHM Z2l Ld a NH5 1d 61d 1d cL Ed X8 LL Ed agy OL d 1d 6 d 1d 8 d 13A L d n18 9 d NYO v d LHM d SSANYVH H3MOd Od M18 Zl d M18 LL Ed Gay OL d 1d 6 d 1d 8 d 13A L d M1 9 d NYO t d LHM d o 6 8 L 9 S v e L Ajddns sam0g 3a iagram D iring Figure 4 65 Power Supply Drawer W 4 65 VITEK Z amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation Chapter Five Component Installation This chapter contains the common field repair procedures for replacing various defective components of the VITEK 2 integrated system instrument Before performing any of these repair procedures be sure you have used the troubleshooting procedures in Chapter Six of this manual to properly isolate the instrument s problems Ensure you read and understand the following warning information prior to performing any maintenance or entry into the instrument WARNING WARNING WARNING gt gt WARNING gt WARNING gt WARNING gt Only Authorized VITEK 2 instrument service technicians should attempt to perform any component installation or servicing of this instrument beyond normal operational and routine maintenance tasks Contact bioM rieux for any additional information or procedural direction Laser Bar Code Scanner is a laser light beam Do not stare into the beam The
54. LL 9 Perform VITEK 2 Fluorescence Optics Calibration Procedure Follow procedure in Appendix F 10 From the diagnostic window Default the instrument settings by typing inst defaults and press ENTER 11 Type cold and press ENTER Verify instrument initializes properly and no errors occur VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 2 17 Chapter Two System Setu Specifications The VITEK 2 integrated system has the following features and capabilities CAPACITY DILUTER PIPETTOR VACUUM SEALER INCUBATOR OPTICS WASTE CAPACITY ENVIRONMENTAL 2 18 4 Cassettes 60 cards maximum for VITEK 2 120 cards maximum for VITEK 2 XL Dispensing 2 33 ml 2 63 ml disposable shot tube Capacity 1000 ml bag user replaceable Volume 100ul to 300ul 5 or Sul whichever is greater Capacity 350 pipette tips maximum user loaded Draw down 0 6 PSI sec max Minimum Pressure 0 89 0 06 PSIA Return to atmosphere 0 10 to 43 5 PSI sec Stub length 0 025 mm to 2 5 mm Sealed Temperature 35 5 C 1 C Average Capacity 60 cards for VITEK 2 120 cards for VITEK Z XL Transmittance LED s emission wavelengths 660nM 568 nM transmission range 30 to 100 10 Reads each card once every 15 minutes 8 channels columns 1 8 for rows 1 8 64 wells total Fluorescence Emission wavelength 365 nM Detection wavelength 445 nM Ochannels 2 7 for rows 1 8 48 wel
55. Potest diete ete 5 40 Bottom Carousel Fan Replacement cccccccssssssseccceeeeeaaeseeeeecceeeecaeeeeeeeeeeeeeeaaas 5 40 Carousel Heater Assembly Replacement eeeeeeeessesseeseeeeneneneeeenennnns 5 51 Carousel Quadrant Removal Replacement eeesssseeeeeeenneereee 5 52 Optics System Component Replacement eeeeeesssssssseeeeeeeneee eene 5 54 Transmittance TX Optics Replacement 22 1 212 1 RIS EIE HESIRE DEDI ERE RR bU ER 5 54 Fluorescence FL Auto Cal Assembly Replacement eesessseess 5 56 Fluorescence FL Lamp Cassette Assembly Replacement 5 57 Fluorescence FL Peak Detector Assembly Replacement 5 58 Lamp Power Supply Assembly Replacement essen 5 61 Reader Head Assembly Replacement sseeeesssssseeseeeeenneneeeeneennns 5 62 Reader Head Assembly Drive Belt Replacement eeeeessseeeesesss 5 64 Reader Head Roller Plate Assembly Replacement seeeeeeeeees 5 65 Ar Pump Replico ement sia ase cecaeteitcute sub ecste enews E ic DM MM 5 67 Diluter Dispenser Assembly Replacement cccccccssssseeeeceececeeaeeesseeceeeeeeaeaeeeees 5 68 Pipettor Assembly Replacement cese cic eres pue poeti png ense deans aad gras uH snes we ast dtamsenlaias 5 71 Vacuum Chamber Assembly
56. Processing Errors 112 113 114 115 Processing Errors 116 Fatal Errors 117 Hardware Errors 118 Hardware Errors 119 120 121 Processing Errors VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 99 Processing Errors Processing Errors 103 Processing Errors 06 106 Hardware Errors 07 107 Hardware Errors 09 109 Hardware Errors Processing Errors Processing Errors ALARM MESSAGE MINOR Dispenser Failure Unload Failure Reader Error Occurred conflict at Slot Reader Error Occurred ISEQ Max retries during fix tx read jam Transmittance Process Failure SEQ Could not find first edge of card while processing a tx card Processing Errors Unload Failure SEQ Could not recover from error 102 104 Initialization Errors Power Fail Recovery Failure SEQ Could not recover from a Power Fail SCS and Bar Code Reader DESCRIPTION OF ERROR SOURCE OF ERROR When the diluter system has a pending error condition and a new cassette is loaded into the instrument requiring the use of the diluter boat management will attempt to clear the pending error by sending a diluter initialization command to the diluter SPN board An error will be generated if this initialization fails SEQ Unload failure while attempting to fix tx read jam SEQ Could not get the card out of the carousel during fix tx read jam
57. Replacement ccccccssssseseceececceeeeeeseeeeceeeeeaaeeeeees 5 72 Filler Valve Assembly Replacement cccccsscscccccccceeessssseeccceeseeeesseeeeeeceeenaas 5 74 Vacuum Pump Replacement 9 o motore g ee RSEN dee bx EDS eater aeens 5 75 Instrument Cabinet Fans Replacement eeeeeesssssssessseeeeeeneee eene 5 77 Laser Bar Code Scanner Replacement eese esee bog ege ineat e oed Dre Fon boca eako 5 78 Cassette Button Contacts Replacement eere iie Ere bateau eeu 5 79 Sealer Hot Wire Assembly Replacement ccccccccccccccseessssseeecccceseeeseeeeeeceeenags 5 80 CHAPTER SIX TROUBLESHOOTING 51 12 52 502252202302 02229256530 2206 2252022 5222302 02202202 6 1 Instrument Diagnostics Using Development Macro Language DML 6 1 ACCESS ine Me P E 6 1 Searching for DML Commands and Variables cccccccesesesecceecceeeeeeeeseceeeeeeaaas 6 4 TRANSPORTS otio eitis dia ditavit iubet at cate ed sedan iu eque a a voces 6 6 BARCODE 25 9 qeu et quM qu item cmq et mM x ibsd m qd eU qM 6 13 button Memory RK CASE 2 ooa one ridic aieo odia sao esl uale tai eo codd Ha Rid td 6 14 DEUTER eT 6 15 NONC BUND suicide DN NM IM II AIME I Rte Re arene ee 6 21 SEALER de 6 23 AU TOEROSNDBR eed NOUO dn DEUM LN e UE 6 24 TRANSMITTANCE cereals ten ceed seein vache a la ute uut 6 25 EEUORESCENCE 3 tetiestudi cU eb ri qu out Ue diab ard quU
58. Right Transport SPN Board Reader A Power Supply Distribution Board SPN Board Left Transport Diluter SPN Board SPN Board Vacumn amp Sealer Custom SPN Board Pipettor Pipettor Snout SPN Board poate Figure 4 43 VITEK 2 PC Board Top Level Block Diagram 4 42 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Four System Components Vitek 2 PC Board Top Level 120 Unit Workstation Bay Controller Board B BCB Carousel A Carousel Right Transport Head Control Board HCB SPN Board SPN Board SPN Board Reader A Reader B Power Supply Distribution Board SPN Board SPN Board Left Transport Diluter SPN Board SPN Board Vacumn amp Sealer Custom SPN Board Pipettor Pipettor Snout SPN Board Board Figure 4 44 VITEK 2 XL PC Board Top Level Block Diagram VITEK 2 amp VITEK 2 XL System Service Manual 4 43 Rev 0100 Chapter Four System Components BCB Board A Bay Controller Board BCB controls the optics the communications to the workstation the user interface and serves as the master controller for the Sample Prep integrated Network SPN boards The firmware for the instrument is downloaded by way of the workstation during periodic updates to the flash memory on the BCB This flash memory contains all the upper level processing for the instrument as well as sequentially buffering card data amp alarm messages T
59. See Appendix F VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation Lamp Power Supply Assembly Replacement Refer to Figure 5 39 for the location of the reader lamp power supply Ce NOTE The Fluorescence assembly must be replaced as a complete unit Its parts should not be interchanged Removal l Open the top covers of the instrument Disconnect the drain tube from the Diluter Cover and then unscrew and move the Diluter Cover including the saline bag to the side 2 Perform the FL Lamp Cassette Assembly Replacement Removal Procedure Steps 2 4 and set the lamp assembly aside 3 Tag and disconnect the wiring cables for the Lamp Power Supply Assembly 4 Remove the two mounting screws on the top of the power supply assembly 5 Loosen the bottom right screw of power supply assembly Do not remove the screw 6 Gently lift the power supply from the reader 7 Set the power supply aside to return for repairs or exchange MOUNTING SCREWS y pem NETS a Figure 5 39 Lamp Power Supply Replacement VITEK 2Z amp VITEK 2 XL System Service Manual 5 61 Rev 0100 Chapter Five Component Installation Installation 1 Place the power supply into the reader frame The power supply flange slot should slide onto the loosened pan head screw 2 Install the two top mounting screws to secure the power supply to the reader frame Then tighten the bottom right screw
60. See Figure 6 20 CALWAVE 2 S NOTE Channel 1 is located closest to the optical interrupt VTK2 A gt CALWAVE 2 LOG 17 00 14 36 544 CALT ADC 3401 3401 3399 3398 3399 3401 3401 3399 LOG 17 00 14 36 544 CALT DAC 0746 1264 0855 2078 1893 0885 1615 1609 LOG 17 00 14 36 672 CALT Transmittance Calibration PASSED Wavelength 2 Calibration PASSED Figure 6 20 CALWAVE2 TESTINT TESTINT will cycle the optical interrupts for the Fluorescence Transmittance 1 and Transmittance 2 optics between the on and off states Transmittance 3 not available at this time If the digits under the O 1 2 are not changing between O and 1 then the corresponding optical assembly will need to be cleaned or replaced See Figure 6 21 TESTINT WARNING This command should only be used when cards are not processing or a SEQ PAUSE is invoked VTK2 A testint Scanning Duart Input POL o00105 DUART A opare opare IX A 3 rx A Z2 IX A l FLUOR A O e O N O W Hu H Bu O Level ON O Figure 6 21 TESTINT See the MACROS section for TX TEST VITEK 2 amp VITEK 2 XL System Service Manual 6 27 Rev 0100 Chapter Six Troubleshootin FLUORESCENCE FL STATUS FL_STATUS displays a detailed status of the fluorescence optics See Figure 6 22 FL_STATUS VTK2 A gt FL STATUS Installed Yes Functional Yes Version
61. TX2 660 TRANSMITTANCE TX1 s OPTICS PTICS r illis Figure 4 36 Optics System and Components The VITEK 2 60 reader system is comprised of an optical mechanical head assembly that includes a drive belt motor a reader timing belt a spring loaded roller plate assembly a cam assembly a fluorescence optical system a 660 nM transmittance optical system TX1 and a 568 nM transmittance optical system TX2 The VITEK 2 120 reader system is comprised of two reader systems Reader Section A which includes the same components as the 60 capacity instrument and Reader Section B which only includes the 660 nM transmittance optical systems TX1 There will be an upgrade option allowing installation of a second fluorescence and a 568 nM transmittance to the 120 capacity instrument 4 34 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Four System Components The card ejector pushes a card out of the carousel slot onto the motor drive belt of the reader system The reader timing belt turns counterclockwise transporting the card through the optics system and verifies the cards presence by counting the interrupts on the base of the card Next the timing belt turns clockwise again transporting the card through the optics system this time positioning the card for well readings Once read the cam assembly pushes the card into the same carousel slot for incubation until the next reading cycle The reader rea
62. The carousel slot positions are numbered 0 59 This command can be used in conjunction with the UNLOAD CARD command Example CARA 29 CARO INIT CARO INIT initializes the carousel by referencing the incubator home sensor and aligning the carousel slot O with the reader If the cycle is completed without errors no message will be displayed WARNING This command should only be used when cards are not processing or a SEQ PAUSE is envoked CAROUSEL The CAROUSEL command is strictly for the VITEK 2 120 instrument The command typed is CAROUSEL A or CAROUSEL B This sets the corresponding section A or B as the target thus allowing commands executed to be directed to a specific section LOAD The LOAD command is used to load cards into the carousel by means of the reader When loading a card into the front of the reader the card must be orientated properly The interrupt holes of the card must be toward the bottom of the instrument and the remaining transfer tube nub must be facing the front of the instrument The LOAD command also requires some additional information It needs to know how many cards are being loaded the number of cycles to perform on each card and the card type See Well Map Definition Example LOAD 3 25 1 VITEK 2 amp VITEK 2 XL System Service Manual 6 35 Rev 0100 Chapter Six Troubleshootin FLUSH CAROUSEL FLUSH_CAROUSEL will immediately eject any cards marked Completed from the carousel UNL
63. Tighten the captive and mounting screws to secure the lamp assembly 3 Re install the Diluter Cover including the saline bag amp reconnect the drain tube 4 Close the top access doors that were opened earlier 5 Ensure the instrument is ready to be turned ON and verify the system operation 6 From the diagnostics prompt type SFL TOTAL FLASHES 2 O to reset the flash counter for the new lamp 7 After turning the VITEK 2 instrument ON perform Fluorescence Optics Calibration Procedure See Appendix F VITEK 2Z amp VITEK 2 XL System Service Manual 5 57 Rev 0100 Chapter Five Component Installation Fluorescence FL Peak Detector Assembly Replacement Figure 5 38a shows the locations of the FL optics components for replacement Figure 5 38b and Figure 5 38c shows the location of the peak detector and it removed from the instrument cm NOTE The Fluorescence assembly must be replaced as a complete unit Its parts should not be interchanged Removal Ls 10 11 12 5 58 Open the top covers of the instrument Disconnect the drain tube from the Diluter Cover and then unscrew and move the Diluter Cover including the saline bag to the side Perform the FL Auto Cal Assembly Replacement Removal Procedure Steps 2 4 and set the auto cal assembly aside Perform the FL Lamp Cassette Assembly Replacement Removal Procedure Steps 2 4 and set the lamp assembly aside While supporting each of the optic
64. Work Station If TPL Unsent Commands is greater than 0 this will indicate that the instrument is trying to send information to the Work Station but the Work Station is not receiving these commands This could be a problem with either the instrument or the Work Station Figure 6 47 shows a example of COM_STATUS VTK2 A gt COM_STATUS Communication Status Host Computer BCB Stats TPL Total Sent Commands 72 329 TPL MAX Unsent Commands 14 TPL Unsent Commands EE APL Total Processed Commands 65 APL MAX Unprocessed Commands 26 APL Unprocessed Commands 0 TPL Stats Total ACKs Sent bowl Total ACKs Received 4667 Total NAKs Sent 2039 Total NAKs Received 0 Total ENQs Sent Nx NI Total ENQs Received 85 Total CANs Sent 3 Total CANs Received 0 HOST IBS Name Marcysecret Serial Number 52b3f8004b20 File Name Type Chunks Size Check Sum Elapsed Time Figure 6 47 COM STATUS SHOST COM EN S HOST COM EN enables disables the communication from the instrument to the Work Station This is a variable that 1s stored 1n non volatile memory To determine its value it is necessary to enter PR before the command If a 1 is displayed communication is enabled Typing SHOST COM ENdZO and pressing ENTER will disable the communication For proper instrument operation it is imperative that the communication is enabled prior to exiting DML To accomplish this use the command HOST COM EN 1 or INST D
65. a n Jogs the given transport by n steps VITEK 2Z amp VITEK 2 XL System Service Manual 6 11 Rev 0100 Chapter Six Troubleshooting TRANS L c With the back transport places card c at the carousel load position TRANS M a p Moves the boat to the given transport pocket position See Figure 6 9 VITEK 2 Transport Pocket Locations and Figure 6 10 VITEK 2 XL Transport Pocket Locations TRANS P c With the front transport positions card c at the pipettor TRANS S Executes the sealer fast move with the back transport TRANS T Positions front transport at the button touch memory reader TRANS U a Unhooks boat from front back left or right transport BACK FRONT Figure 6 9 VITEK 2 Transport Pocket Locations BACK LEFT FRONT Figure 6 10 VITEK 2 XL Transport Pocket Locations 6 12 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Six Troubleshooting BARCODE BAR The BAR command can be used to activate and test the bar code reader The three commands to use with this option are BAR O BAR 1 and BAR 2 It is necessary to place a card s bar code in the path of the bar code reader beam to obtain the bar code information By placing a card with a bar code in position typing BAR 0 and pressing ENTER the bar code number will be displayed If the bar code reader fails to detect or read the bar code it will display BAR CODE ERROR No Read
66. a DC Power Supply Bd 3 Lower Fan J6 Incubator B27 J5 J16 J14 Ejector Motor Carousel Motor B26 Ejector Home Switch SW23 Carousel Index Top Sensor MT13 B25 Carousel Index Bottom Sensor MT14 Figure 4 60 Reader SPN Board for VITEK Z XL Section B VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 4 61 Chapter Four System Components Vacuum Sealer Board Hot Wire Sealer Up Down Motor B13 Vacuum Pump Solid State i Relay RLY1 J8 Vacuum Sealer 930724 DC Power Supply Bd TO lt Left Transport SPN Bd O Board 8 b Z Vacuum Solenoid L1 4 way Valve J8 J4 Blank Blank J3 J2 Ji Sealer Hot Wire Encoder Vacuum Vacuum Servo Sealer Chamber Switch Vacuum Valve ne Up Down Home MT7 Chamber Proportional Valve Home Switch Switch Motor SW8 SW9 B12 Figure 4 61 Vacuum Sealer Board 4 62 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Four System Components DC Power Supply Board The DC Power Supply Board is a breakout board mounted on the inside left back plate of the instrument All the SPN boards receive power from this board along with the bay controller board the head controller board s the fluorescence power supply s and the user interfa
67. board fails the diluter fill command up to 5 retries attempts will be made to fill the shot tube If the retries fail to fill the tube the card will be terminated and an error message will be generated 151 Hardware Errors Internal Instrument Temperature ENV_TASK Inside thermister is not installed Controller Failure 152 Processing Error Pipettor Failure During pipettor diluter processing if the pipettor SPN board has a pending error condition from the previous card a pipettor initialization command will be sent to the SPN board An error will be generated if this initialization fails 153 Initialization Error Vacuum System Failure When the vacuum system has a pending error condition and a new cassette is loaded into the instrument boat management will attempt to clear the pending error by sending a vacuum initialization command to the vacuum sealer SPN board An error will be generated if this initialization fails 154 Initialization Error Card Sealer Failure When the sealer system has a pending error condition and a new cassette is loaded into the instrument boat management will attempt to clear the pending error by sending a sealer initialization command to the vacuum sealer SPN board An error will be generated if this initialization fails 155 Fatal Errors Call bioMerieux SYS Task says that the Main Heap is less than 20 free continued VITEK 2 amp VITEK 2 XL System Service Manual D 7 Rev 0
68. connect SCS to Work Station It only needs to be connected when the SCS needs a firmware update Turn on SCS verify proper operation verify all cassettes with button memory can be read and record firmware version SCS Program Version Turn on VITEK 2 Instrument and Work Station if applicable Remove shipping foam block from beneath VITEKe2 vacuum chamber Clean Vacuum Seal all boat surfaces and all optics assemblies Install Drum Magazine Assembly and Motor Shield Install Quads Incubator Cover amp Boats using the VITEK 2 User Interface Configure Work Station to communicate with VITEK 2 and SCS using vt2setup Only define the ports which will be used by the VITEK 2 and SCS Physically connect the communication cable from the appropriate tty ports on the Work Station to the VITEKe2 instrument See Table 2 2 Station software Verify the instrument association from the Work Station software Setup and verify remote diagnostics For security purposes turn modem off when not in use Verify proper function of Optics Card Transport amp Vacuum from the User Interface of the VITEK 2P With diagnostic window opened on the Work Station verify sys status and proper fan operation fan 100 Record the instrument firmware versions of BCB BOOT amp SPN Ver BCB BOOT SPN ltrans rtrans dil pip vac seal reader cara a cara b From vt2setup associate the installed instrume
69. diluter pump 1s activated which forces the saline from the dispensing tube at a controlled rate into the test tube The controlled rate of air flow prevents splashing of the solution After a preset amount of motor steps the air pump is shut off The diluter motor assembly rotates the dispensing tube counterclockwise until the optical sensor detects the signal flag and then the motor stops in its home position Pipettor System The pipettor system transfers a preset volume of the fluid bacterial suspension as determined by the bar code of an identification card into the test tube of its companion susceptibility card via a disposable pipette tip It then leaves the tip into the test tube for disposal The pipettor system consists of a pipettor pump assembly a pipettor vertical motor a pipettor pivoting motor a drum motor a pivoting home optical sensor a vertical home optical sensor a hall effect sensor a sample prep node SPN board disposable pipette tips and a drum which hold the pipette tips Figure 4 22 shows an illustration of the pipettor system PIPETTE TIP DRUM PIPETTOR PUMP amp ASSEMBLY Figure 4 22 Pipettor System 4 20 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Four System Components To prevent contamination the instrument uses single use disposable pipette tips Pipette tips are loaded into the pipette tip drum which is designed to hold up to 350 pipette tips The
70. drum has a slot at the bottom along with rotating fingers to properly deliver a disposable pipette into the slot for the pipettor pump to pick The drum can be rotated 90 degrees vertical to allow for loading the pipette tips When the drum is returned to the horizontal position the bottom of the drum rests on a horizontal slide When the pipette tip is in the drum slot it also rests upon the horizontal slide A aluminum plate covers the opening of the drum to keep the pipette tips inside the drum Software will prompt the user when the drum 1s approaching the empty level Figure 4 23 shows the drum in the vertical position loaded with pipette tips Figure 4 23 Drum Loaded with Pipette Tips The pipettor pump assembly is mounted on a motor driven rotating base which also raises and lowers the pipette tip to the test tubes by way of a vertical column The pipettor pump assembly consists of a hollow tapered pin a taper pin motor assembly an optical taper pin home switch assembly a pipettor pump motor assembly an optical pipettor pump home switch assembly and a pipettor snout board which includes a pressure transducer VITEK 2 amp VITEK 2 XL System Service Manual 4 21 Rev 0100 Chapter Four System Components Figure 4 24 shows the pipettor pump assembly in the instrument M BR OM SNOUT OPTICAL SENSOR X VERTICAL COLUMN LI LE A IPETTOR PUMP HORIZONTAL HOLLOW ASSEMBLY SLIDE TAPERED PIN Figure 4
71. edge Otherwise mount directly to the base pan Positioning of the green and white wires for both reflective sensors should be closest to the front of the instrument 2 Reconnect the cables to the SPN circuit board connector that were previously removed 3 Install or close any access doors or covers previously removed 4 Ensure the instrument 1s ready to turn ON and verify the sensor 1s operating properly See Table 5 7 for wiring information VITEK 2Z amp VITEK 2 XL System Service Manual 5 45 Rev 0100 Chapter Five Component Installation Snap Action Switch The snap action switch is located at the waste collection station and signals when the waste collection tray is in place The switch is a make break switch and located under the front lip Figure 5 27 shows the location of the snap acting switch Removal 1 Open the waste collection station access door Remove the collection tray and set aside 2 Remove the screws and lock washers holding the switch 3 Tag and remove the wires from the switch Note the switch position and remove the switch from the instrument SNAP ACTION SWITCH TA Switch is shown under waste collection Figure 5 27 Example Snap Action Switch Installation 1 Reconnect the wiring to the switch terminal spade connections 2 Place the new switch in the instrument to the position as noted from the removal Install the mounting screws 3 Install the waste collection tray and clo
72. gear engages the rack enough to remove backlash but not tight enough to produce binding 4 Carefully reinstall the stacker card assembly and secure the three pan head screws 5 Connect the motor wires to the Reader SPN board as previously noted 6 Reinstall the magnet bracket waste door and magazine assembly 7 Install or close any access doors or covers previously removed Direct Drive Drum Motor Refer to Figure 5 23 for an example of the direct drive drum motor Removal 1 Open the large front door and the pipettor drum lid to expose the direct drive drum motor 2 Tag and disconnect the motor wires attached to the pipettor SPN board 3 Open the pipettor drum lid and remove the pipettor drum assembly NOTE Take caution not to contaminate the pipette tips inside the drum 4 Loosen and remove the four screws mounting the drum motor assembly to the pipettor drum cam plate Remove the drum motor assembly Measure and note the distance of the drive lug mounted on the motor drive shaft Loosen the drive lug set screws and remove from the motor shaft Discard the motor bu ed DIRECT DRIVE PIPETTOR DRUM PIPETTER DRUM MOTOR CAM PLATE DRUM MOTOR SCREW INSIDE ASSEMBLY Figure 5 23 Direct Drive Drum Motor 5 38 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation Installation 1 Install the drive lug on the motor shaft to the distance measure
73. heater into the carousel stack and that the power cable 1s positioned to the access area of the incubator chamber 2 Install the lock washers flat washers and screws to attach the carousel heater assembly to the carousel incubator housing 3 Install right and left hockey table plate to inside of incubator 4 Reconnect the wiring cables to the heater assembly fan and install the back covers of the instrument removed during disassembly Power ON the instrument and continue with the Carousel Quadrant Installation Procedure VITEK 2Z amp VITEK 2 XL System Service Manual 5 51 Rev 0100 Chapter Five Component Installation Carousel Quadrant Removal Replacement Ce NOTE This procedure must be performed when no cards are being processed in the instrument Removal 1 From the Display Assembly s Main Menu select Utilities Maintenance Cleaning Carousel Cleaning 2 Select the option remove a section After removing the Incubator Access Cover follow the display as it steps you through the quadrant removal process 3 The carousel quadrants are removed in four sections Do so by gently pulling the quadrant to the right and toward the front of the instrument when prompted Installation 1 While still in the Carousel Cleaning menu select replace a section Follow the display as it steps you through the quadrant replacement process 2 To replace grasp the carousel quadrant section and place the quadrant on the carou
74. if voltage is incorrect 2 No power output at AC Check incoming AC power Power Board Check installed fuses Check Toroid Transformer windings Replace transformer if windings are bad Replace AC power board 3 No output power supply Verify input from AC power board voltages Replace Power Supply Verify incoming AC power to instrument lit on BCB board Verify proper functioning of power supply Check fuses on the BCB Replace BCB Verify incoming power to board 5 No indicator lights are lit on DC power supply Verify proper functioning of incoming power supply board for SPN board y prop EP PP 4 Power indicators are not Replace DC power supply board 6 58 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Six Troubleshooting Table 6 4 General Instrument Troubleshooting Information con t MALFUNCTION 6 Transmittance Optical Interrupt failures 7 Transmittance Calibration errors failures 8 Reader jamming GENERAL TROUBLESHOOTING ACTIONS Run testint from the instrument diagnostics menu to check the proper functioning of transmittance optical interrupts Clean both emitter and detector glass of transmittance optics Replace corresponding transmittance optics based on information attained Clean both emitter and detector glass of transmittance optics Check flat ribbon cable connection Run flash_log_grep CALT from the instrument diagnostics menu to check the error log for
75. in place 5 Note the placement of the timing belt on the reader head Loosen and remove the screws securing the reader motor bracket to the roller plate assembly Remove the eight screws securing the roller plate assembly Remove the three springs 8 Carefully remove the plate assembly from the reader head Take care not to allow linear way rails to drop 9 Carefully remove linear way rails by sliding them off of the reader head assembly NOTE Ball bearings in linear way rails have minimal retainers Extreme caution should be used otherwise bearings will fall out See Figure 5 42 for direction of proper removal 10 Remove the seven card rollers and the four reader belt rollers from the plate assembly 11 Discard plate assembly DUE VITEK 2 amp VITEK 2 XL System Service Manual 5 65 Rev 0100 Chapter Five Component Installation TA ELT HEAD HR D M il Er i T qf LINEAR WAY E PP it LINEAR WAY REMOVAL Ee T i Eee T REMOVAL DIRECTION EU ace Lez i k E DIRECTION T Figure 5 42 Reader Head with plate assembly removed Linear way removal direction Installation 1 Using thread locking adhesive on the shoulder screws install the seven card rollers along the top of the plate assembly and the four reader belt rollers on the remaining bearings Tighten securely 2 Carefully install the linear way rails the opposite direction from removal 3 Carefully install the plate assembly while routin
76. is given BOAT RESUME BOAT RESUME sends a resume command to each active boat BOAT ADVANCE BOAT ADVANCE can be used to advance the boats to its next idle position This can also be performed through the User Interface by selecting from the Main Menu Utilities and Move Boat BOAT PLAN BOAT PLAN can be used only after a cassette has been read and accepted by the bar code reader and touch memory It must still be processing within the transports Each boat has a number relative to how it was installed 1 e 1 4 The BOAT PLAN command must identify which boat to display the cassette processing information therefore to check the BOAT PLAN for boat 1 type BOAT PLAN 1 and press ENTER See Figure 6 7 BOAT PLAN VTK2 A gt boat plan 1 Current Spot SPOT 4 0 Total Cycles 1362 Retries 355 Failures 4 Status Loaded Paddle 3 SCS ID 7 Noi Status Real Vacuum O0 Sealer 1 Slot Source Pip Source Pip Vol Dil Card Info Cycles Bar Code Carousel 1 67 0 0 O 103 S N ST GN06 Zoe 031628200002069 A 2 67 0 0 O 103 S N ASI GNOO 73 1031628200002030 A 3 67 0 0 O 103 S N AST GNO6 73 1031628200002036 A 4 67 0 0 O 103 S N AST GNO6 73 1031628200002047 A 5 67 0 0 O 103 S N AST GNO6 73 1031628200002012 A 6 67 0 0 O 103 S N AST GNO6 73 1031628200001997 A 7 67 0 0 O 103 S N AST GNO6 73 1031628200002082 A 8 67 0 0 O 103 S N AST GNO6 73 1031628200002059 A 9 67 0 0 O 103 S N AST GNO6 73 10316
77. lever 5 64 Perform the Fluorescence Auto Cal Assembly Replacement Removal Procedure Steps 2 through 5 Tag and disconnect the accessible ribbon cable plugged into the TX optics on the top of each of the TX optics modules Gently allow the optics to hinge down Press on the belt where the optics sit and make a mental note of the belt tension Also turn the motor shaft and pulley of the reader head motor and make a mental note of the force required to turn it by hand When re assembling the belt will need to be adjusted accordingly Note the placement of the timing belt on the reader head Loosen and remove the drive motor mount bracket screws slip the belt off of the drive pulley and set the motor assembly aside Remove the belt partially by pulling it over the upper right corner of the roller plate assembly Then with the optics opened maneuver the belt around and down so it comes off the TX optics Remove the belt from the Reader Head Assembly sia READER ASSEMBLY REMOVED DRIVE BELT DRIVE BELT MOTOR Figure 5 41 Reader Head Assembly Drive Belt Replacement VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation Installation l Install the belt on the card reader assembly as noted from the removal 2 Manipulate the belt up and over the optics and reposition the belt around the roller plate assembly Carefully close each of the optics modules until the clamp lev
78. motor assembly retracts the hollow tapered pin forcing the contaminated pipette tip off of the tapered pin Then each contaminated pipette tip will remain in its corresponding sample tube for disposal 4 22 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Four System Components Vacuum Station The vacuum station fills the test cards with the inoculum solution using vacuum displacement inside the vacuum chamber The vacuum station consists of the vacuum chamber a vacuum pump vacuum sealer SPN board with a mounted pressure transducer vacuum assembly vertical motor timing belt vacuum home sensor vacuum encoder sensor solid state relay proportional valve 4 way valve air filter and the associated pneumatic components Figure 4 25 shows the vacuum station vacuum chamber and pneumatic components Figure 4 26 shows the vacuum pump mounted in the instrument VACUUM SEALER SPN BOARD MOTOR DR VE BELTS if ENCLOSED P COLUMNS FOR RAISING LOWERING AV VACUUM CHAMBER r 1 I E _ Figure 4 25 Vacuum Station Vacuum Chamber and Pneumatic Components RELAY HIDDEN MOUNTING SCREWS Figure 4 26 Vacuum Station Vacuum Pump Back View VITEK 2 amp VITEK 2 XL System Service Manual 4 23 Rev 0100 Chapter Four System Components The top of the vacuum chamber is mounted on two vertical lead screw columns driven by a drive motor and drive belt arrangement located on top o
79. one cassette is loaded To accomplish this the card ejector must push the card out of the carousel onto the reader belt and card guide The card ejector assembly consists of an ejector guide ejector blade card ejector motor tray drive gear and ejector home sensor The card ejector motor turns a rack gear attached to the card ejector blade The motor fully extends the card ejector blade which pushes the card from the carousel to the reader The ejector blade then retracts to the ejector home sensor See Figure 4 33 for some of the ejector components EJECTOR HOME SENSOR on EJECTOR MOTOR Figure 4 33 Ejector Components VITEK 2 amp VITEK 2 XL System Service Manual 4 3 Rev 0100 Chapter Four System Components Carousel Incubator The carousel incubator is comprised of a rotating carousel capable of holding up to sixty 60 test cards contained inside an incubation chamber with a heater two thermistors and two circulating fans used to incubate the cards during a test A incubator motor for the carousel exists outside the incubation chamber at the rear of the instrument Positioning the carousel is accomplished by three 3 optical sensors The first is the incubator top sensor which reads the positioning slots on the outside edge of the carousel quadrants This sensor is used to align the carousel slots with the reader so the ejector assembly can push the card into the reader to be read The second is the incubator home
80. overwrite the existing alignments VTK2 A gt spnvar show h Unknown flag H a Alignment Vars p c Tato Mats p Parametric Vars d Show differences only S Synchronize vars ask first will upload or download f Fix all differences BCB gt SPN does not ask g Get vars from SPN boards does not ask e Compare against EPROM defaults not NV data n Nonstop display no screen pauses To display all changeable variables use ap To narrow down to those that are changed use apd Figure 6 42 SPNVAR SHOW Example 1 To list all alignment variable relating to the Vacuum SPN Board it is necessary to first enter N VAC to point to the current board and then enter SPNVAR SHOW A VTK2 A gt N VAC VTK2 A gt SPNVAR SHOW A NV data stored at Wed Nov 04 13 41 52 1998 ic Va CU GaL SS ssa 139 Vac Touch Pos vA 29201 2605 ANA 161 Vac Fine Holdpoint 3253 94 CQ FXX Motor Vacuum Home Offset A 0 Motor Sealer Home Offset 7A 0 Figure 6 43 SPNVAR_SHOW Alignment for Vac Seal SPN Ee NOTE The that appear to the far right indicate that this alignment differs from the stored alignment in the Bay Controller Board This will cause the instrument alarm Hardware Error Internal Data Failure 169 If this is the case it is necessary to enter the SAVE ALIGNMENT macro VITEK 2 amp VITEK 2 XL System Service Manual 6 47 Rev 0100 Chapter Six Troubleshooting Example 2 To list
81. pan If helpful as an aid you may place the 0 002 blade of the feeler gage into the appropriate corner of the base pan for the transport being aligned Step the boat in as instructed until you first start to feel some pressure on the paper from the boat This can help you determine when the boat just touches the rail 3 1 Front Transport When the front transport 1s properly aligned the paddle will cause the boat to just touch the left side rail The free play of the boat between the left side rail and the paddle just is removed Dust Place an empty boat in the front left corner of the base pan Note Raise paddles by hand if necessary to place boat in this position Atthe Prompt type ALIGN FTRANS andhit Enter This starts the front transport alignment routine Following the prompts on the screen position the boat as requested and adjust the front transport so the boat 1s just barely touching the left side rail Do not force the boat into the rail under pressure from the paddle Press Enter when done to save the adjustment If the paddle does not look centered in the boat pocket after completion of this alignment then recheck alignment belt tension or transport itself for problem VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Appendix E Alignment Procedures 3 2 Left Transport When the left transport is properly aligned the paddle will cause the boat to just touch the back rail The free
82. position for access Using the center Philips head screw on the front of the plate adjust the entire pipettor assembly in or out as needed to center the pipettor tip over the test tube in position 15 of the cassette Verify the pipettor plate did not rotate and is still parallel to the Rifle then tighten the two allen head set screws securely Newer Cast Rifle Rotate the drum to a vertical position for access and loosen the Allen head set screw located directly above the center Philips head screw on the front of the plate Using the center Philips head screw adjust the entire pipettor assembly in or out as needed to center the pipettor tip over the test tube in position 15 of the cassette Tighten the allen head set screw securely 7 8 5 Follow instructions for your Rifle type identified in a previous step Original Machined Rifle Loosen the allen head set screw on the Pipettor Plate Clamp lower left corner of the Pipettor mounting plate Loosen the two Phillips head screws holding the pipettor plate to the intermediate support Adjust the assembly left or right as needed to center the pipettor tip over a test tube in position 15 of the cassette Verify the pipettor plate did not rotate and is still parallel to the front frame then tighten the two Phillips screws and allen head set screw securely Newer Cast Rifle Loosen the two Phillips head screws holding the pipettor plate to the intermediate support Adjust the assembly left or righ
83. provides the user with local access and monitoring of the instrument operation The keypad and screen are mounted together on an easily removable mounting plate for servicing An audible alarm feature installed in the instrument and a flashing display is used for alerting the user in the event of instrument alarm conditions The keypad is composed of a set of numeric digit keys and several function keys for the user to communicate commands to the instrument The screen is a back lit Liquid Crystal Display LCD Five function buttons are located beside the LCD The screen provides the visual information during user intervention when selecting the menu options VITEK 2Z amp VITEK 2 XL System Service Manual 4 Rev 0100 Chapter Four System Components The keypad and screen allows the user functional support of the following Local instrument operation and system status Consumables loading Diagnostics and maintenance operations Available card slots Incubator temperature Error messages Multi language support 9 9 9 9 9 9 Figure 4 1 shows the keypad and screen along with the location of the keys LCD screen and buttons LCD Display Screen Function Buttons Previous Screen Key Message Key Undo Key Numeric Keys Arrow Keys Enter Key Figure 4 1 Keypad and Screen There are three ways the Status screen can be viewed When the instrument is turned on when the user interfac
84. sensor which 1s located behind the carousel not shown It 1s used to determine the carousel home position slot 0 The third is the incubator bottom sensor located at the bottom of the carousel not shown It is used for proper positioning when cards are loaded from the auto loader station into the carousel The temperature inside the incubator is controlled at an average of 35 5 1 C 95 9 F 18 F Figure 4 34 shows the carousel system and components in the instrument TOP OPTICAL POSITION amp SENSOR CAROUSEL QUADRANTS 2 of 4 Shown Figure 4 34 Carousel System and Components CAROUSEL The auto loader station loads the carousel with the test cards The carousel holds the test cards throughout the complete incubation cycle The cards are removed from the carousel once every fifteen minutes for optical measuring The carousel is divided into four sections called a quadrant Each carousel quadrant can be removed independently for easy cleaning 4 32 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Four System Components Incubator Temperature Control The incubator heater is monitored and controlled through the use of two remote precision thermistors monitored by an A D converter One thermistor is located below the heater and the other is located behind the carousel quadrants and the right hockey table plate not shown These inputs are compared to voltages produced by high pre
85. that is obtained during normal operation of the vacuum cycle must be between 0 89 0 04 PSIA This must be set calibrated using a calibrated traceable Absolute Pressure Gauge 8 2 1 Disconnect the smaller vacuum line coming from the vacuum chamber at the pressure transducer on the Vac Seal SPN board and connect a tee fitting as required to connect your Absolute Pressure Gauge Be sure to get the tubing connected to the same fitting it was originally attached Caution Be careful not to break or crack the circuit board when removing the tubing 8 2 2 Atthe Prompt type CAL VAC and hit Enter This starts the vacuum transducer calibration routine 8 2 3 Following the prompts on the screen adjust the vacuum level up and down as needed until the Absolute Pressure Gauge reads 0 89 0 04 PSIA Note The screen will display the current set point and transducer reading in A D counts The keys for adjusting the set point up or down U and D do not run the pump You must Test the set point T to run the pump and to see what vacuum level you obtain on your gauge Tip It takes approximately 3 to 4 A D counts for each 0 1 PSIA change in vacuum 8 2 4 Press Enter when done to save the adjustment 8 2 5 Atthe Prompt type VAC CYCLE and hit Enter This runs a standard vacuum cycle Verify the chamber runs through a complete cycle and the 0 89 0 04 PSIA specification is met If it 1s not re
86. the adjustment 7 8 Pipettor Diluter Mechanical Alignment The pipettor must be positioned so that it is centered over tube 15 of a cassette when the boat 1s fully against the left side rail Also the diluter shot tube must be positioned so that it is centered over tube 9 of a cassette when the pipettor is centered over tube 4 7 8 1 Place a boat and cassette with empty test tubes in positions 4 9 and 15 into the left front corner Make sure the test tubes are properly centered and vertical in their holder in the cassette The boat must be resting against the left side rail 7 8 2 Atthe Prompt type PIP POINT andhit Enter This will lower the pipettor without a straw 7 8 3 Look at the front aluminum frame also called the Rifle supporting the Pipettor Diluter Stacker etc to determine which type you have The Original Rifle is solid machined aluminum with a yellow coating The Newer Rifle is cast aluminum with some machined surfaces Follow the appropriate instructions below based on the Rifle type you have E 18 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Appendix E Alignment Procedures 7 8 4 Follow instructions for your Rifle type identified in a previous step Original Machined Rifle Loosen the two Allen head set screws which clamp the support post located behind the pipettor mounting plate and rifle just enough to allow for in and out adjustment without sag Rotate the drum to a vertical
87. the boat is pulled through the front and back transport the rotation of the encoder is monitored If there are any stalls on the transport it is detected by the sensor and the instrument will respond appropriately There is a reflective boat sensor that monitors the presence and verifies removal of the boats during the boat cleaning process It is mounted to the front left corner of the basepan VITEK 2 amp VITEK 2 XL System Service Manual 4 11 Rev 0100 Chapter Four System Components Card Preparation System The VITEK 2 card preparation system is made up of the following primary internal components Cassette Scan Station Dispenser Pipettor Station Vacuum Station Card Sealer Station 9 9 9 Cassette Scan Station While passing through the cassette scan station each test card 1s positioned in front of the bar code reader A card separator holds each card in place so the laser from the bar code reader can scan the bar code information of the test card Figure 4 11 shows the laser bar code scanner Figure 4 12 shows the card separator EN d 1 7ES X iu CA XE im a E E a M LASER BARCODE SCANNER CASSETTE SCAN STATION Figure 4 11 Laser Bar Code Scanner 4 12 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Four System Components CARD SEPARATOR Figure 4 12 Card Separator Card Separator Each cassette test card makes contact with the plunger of the card separa
88. the communication package COM port as follows Terminal VT100 Baud Rate 9600 Parity None Data Bits 8 Stop Bits 1 Flow Control none 9 9 9 9 3 From the communication window press the SPACE and BACKSPACE key each once The instrument prompt should appear The prompt will be displayed with the given instrument name Warning Pressing the ENTER key will execute the last command the instrument was given Accessing DML using remote communication Remote communication to the instrument can occur two different ways Communication can be established via modem or network This section will only define remote communication via modem 1 Ensure VITEK Z system modem was previously configured connected and turned on See Chapter Six Remote Diagnostics Setup 2 Open Hyper Terminal or an equivalent communications software package on the PC 3 Configure the communication package COM port as follows Terminal VT100 Baud Rate XXXX Setting should be appropriate for PC modem Parity None Data Bits 8 Stop Bits 1 9 9 4 Dial the VITEK ZP system modem phone number and wait for a connection A login prompt will appear if connected successfully 5 Atthe login prompt type dms and press ENTER A password prompt will appear Type dms and press ENTER 7 A dms prompt will appear At the dms prompt connect to the corresponding VITEK 2 diagnostic port This would be accomplished by typing either dm
89. the filling of the dispensing tube begins the dispensing chamber will be in a idle position When a susceptibility test 1s encountered the dispensing tube will move to a fully counterclockwise position and the optical sensor flag will be sensed by the optical sensor home position An electrical solenoid inside the dispenser assembly opens a valve allowing saline from its bag to start filling the dispensing chamber When the optical sensor located at the tip of the chamber detects the saline the solenoid closes the valve and stops the flow of saline With the chamber full and the saline flow stopped the dispensing tube rotates over the susceptibility tube With the dispensing tube positioned over the susceptibility tube an air pump is activated The air forces the saline from the chamber into the susceptibility tube at a controlled rate to prevent splashing This process will be repeated for each susceptibility tube within a cassette A filter 1s fitted 1n the air tubing from the air pump to prevent any particulate contamination VITEK 2Z amp VITEK 2 XL System Service Manual 3 9 Rev 0100 Chapter Three System Overview airs FILTER amp PEA OPTICAL SENSOR SALINE BAG ww DISPENSING TUBE LES DISPENSING CHAMBER an em i iem CU eme Dinh 4 0 tm a Figure 3 13 Dispensing Chamber Both the dispensing tube assembly and the saline bag are disposable The operator is required to replace the saline bag and
90. the instrument Replace SPN board control Note Air flow of fan above Vacuum Assembly should be blowing into instrument Air flow of fan next to Incubator Assembly should be blowing out of instrument Verify 12v amp 24v motor supply voltages on DC power supply board Verify positioning sensor integrity Replace affected SPN board control Replace affected motor Run com status and look for Communication Status Host Computer If Communication Status is disabled try running host com en 1 Verify RS 232 cable between instrument and computer is connected Run VT2SETUP from the Command Terminal of the Workstation Check tty configuration Stop and start instrument deamons Reboot Workstation Replace instrument RS 232 cable Verify power supply voltages on the DC Power Supply Board Replace BCB board See Bay Controller Board BCB Replacement VITEK 2 amp VITEK 2 XL System Service Manual 6 61 Rev 0100 Chapter Six Troubleshootin Table 6 4 General Instrument Troubleshooting Information con t MALFUNCTION Failures 15 Pipettor Alarms or Failures 6 62 Replace SPN board control GENERAL TROUBLESHOOTING ACTIONS Check the Sterile Saline Solution Bag is properly installed and full 1000ml Verify dispenser tube 1s functioning properly Replace dispenser tube if necessary Verify home positioning sensor is functioning Replace if necessary Verify there is nothing in the ro
91. the reader head be adjusted properly mechanically and lined up with the ejector blade and carousel before performing this alignment 10 2 1 Atthe Prompt type MN CARO andhit Enter 10 2 2 Next at the Prompt type ALIGN MOT and hit Enter 10 2 3 Following the prompts on the screen move the carousel left or right as needed so that the first slot of the upper left quad is positioned so that the reader head drive mechanism is centered Try to visually line up the top card guide rail of the reader head with the top of the carousel slot peak of the arch of the slot You can also visually line up the reader head belt with the bottom of the carousel slot It is very important that the ejector blade moves freely in and out of the back of the carousel Blade can be moved by hand O will move the carousel clockwise I counterclockwise Note Press the H key when done to cycle the carousel Verify your alignment and readjust if necessary Tip It is helpful to remove the carousel access cover rear access panel and open up the transmittance and fluorescence optics remove the stacker tray and hold up the stacker latch If desired also move the stacker push arm to the right 10 2 4 Press Enter when done to save the adjustment B 24 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Appendix E Alignment Procedures 10 3 Top Bias The top bias is properly aligned when a carousel slot is ce
92. the stacker assembly Remove the magazine assembly and the waste door and set them both aside Remove the magnet bracket and set it aside Tag and disconnect the motor wires attached to the Reader SPN Board Loosen and remove the three pan head screws securing the stacker card assembly Carefully remove the stacker card assembly by lifting it up and out to the right Warning The wide optical switch assembly in the stacker card assembly may be damaged during removal If there is resistance when removing the stacker card assembly loosen the pipettor diluter cover to allow clearance for the optical switch Remove the push rack from the push slide bracket Loosen and remove the four mounting screws attaching the motor to the push slide bracket Note the orientation of the motor to the push slide bracket Measure and note the distance of the tray drive gear mounted on the motor drive shaft 10 Loosen the set screws and remove the gear from the motor shaft 11 Discard the motor Figure 5 22 Stacker Motor VITEK 2Z amp VITEK 2 XL System Service Manual 5 37 Rev 0100 Chapter Five Component Installation Installation 1 Position the tray drive gear on the motor shaft to the distance measured during removal and tighten set screws securely 2 Mount the replacement motor onto the push slide bracket in the same orientation as when removed Reinstall the push rack 3 When tightening the motor mounting screws make sure the drive
93. to 34 5 C Cards will not be processed until this average temperature has been accomplished then the User Interface status will change to OK This average temperature can also be accessed through the User Interface by selecting Utilities Diagnostics Temperature ROUSEL CA CARAMAP CARAMAP indicates the number of cards in the carousel the position of each card the remaining number of readings to be processed on each card the number of readings alre ady taken on each card the status of each card card information and the card bar code See Figure 6 28 CARAMAP VTK2 A caramap Pos 6 34 Remaining Current Cycles Cycle Status Card Info Bar Code 66 11 Sequencing 16 6 N AGT NO09 xs DIOLSLgSS0000352LD6 50 15 Sequencing 12 I RDS oer 0121394300004917 0 Ops Completed DE Si AoIL CPOUD t 505911963000003595 Os C Completed 99 45 P AST P5UG 0591196300000554 Oe Ox Empty D 15 Terminated VO On dM AOISNDUS 2 O 7613 76300004153 Os 1 Sequencing LOE UM ID GNB e POTO WSS SOOO Zila d 0 Sequencing OA d P AST P515 0821304300002917 304 1 Sequencing LE d iP ID GPC LOUDOTLLIOG53000025909 Figure 6 28 CARAMAP Pos Indicates the slot position the cards are loaded into the carousel The slot position with an indicates the current read position such as position 24 above There are 60 available slots in each carousel 0 through 59 Remaining Cycles Indicates
94. to the instrument Bay Controller Board flash memory This command can be used for loading new firmware onto the instrument by entering FILE REQUEST followed by BCB Firmware mot The exact case for BCB Firmware mot must be entered Another way to update the firmware is through the User Interface main menu by typing 3476 and pressing ENTER XMIT The XMIT command can resend data stored in the instrument flash memory to the Work Station There are three options with this command XMIT 1 XMIT 2 and XMIT 3 XMIT 1 will resend all data from the instrument to the Work Station This can be used if a hard drive from the Work Station is replaced XMIT 3 will resend cassette data specified by a cassette name to the Work Station XMIT 2 is used for development purposes only 6 46 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Six Troubleshooting SPNVAR SHOW SPNVAR SHOW will list the SPN board alignments parameters and information for a specific node The alignment variables are set while performing the instrument alignment procedure The parameters are items such as motor speed and tolerances Information are items such as firmware versions and compile dates There are 10 options used with this command To list all of them type SPNVAR SHOW h and press ENTER Refer to Figure 6 42 for the 10 options of this command WARNING The flags af are used to download alignments from the BCB to the SPN boards Doing this will
95. transfer information from the Smart Carrier Station SCS to the instrument Central Processing Unit C ro empty susceptibility tube This system includes a saline dispensing system 1 000 ml bag of sterile saline and a fixed volume dispensing chamber Dispensing Tube A fixed volume chamber used to measure and dispense 2 5 mL of saline into a susceptibility tube Dispenser Tube Fluorescence Optics The optical detection system designed for use with fluorescence substrates with nominal excitations 365 nM and emissions 445 nM Diluter Dispenses 2 33 ml 2 63 ml of saline Diluent into a Growth Wells The pockets in the cards which are filled with the prepared sample and which have previously been filled with a test antibiotic or growth media GUI Graphical User Interface to incubate the cards during test The temperature is monitored and controlled through the use of two remote precision thermistors monitored by an microprocessor holding the card at an average temperature within IOTI Light Emitting Diode Memory location that does not rely on external power to LED Non Volatile maintain information Incubator The incubator contains a heater and a circulating fan used VITEK 2 amp VITEK 2 XL System Service Manual C 1 Rev 0100 Appendix C Glossary Optics Head The physical mount for the optical sensors and transport system to move the cards through the optics
96. transmittance calibration failures Run tx_test X from the instrument diagnostics menu to test the transmittance optics X the suspected optic 1 2 or 3 Replace corresponding transmittance optics based on information attained Check integrity of reader head roller plate and belt assembly Verify proper functioning of reader head motor amp pulley Verify reader head to carousel alignment by checking the home offset top bias and bottom bias Refer to Alignment Procedure for details See Appendix E VITEK 2 Alignment Procedure Verify proper functioning of cam assembly Refer to Alignment Procedure for details Check carousel quadrant for obstructions Check waste collection tray for proper alignment Verify proper functioning of power supply 24 VDC Replace SPN board for affected transport control VITEK 2 amp VITEK 2 XL System Service Manual 6 59 Rev 0100 Chapter Six Troubleshootin Table 6 4 General Instrument Troubleshooting Information con t MALFUNCTION GENERAL TROUBLESHOOTING ACTIONS 9 Carousel jamming 10 Incubator Temperature Failures amp Errors 6 60 Verify incubator access cover is properly seated Verify quadrant is properly seated into carousel hub Run caro init to check the home carousel sensor and proper motor operation Verify reader head to carousel alignment by checking the home offset top bias and bottom bias Refer to Alignment Procedure for details See
97. utes edad 6 28 INCUBATOR cecco Se aui ce oi Dae n Loo RE 6 33 CAR OU SE duse etu d edt oeiutes dert tuse dur uctubvsde tim datus edu mebubets 6 34 STACKER eea tesa et toast he ete eee eto 6 38 FES EEO a nennt ntes eRe cet eon uud det uet catu ed dtp 6 39 SAMPLE PREP NODE BOARDS pue E UN biu E MM qbus 6 41 MOTOR C T M 6 44 VITEK 2 amp VITEK 2 XL System Service Manual ili Rev 0100 MACROS carecer ari a a a 6 49 SXSTE VE eae a a A E 6 51 ALIGNMENT orrea a ne MEER 6 57 VITEK 2 Reader General Troubleshoot i reae ERN bud Mdmm MAE 6 58 Motor Number and Name LASUtTg riii ette eene aa en e pre dando 6 64 APPENDIX A DRCONTAMINA TION 5 5 25556255556 a e Sa Pasa a eaa asas e esa Pas neaausesuue ca bass A 1 Decontamination Procedure VITEK 2 Integrated Syste Meien A 1 APPENDIX B SCHEMATICS AND DIAGRAMS ssssssssssssssscsssccccccccssssees B 1 BOB BONG e e e B 3 Head Control BOOTS uie tet a E E deos o DEV eu did B 6 DC Power nupp y Board ereraa inuito can ry au nunt s B 9 Sample Prep Integrated Network Board eeeessseeeee B 10 sealer C onnecton BOSE eee Eu Dt EA B 23 User Interface Ub BOSE ee co pe tert ident veneto deat pae atentado dtu tede ie itai iioooias B 24 Dar Code DOSE ioc ner nan nnn arr Chora iver ee eT umm ee en ve ner iter hearer er arr ere hirer tie B 24 Fluorescence Optical Interrupt Board 0 0 0 0 ceccccccccccceceeseseeecceeeeesaeeeseeeeee
98. uw i 7 a CJ 9f E c pec Lb 2 ERR a em m ONE W Ci EZ a EA 6 D zT t l TP3 ca2 L3 GND au 3 F1 5A F2 1 5A Figure B 2 Bay Controller Board BCB VITEK 2 amp VITEK 2 XL System Service Manual B 3 Rev 0100 Appendix B Schematics and Diagrams Figure B 3a shows the VITEK 2 instrument system electronics and the connections to the BCB Figure B 3b shows the VITEK 2 XL instrument system electronics and the corrections to the BCB Vitek 2 System Electronics LCD Assy Diluter zo OPN NENNEN uma uU n 2 Wire Harness 2 Wire W8 Harness 40 Pin TP 34 Pin TP 4 Wire W13 Ribbon Cable Ribbon Cable Harness Read er Pi petter J10 S P N J10 S P N P6 P1 W6 10 Pin TP Ribbon Cable DB25 Conn Bay Controller 14 Pin TP Board BCB Carousel SCS I F 14 Pin TP Ribbon Cable DB9 Conn Left Trans 24 Pin TP Ribbon Cable T UPS I F 16 Pin Ribbon Cables E J6 J8 J17 J23 _ gt SPN Board Connectors I W11 DB9 Conn DC Power Supply Board Figure B 3a VITEK 2 System Electronics and BCB Connections B 4 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Appendix B Schematics and Diagrams Vitek 2XL System Electronics LCD Assy see HCB A diag DB9 Conn A FL Power Supply L 4 2 Wire 2 W Harness Harness 40 Pin TP 34 Pin TP 4 Wire Hibbon Cable Ribbon Cable Harness
99. 0 LOG 12 22 00 19 968 SPNLOG Motor home failure Right Transport of 16 steps LOG 12 22 02 29 248 Door closed with new cassette Signaling start SINGLE process LOG 12 22 02 34 648 SPNLOG Motor home failure Right Transport of 20 steps LOG 12 22 02 59 584 CASSETTE LOAD 002 EP Real Vac 1 Seal 1 Mode 0 Cards 6 0A0A0A0A0A0AO000 LOG 12 22 03 13 152 SEQ head A is starting autoloader sequence LOG 12 22 03 33 144 SEQ head A is Resuming Processing from autoloader sequence Figure 6 30 FLASH LOG TAIL VITEK 2 amp VITEK 2 XL System Service Manual 6 39 Rev 0100 Chapter Six Troubleshooting FLASH LOG BOOT FLASH LOG BOOT will list all boot times in flash memory of the Bay Controller Board and all logged messages since the last instrument boot See Figure 6 31 VTK2 A flash log boot LOG 00 00 00 01 022 EBOOT Time Thu Jul 08 10 55 08 1999 cde LOG 00 00 00 01 022 EBOOT Ti Thu Jur 1508444530 L999 8 NOE LOG 00 00 00 01 022 EBOOT Ti TAO ub 3092221904999 5 5 Net LOG 00 00 00 01 022 EBOOT Ti Fri Jul 16 13 42 47 1999 LOG 0050070050022 EBOOI Exe TiM Fri Jul 16 14 33 14 1999 x Logs 99 of 924 LOG 00 00 00 01 022 EBOOT Time Fri Jul 16 14 33 14 1999 EX LOG 00 00 00 01 042 NSB Firmware BCB 4 Version BOOT 04 03 Mar 30 1998 LOG 00 00 00 01 167 BOOT Touch Serial Number Verifies LOG 00 00 00 36 823 BOOT FLASH Log File Verified with 805 Logs and 20
100. 0 none 8 i Eu BC itu disable no 9600 none 8 1 pare VT2 i yZ disable no 19200 none 8 1 by EY Ed yi disable no 9600 none 8 1 pers VIK tty4 enable no 9600 none 8 T tuy VTE Gey enable no 9600 none 8 1 pene SS ttyo6 enable no 9600 none 8 1 tty SW EEY enable no 9600 none 8 1 Bo So Liye enable no 9600 none 8 a Figure 2 7 Device Configuration Window VITEK 2 amp VITEK 2 XL System Service Manual 2 9 Rev 0100 Chapter Two System Setu 4 Once the data diagnostic and SCS ports have been defined type q and press ENTER to return to VITEK 2 Setup Then type 3 and press ENTER for Subsystem Control A series of options will be displayed See Figure 2 8 Subsystem Control 1 start instrument daemons 2 stop instrument daemons 3 stop all background daemons 4 list daemons Q return to main menu Figure 2 8 Subsystem Control 5 Type 1 and press ENTER to start instrument daemons Then press ENTER to return to Subsystem Control 6 Next type q and press ENTER to return to VITEK 2 Setup 7 Physically connect the communication cable from the VITEK e2 instrument to the appropriate tty ports on the Work Station 8 Type 2 and press ENTER for Instrument Association See Figure 2 9 Instrument Association has four columns The first column header is labeled This label is the identification for the buttons on the VITEK 2 Work Station software The second column is labeled Instrument This is the corresponding serial
101. 00 Chapter Five Component Installation Removal 1 Open the top access doors of the instrument 2 Disconnect the drain tube from the Diluter Cover Unscrew the diluter cover D disconnect the dispensing tube and filter from the dispenser assembly and then move the diluter cover including the dispensing tube and saline bag to the side Tag and disconnect all wires and cables from the diluter SPN board that are going to another location other than the diluter dispenser assembly Tag and disconnect all plastic tubing associated with the dispenser assembly Supporting the dispenser assembly remove the two mountiing screws holding the dispenser assembly to the instrument frame Refer to Figure 5 44a and 5 44b for the location of screws Carefully maneuver the dispenser assembly with the pump attached out of the instrument If the pump makes it difficult to remove the dispenser remove the mounting screws for the pump and bring both assemblies out individually Carefully maneuver the dispenser assembly out of the instrument Set the dispenser assembly aside to return for repairs or exchange EE WIRING CABLE AIR FILTER MOUNTING SCREWS E E RELEASE LEVER DISPENSING TUBE Figure 5 44a Dispenser Assembly Location old design VITEK 2Z amp VITEK 2 XL System Service Manual 5 69 Rev 0100 Chapter Five Component Installation ru DISPENSING 7 TUBE MOUNTING SCREWS Figure 5 44b Dispenser Assembly Loca
102. 1 2 Left Transport JP3 JP9 1 2 Right Transport JP4 JP9 1 2 Diluter JP5 JP9 2 3 NODE i I Pipettor Vacuum Sealer JP7 JP9 1 2 Reader A JPS JP9 1 2 Carousel A J SPN BOARD P N 530704 2 INSTALLED JUMPERS BOARD FUNCTION EH lt BCB gt Left Transport Right Transport Diluter Mm BR G bd E NO Pipettor Be N 6 Vacuum Sealer 7 JP7 Reader A 8 JP8 Carousel A 4 52 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Four System Components Table 4 3 Sample Prep Node Board SPN for the VITEK 2 120 SPN BOARD P N 530704 2 Ww N Un amp oo NIA EN JP2 JP3 JP4 JP5 JP7 JP8 JP1 Left Transport Right Transport Diluter Pipettor Reader A Carousel A Reader B Carousel B Vacuum Sealer VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 4 UA W Chapter Four System Components Figure 4 53 through Figure 4 65 shows the various PC board block diagrams of the SPN boards and the major components sensed or controlled by each board Left Transport SPN Board Fan Control Thermistor Left Transport Motor B7 J19 Front Transport Motor B2 Blank J18 Blank J11 Left Transport SPN Board 530704 Front Transport Home Switch SW1 TO E Al Vacuum Sealer SPN Bd
103. 100 Appendix D Error Code Text ALARM MESSAGE MAJOR 156 Host Communication Errors 157 Host Communication Errors Processing Warnings 158 159 Hardware Errors 3 QN 161 Hardware Errors 162 Hardware Errors Hardware Errors Hardware Errors Hardware Errors Hardware Errors ON C5 CS ON ON Nn I W Hardware Errors 168 Hardware Errors EMEN ON O 170 Optical Error 171 Optical Error 172 173 Processing Errors 174 175 Processing Warnings Processing Warnings Optical Error 176 177 ON J 178 Optical Error Initialization Errors Hardware Errors Optical Error Processing Errors ALARM MESSAGE DESCRIPTION OF ERROR SOURCE OF MINOR ERROR Card data has been lost Data task has erase a data sector that contains untransmitted data in the FCT Card data has been lost Data task has erase a data sector that contains calibration limits Transport Failure Internal Data Failure Internal Data Failure Internal Data Failure Internal Data Failure Internal Data Failure Internal Data Failure Internal Data Failure Internal Data Failure Internal Data Failure Internal Data Failure Calibration calibration qc cards calibration qc cards is not available is full The fluorescence is approaching Fluorescence Calibratio
104. 11 dm12 dml3 or dm14 and press ENTER Refer to Table 6 1 Sn VITEK 2 amp VITEK 2 XL System Service Manual 6 3 Rev 0100 Chapter Six Troubleshootin Table 6 1 Remote Diagnostic Connection INSTRUMENT DONATION STIC COMMAND TO TYPE 1 tty3 dml1 2 tty5 dml2 3 tty7 dmi3 4 tty11 dml4 RR A 8 Press the SPACE and the BACKSPACE key each once to display the instrument diagnostic prompt Warning Pressing the ENTER key will execute the last command the instrument was given To disconnect from DML press the CTRL and keys simultaneously immediately followed by the letter c To disconnect from the Work Station at the dms prompt type exit and press ENTER Searching for DML Commands and Variables There are over five hundred commands and variables in the VITEK Z DML To simplify searching for a specific command there have been tools put into place They are MANUAL WORDS CMDS and VARS There is no case sensitivity to DML commands or variables so they can be typed in either upper or lower case Entering a question mark 7 after a command or variable will display a help text of that command MANUAL is the entire list of commands and variables in DML a
105. 14 Pin TP W9 P6 P1 Ribbon Cable J2 p2 W2 10 Pin TP Ribbon Cable DB25 Conn P5 Bay Controller Board BCB SCS I F 14 Pin TP Ribbon Cable DB9 Conn W1 24 Pin TP Ribbon Cable UPS I F J4 J6 J8 W11 DB9 Conn Figure B 3b VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 W13 see HCB B diag DB9 Conn FL Power Supply XMasssansasscansEnuuanrrruazucrtanuuucuanuauanralenuanzsauasansauasnuaruruumauuauaran 14 Pin TP Ribbon Cable 34 Pin TP Ribbon Cable 4 Wire Harness Diluter Carousel A 10 SPN Reader Carousel B Reader J17 J23 SPN Board Connectors DC Power Supply Board VITEK 2 XL System Electronics and BCB Connections B 5 Appendix B Schematics and Diagrams Head Control Board The Head Control Board HCB connected to the BCB provides the local control functions and data sharing for the laser bar code reader the button memory and the instrument optics control Figure B 4a shows the HCB A board Figure B 4b shows the HCB B board Figure B 4c shows an illustration of the HCB Head Control Board A FL Optics TX Emitter J2 W12 26 Pin TP 16 Pin TP Ribbon Cable W16 Ribbon Cable For 60 Only not 120 es w17 Dallas Touch 2 Wie Memory Harness Nu um nio nire me mr Ve EN Mem ep eiu cuum cen fm Tei tme VER Rue Head CTRL A Head Control 34 Pin TP Board Cable HCB A W15 24
106. 2 bioM rieux VITEK 2 amp VITEK 29 XL INTEGRATED SYSTEM SERVICE MANUAL 510726 2 REV 0100 bioM rieux Inc 595 Anglum Road Hazelwood Missouri 63042 2320 tel 314 731 8500 fax 314 731 8800 Updates are made periodically to this document Software revisions and other changes will be included in subsequent versions This instrument is protected by U S Patent D377455 other patents pending No part of this publication may be reproduced transmitted transcribed stored in a retrieval system or translated into any human or computer language in any form or by any means whatsoever without the previous express and written consent of bioM rieux Inc BIOMERIEUX BIOMERIEUX LOGO VITEK VITEK Z are registered trademarks belonging to the BIOMERIEUX Group All other trademarks or trade names are property of their respective holders VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 WARRANTIES Limited Warranty for New Products bioM rieux Inc warrants the Product delivered thereunder to the original purchaser for a period of one 1 year after the date of installation against defects in material and workmanship and defects arising from failure to conform to specifications applicable on the date of installation The liability of bioM rieux Inc is limited to repair or replacement of the Product at its own discretion and option bioM rieux Inc shall in no case be liable under th
107. 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Two System Setup Table 2 4 Remote Diagnostic Connection INSTRUMENT PHYSICAL DIAGNOSTIC COMMAND TO CONNECTION TYPE o 1 m s dmi k 2 m m k 3 m m tty3 dml1 tty5 dml2 tty7 dml3 tty11 dml4 A 8 Press the SPACE and the BACKSPACE key to display the instrument diagnostic prompt WARNING Pressing the ENTER key will execute the last command the instrument was given 9 To disconnect the diagnostics press the CTRL and keys simultaneously immediately followed by the letter C 10 To disconnect from the Work Station at the dms prompt type exit and press ENTER 11 Turn the external modem OFF Verify Proper Operation and Alignment of VITEK 2 l From the main menu of the VITEK 2P user interface screen select Utilities and then Diagnostics Verify the proper functioning of the Optics Card Transport and Vacuum by selecting the corresponding options Open a diagnostics window from the Work Station by doing the following From the Main Menu select System System Maintenance and Diagnostics Then select the corresponding tty communication port Click EXECUTE A diagnostic window should now be displayed Press the ESCAPE key twice to display the prompt WARNING Pressing the ENTER key will execute the last command the instrument was given Verify the system status from the diagnostic window prompt by typing sys_ status and press
108. 28200001968 A 10 67 0 0 O 103 S N AST GNO6 73 1031628200001977 A 11 67 0 0 O 103 S N AST GNO6 73 1031628200001343 A 12 67 0 0 O 103 S N AST GNO6 73 1031628200001327 A 13 67 0 0 O 1103 S N AST GNO6 73 1031628200000825 A 14 67 0 0 O 103 S N AST GNO6 73 1031628200000856 A 15 67 0 0 O 103 S N AST GNO6 73 1031628200001220 A Figure 6 7 BOAT_PLAN VITEK 2 amp VITEK 2 XL System Service Manual 6 9 Rev 0100 Chapter Six Troubleshootin BOAT STATUS RESET BOAT_STATUS_RESET zeros the BOAT_STATUS parameters If BOAT_STATUS_RESET is entered it will display WARNING BOAT Status Non Volitale Values will be changed and ask Do you wish to continue Y N If Y is entered Total Cycles Retries and Failures will be set to 0 See Figure 6 8 BOAT_STATUS_RESET BOAT_STATUS_RESET also zeros the total number of boats processed in COMP_STATUS VERS A gt BOAT STATUS RBESEI WARNING BOAT Status Non Volitale Values will be change Do you wish to continue Y N Y VTK2 A gt BOAT STATUS Current Spot SPOT 6 0 Total Cycles 0 Retries O0 Failures O0 status Empty Paddle Current Spot SPOT 5 0 Total Cycles 0 Retries 0 Failures O0 otatusi Empcy Paddle Current Spot SPOT 4 0 Total Cycles 0 Retries 0 Failures O0 olgluss dmmob5y Paddle Current Spot SPOT 1 0 Total Cycles 0 Retries O Failures O0 Status Empty Paddle 1 4 Figure 6 8 BOAT STATUS RESET S BOAT COUNT BOAT COUNT is a variable and can be used to introd
109. 30 Processing Tip Level Low Warnings and it is too low for the current cassette 131 Processing Insufficient carousel slots to Boat Management has verified the number of Warnings process this cassette available slots and has failed 132 Processing Errors 133 Processing Errors E information has errors as Get Cassette Info SCS says to dilute into a tube Slot with no card 134 Processing Errors Grouping Error at Slot are of different groups N or P 135 Processing Errors Inoculum source not available for Get Cassette Info No Inoculum source for the target S card Slot 136 Processing Error Pipettor Failure When the pipettor system has a pending error condition and a new cassette is loaded into the instrument requiring the use of the pipettor boat management will attempt to clear the pending error by sending a pipettor initialization command to the pipettor SPN board An error will be generated if this initialization fails are of different groups N or P 138 Processing Errors 2 information has errors as P Cassette Info Pipette source is type S Slot 139 Processing Errors Bar Code Reader failure at Slot Get Cassette Info has found duplicate Barcodes in the same cassette Call bioMerieux Exception Handle Buss Address error Call bioMerieux Main Heap is full and we are adding the reserve 140 Fatal Errors 41 Fatal Errors 142
110. 88 88888888 88888888 88888888 88888888 88888888 88888888 88888888 QC F 4 Jlis 28r Tes O F 88888888 88888888 88888888 88888888 88888888 88888888 88888888 88888888 Flr Pos Card 5 100 100 S O F 11111111 11111111 11111111 11111111 11111111 11111111 11111111 11111111 ENG 5 6 X100 0 Ses O F 322222222 22222222 22222222 22222222 22222222 22222222 22222222 22222222 ENG 6 E 9 140 Qs O E 483333333 333333339 33333333 333323333 33333333 33333333 33333333 3339323333 31 QC D 8 100 0 Ts O F 88888888 88888888 88888888 88888888 88888888 88888888 88888888 88888888 ENR 8 9 TOO Ws O O F 33333333 33333333 33333333 33333333 88888888 88888888 88888888 88888888 ENR 9 rO 3 Los Oe T4 N F 88888888 88888888 88888888 88888888 88888888 88888888 88888888 88888888 ID GNB Ii s 21 0 Ts Ps F 88888888 88888888 88888888 88888888 88888888 88888888 88888888 88888882 ID GPC 1 274 61 0 Ts F 88888888 88888888 88888888 88888888 88888888 88888888 88888888 88888888 ID YST 1358 Tae Ox T F 88888888 88888888 88888888 88888888 88888888 88888888 88888888 88888888 ID ANA 40 T3320 SS N T 11111111 11111111 11111111 11111111 11111111 11111111 11111111 11111110 AST GNO1 44 73 120 S3 N Tek 111 111 111110 AST N002 49 735235 Sa Ps Tux 11 11 1100000 AST P504 59 73329395 Ss pis T 00000000 00000000 00000000 AST P506 60 T3523b5 4 S4 Ps T3 1111 I La a0 9 AS TSP 507 61 138 235 94 Ps Toz 10 AST P508 76 73 120 Ss N T 110 A
111. 9 2 93 Reading 10 SOL 8 9 10 LZ LT L2 250 Config ratromt L0 amples 2 Lo Pitched 2 Hi Patched Channel AVG SPREAD HIGH LOW SD CV 1 9 990 80 3 Ww S2 Z0 0 981 2 VO 3 L2 9 Qu O03 3 ie 1 14 15 0 47 Dou d Ug 4 2 3 LI 8 0 94 POLO 6 9 14 4 16 12 IEAS e Te 6 TI Z 12 10 0 59 Oud gr J J iS D bG Ll Zio 105302 7 8 27 1 2 2 24 OC AT s lo ve Figure 6 26 READROW 111 SCREEN DUMP SCREEN DUMP is a variable and is used to set the output of READWAVE or READROW to a specific format They are SCREEN_DUMP 0 No Dump SCREEN DUMP 1 RAW and Calculations SCREEN DUMP 2 SORTED and Calculations SCREEN DUMP 3 Calculations Only SCREEN_DUMP 4 Averages via Echo Port SCREEN_DUMP 5 Averages via DML 6 32 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Six Troubleshootin VALFLUOR VALFLUOR performs fluorescence optical validation and calibrates if out of range WARNING This command should only be used when cards are not processing INCUBATOR INCU STAT INCU STAT displays the status of the incubator See Figure 6 27 INCU STAT NOTE This is real time information about the incubator The temperature accessed through the User Interface does not show this value but instead 1s a three minute average Vin A Ee INCU SA Cards 295 5 C C215 Actual 9 94 Heater 38 C 94 Staves lt 2 Heater Drive 24 Std Counts 220 Need O0 Pend 88 Maintain Bias 9 Pend Offset 40 Figure 6 27
112. AULTS 6 20 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Six Troubleshooting VACUUM VAC INIT VAC_INIT initializes the Vacuum If the cycle is completed without errors no message will be displayed Vac_init includes Checking ambient pressure using vacuum pressure transducer and verifying that it is within range Using the vacuum motor to position the vacuum chamber in its home position and then returning to its idle position The vacuum home position is determined when the vacuum flag is detected by the vacuum home sensor VAC DOWN VAC_DOWN lowers the vacuum chamber while using the vacuum encoder sensor to detect stalls Note The vacuum home sensor is not used If the cycle is completed without errors no message will be displayed VAC UP VAC UP uses the vacuum chamber motor to raise the vacuum chamber while using the vacuum encoder sensor to detect stalls Note the vacuum home sensor 1s used If the cycle is completed without errors no message will be displayed VAC CYCLE VAC CYCLE will lower the vacuum chamber onto a pre existing boat perform a vacuum process raise the vacuum chamber back home and then return to its idle position The vacuum home position is determined when the vacuum flag is detected by the vacuum home sensor A vacuum encoder sensor is used to detect any stalls while moving the vacuum chamber up or down If the cycle is completed without errors no message will
113. Blank Autoloader Motor J12 Blank Reader A SPN Board Front 530 04 pre i A4 60 Carousel SPN Board A A10 1 20 Loading Door 120 only Locking SPD SERERE NP MI Solenoid L3 DC Power Supply Bd 60 amp 120 J5 Optical Shuttle Home Switch SW16 Card Sensor 60 Front Slide Optical Shuttle Motor B20 Figure 4 57 Reader SPN Board for VITEK 2 amp VITEK Z XL Section A 4 58 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Four System Components Reader B SPN Board 120 Only Flourescence Optical Interrupt Stacker Tray Board 530722 Stacker Home Switch SW19 Stacker Cover Sensor 120 MT18 Stacker Present Motor Switch SW20 B22 J19 44 J1 J8 Autoloader Motor B19 J12 Blank Header B SPN Board 530704 TO Loading D Carousel SPN Board B A1 0 1 20 oro x Solenoid DC Power Supply Bd L3 J6 J5 Optical Shuttle Home Switch SW16 Optical Shuttle Motor B20 Card Sensor 60 Front Slide Sensor 120 MT9 Figure 4 58 Reader SPN Board for VITEK Z XL Section B VITEK 2 amp VITEK 2 XL System Service Manual 4 59 Rev 0100 Chapter Four System Components Carousel A SPN Board
114. CH VTK2 A touch search Family Code OxO0C DS1996 64Kbit Touch Memory Serial Number 0x0000000439B9 CRC OXED Family Code 0x01 DS1990A Touch Serial Number Serial Number O0x000001EFDDCD CRC a Ox Ze Figure 6 13 TOUCH SEARCH TOUCH INIT TOUCH INIT initializes the button memory getting it back to a known state This is done by positioning a cassette in front of the button memory reader and executing the TOUCH INIT command The sentence The touch is now initialized will be displayed when complete DILUTER DIL DOWN DIL DOWN rotates the diluter dispensing tube to the down position If the cycle is completed without errors no message will be displayed Dil down includes Rotating the diluter motor to a pre aligned number steps clockwise so the dispensing tube is in the down position DIL INIT The command DIL INIT initializes the Diluter If the cycle is completed without errors no message will be displayed VITEK 2 amp VITEK 2 XL System Service Manual 6 15 Rev 0100 Chapter Six Troubleshootin Initializing the diluter includes The diluter motor rotating the dispensing tube counterclockwise to its home position The home position is determined when the diluter home sensor detects the flag on the diluter block Returning the dispensing tube to its idle position Running diluter pump motor all the way out until detected by diluter pump home sensor and then returning to its idle s
115. EFAULTS VITEK 2 amp VITEK 2 XL System Service Manual 6 53 Rev 0100 Chapter Six Troubleshootin TIME TIME displays the BCB time since it was first turned on This actually begins when the BCB is tested at the manufacturer before it is placed in the instrument This is the time stamp that is sent to the Work Station so it can sort out new vs old data Because this command begins with a it is a variable and has a value assigned to it To determine its value it is necessary to enter PR before the command The output will be displayed in Year Days Hours Minutes Seconds Milliseconds TIME TIME is a command and displays the RTC time the current time and the sys time SYS STATUS SYS STATUS displays installed instrument components and any errors associated with those components Figure 6 48 is a example of SYS STATUS with two errors These errors codes are 202 and 204 It indicates that the Transmittance 2 and Fluorescence Optics have not been detected by the instrument firmware Refer to Appendix D for more details If there is an error code listed in the Error Codes column the instrument will display a status of Errors on the User Interface screen until the error has been corrected VTK2 A gt sys_status 6 54 Component Reader Stacker Autoloader Incubator HCB Head TX 1 Head TX 2 Head TX 3 Head FL Head Reader Stacker Autoloader Incubator HCB Head TX 1 Head TX 2 Head TX 3 Head FL Head
116. EK 2 amp VITEK 2 XL System Service Manual Rev 0100 ve an Appendix B Schematics and Diagrams The SPN boards receive power from the DC Power Supply Board mounted on the inside left back plate of the instrument via connectors and flat ribbon cables See Figure B 6 e T Lig SPN bigti pre PI usns Wheel Jac ae nd n Fe Mer Im Lee H x ET ee E O a XR pM m Wac ag R29 E L kn ia Lu EM ad Ll Figure B 6 Sample Prep Node SPN Board B 12 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Appendix B Schematics and Diagrams Figure B 7 through Figure B 14 shows the various PC board block diagrams of the SPN boards and the major components sensed or controlled by each board SPN Board Block Diagram Temperature Sensor Address Jumpers Uni polar Stepper Motor Driver SPN Network Interface Uni polar Stepper Motor Driver Solenoid Driver FET Motorola 68HC711E9 Microcontroller Thermistor Gain Stage Bi polar Stepper Motor Driver 12VDC Bi polar 24VDC Stepper Reset Motor Network Driver Figure B 7 SPN Board Block Diagram VITEK 2 amp VITEK 2 XL System Service Manual B 13 Rev 0100 Appendix B Schematics and Diagrams Left Transport SPN Board Fan Control Thermistor Left Transport Motor B7 Lef
117. ELOW CAPTIVE SCREWS MOUNTING Figure 5 46b Vacuum Chamber Assembly Column VITEK 2Z amp VITEK 2 XL System Service Manual 5 73 Rev 0100 Chapter Five Component Installation Installation 1 Carefully place the vacuum chamber assembly into the instrument 2 Tighten the two slotted screws on each vertical support to secure the vacuum chamber assembly in the instrument 3 Connect all wiring cables and vacuum tubing disconnected from the removal 4 Install the left side access cover on the instrument 5 Re install the Diluter Cover including the saline bag and then re connect the drain tube 6 Close the top access doors 7 Ensure the instrument is ready to be turned ON and verify the system operation 8 After turning the VITEK 2 instrument ON perform Alignments See Appendix E Alignment Procedure Filler Valve Assembly Replacement Refer to Figure 5 47 for the location of the filler valve assembly Removal NO me PLI 5 74 Open the top left cover of the instrument Tag and disconnect the wires for the corresponding valves where attached to the circuit boards Note the positioning of the various fittings and piping components Disconnect the two large vacuum tubes from the valve assembly Remove the two mounting screws and then remove the valve assembly Set the valve assembly aside to be returned for exchange or repair 1f required Z MOUNTING SCREWS PROPORTIONER VALVE 4 4 WAY VALVE
118. ENG 8 Susceptibility Card ENG 5 Identification Card ENG 8 Susceptibility Card ENG 5 Identification Card ENG 8 Empty test tube 2 oO A Test tube filled with water or saline Ol Empty test tube o Test tube filled with water or saline Empty test tube c e Test tube filled with water or saline Empty test tube N oO Test tube filled with water or saline 1 Identification Card ENG 8 Susceptibility Card ENG 5 Susceptibility Card ENG 5 Figure 2 12 VITEK Z amp VITEK 2 XL Section A Engineering Test Cards Arrangement A Empty test tube 1 Susceptibility Card ENG 5 Empty test tube 15 o o a g m o x g E g o o 2 16 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Two System Setu Figure 2 13 VITEK 2 XL Section B Engineering Test Card Arrangement Test tube filled with colored water Empty test tube Test tube filled with colored water Empty test tube Test tube filled with colored water Empty test tube Test tube filled with colored water Empty test tube Test tube filled with colored water Empty test tube Test tube filled with colored water Empty test tube Test tube filled with colored water Empty test tube V4 4 bey bt bed 4 y 4 4 Q o O seep coana TC AC s O oe AC s O smn eaen C JOLE jJe o JOME C JON s_
119. Hd HL M Aid QU Dg Qu LHM IHd LL Dd TETTE X18 6 Ld mo Romo NH8 IHd LL LHM Zl ld 2oozmm OL L quvog H3MOd d iia m22r5c P Ni rid L G 5 nos Ead N1d L Ld OAS I X18 1Sd Idd LHM 8 LSd m o D ES OVAOCL m YAWYOASNVYL 9L SLPLELZL TE OF 9L SLvLELZI TI OF GiIOHO L M1d 9L 1Sd Q3H 0L LSd FN Z 9 39 9 v S w id m o 1HM 2d gp c i 0 z im 1 E X18 b bd TAA Lid q3d ol ld wd 91d 8 b bd NHO f ld n8 91 1Sd zz al X18 Sd G34 2d m NOP Jno00L n8 9L 1Sd 6 X18 ved 8 TAA Lad n ma 0L 1Sd 9 S NHO 9 zd 1HM 0L 1Sd e e L SS3NHVH AlddNS H3MOd 9G INVHO9VIG L3NISVO AlddNS H3MOd aaaivug LHOddNS SISSVHO GND SISSVHO OL T3A QND 9 Id TIHA QNO H4 aaaivag 1H5IH gunionuis uvau QNO SISSVHO OL LHM d LHM d 1d L d 1d LLATH LHM Z vd X18 L vd T3A NHD c3 X18 Hd NH8H O L14 LHM 8 F14 ma V V14 Id ZHO09 0S OVAOrZ 00c OVAOZL 00L T3A NHO 23 aInpow 49 14 eSn4 Md ktd LHM Z ld NHH d X18 fid indu ov 113 31V1d dWnd QNO SISSVHO THA NHO GNOSVHO M18 cLIATH LHM cL Ld M18 61d y8 cL Ed X8 LL Ed agy OL d 1d 6 d 1d 8 d 73A Z d na 9 d NYO v d LHM d SS3NHVH H3MOd Od AN9 SISSVHO 23 e SS3NHVH H3MOd OV LHM h ld X18 Ob bd M18 Zl d M18 LL Ed Gay OL d 1d 6 Ed 1d 8 d 73A L d M1 9 d NYO t d LHM d o 6 8 L 9 S v e L LVLSOWYSHL IVLS
120. INCU_STAT Card Indicates a calculated card temperature referencing the Actual reading There is no thermistor for this value The incubator maintains card temperature at 35 5 C 1 Actual Indicates the real time temperature of the thermistor located inside the Incubator Heater Indicates the temperature reading from the thermistor located next to the Heater State Indicates the state of the incubator 1 is warming 2 is stable Anything other than or 2 signifies the heater is not functioning properly Heater Drive Indicates the percentage of output for the heater located inside the carousel incubator If Heater Drive 0 then the heater is currently OFF After the instrument is turned on the heater will usually be at 100 output and will continue until the card temperature reaches close to 34 5 C INIT HEATER INIT HEATER initializes the incubator heater It may be necessary to enter INIT HEATER when the heater drive stays at 0 VITEK 2 amp VITEK 2 XL System Service Manual 6 33 Rev 0100 Chapter Six Troubleshootin SAVE INCU TEMP A VE_INCU_TEMP indicates the three minute running average temperature of the incubator Because this command begins with a it is a variable and has a value assi gned to it To determine its value it is necessary to enter PR before the command The status on the User Interface will indicate Warming until the average incubator temperature has risen
121. ITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Two System Setup 1 Place the VITEK 2 integrated system in its permanent location Position the instrument to meet the minimum clearance of 50 mm 2 in on all sides for ventilation and 50 cm 20 in above the instrument to provide necessary access for cleaning and maintenance 2 Properly connect all cables except for the instrument communications cable which connects the Work Station to the VITEK 2 This will be done after configuring the tty serial ports Refer to Figure 2 2 through 2 4 for cabling diagram See Table 2 1 for cable connection locations 3 The Smart Carrier Station SCS can be placed in its working location connected only to a power outlet Turn on the SCS The Configuration screen should be displayed If not press F2 Press the right arrow once and the Smart Carrier Firmware Status will be displayed Record SCS Program Version Press F2 to exit Verify the button memory of all the cassettes by placing them on the SCS and confirming that Data Entry screen is displayed Verify the proper functioning of the bar code wand The SCS cable should be connected to ttyO and coiled up next to the Work Station When a SCS firmware update is performed the SCS will temporarily be connected to this cable ttyO and then will be returned to its proper location Table 2 1 VITEK 2 Cable Connections CONNECTIONS VITEK 2 CO
122. K Z XL Section A Engineering Test Card Arrangement VITEK 2Z amp VITEK 2 XL System Service Manual 2 15 Rev 0100 Chapter Two System Setu If the alignment is being verified for a VITEK 2 XL also setup engineering test cards in a cassette as shown in Figure 2 13 VITEK 2 XL Section B Engineering Test Card Arrangement e Insert the loaded cassette 1n the Load Unload Station and close door f Visually check the operation of the VITEK e2 as the cards are moved from one station to the next and note any problems or misalignments g Once the cards have loaded into the carousel verify carousel alignments and note any problems or misalignments h If the VITEK 2 XL alignment is being verified perform steps e g again using the second prepared cassette i Once cards have been successfully loaded into the carousel s and the alignments have been verified unload the cards as described below Watch the unloading process and verify the proper height and left right adjustment of the waste collection station Ifunloading a VITEK ZP type unload flush carousel and press ENTER Ifunloading a VITEK Z XL type cara a and press ENTER At the carousel A prompt type unload flush carousel and press ENTER Next type cara b and press ENTER At the carousel B prompt type unload flush carousel and press ENTER Test tube filled with colored water 1 Identification Card ENG 8 Susceptibility Card ENG 5 Identification Card
123. L System Service Manual Rev 0100 Appendix F Fluorescence Optics Calibration 3 3 Set the Fluorescence card reading position called FSTEPS using the following procedure Access the service menu on the User I F by typing 7378 on the root menu screen and pressing ENTER Choose the Load a Card menu item and select one card for one cycle as card type 4 Before you answer yes to load the card insert a black card into the reader head through the Stacker The angled corner of the card should be on top and inserted into the read head first Transfer tube port will be down and out See figure below Once the card is inserted you may answer yes to load the card This process takes approximately eight minutes Wait until the black card has finished processing and the instrument emits a series of tones before continuing Note If the black card ejects accidentally before completing you will not hear the tones In this case it will be necessary to reload the black card as instructed above so it can complete normally It may also be necessary to use the zeroslot command to clear a terminated card from the carousel status Insert Black Card as Shown Here with white card Corner Transfer Tube Port 3 4 Fill each test tube with one vial of 4MU solution and put the filled tubes in positions 1 2 and 3 in the Vitek 2 cassette be sure the cassette s memory has been erased Install the cards with transfer tubes in t
124. N perform Alignments See Appendix E Alignment Procedure Vacuum Chamber Assembly Replacement Refer to Figure 5 46a for the location of the vacuum chamber assembly Figure 5 46b shows a close up view of the column assembly and slotted screws from the area circled on Figure 5 46a Removal I 5 72 Open the top covers of the instrument Disconnect the drain tube from the Diluter Cover and then unscrew and move the Diluter Cover including the saline bag to the side Do not disconnect the bag Remove the left end panel of the instrument to gain access to the vacuum chamber assembly VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation 3 Tag and disconnect all wires and cables for the vacuum chamber assembly where attached to the left transport SPN board and DC Power Supply Board 4 Tag and disconnect all wires and cables from the Vacuum Sealer SPN board that are going to another location other than the diluter dispenser assembly 5 Tag and disconnect the vacuum tubing from the vacuum chamber to the vacuum pump 6 Loosen the two slotted screws on each vertical support of the vacuum chamber frame 7 Gently lift the vacuum chamber assembly from the instrument and set on a flat table top surface 8 Set the vacuum chamber assembly aside to be returned for exchange or repair if required FF NE m pr VACUUM CHAMBER Hm MOUNTING COLUMNS ms m THIS AREA SHOWN B
125. NAME for DML mn command VACUUM LEFT LPADDLE FRONT FPADDLE RIGHT RPADDLE BACK BPADDLE AUTOLOADER SHUTTLE STACKER CAM CAROUSEL EJECTOR 6 64 SEALER DESCRIPTION Vacuum up amp down Left Transport Movement Left Paddle Front Transport Movement Front Paddle Right Transport Movement Right Paddle Back Transport Movement Back Paddle l Drum Tip Rotor Pump Vertical Autoloader Optical Shuttle Stacker Cam Carousel Ejector Sealer up amp down CONNECTED TO NODE Filler Left Transport Left Transport Left Transport Left Transport Right Transport Right Transport Right Transport Right Transport Diluter Diluter Pipettor Pipettor Pipettor Pipettor Pipettor Reader Reader Reader Reader Carousel Carousel Filler VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Appendix A Glossar Appendix A Decontamination Decontamination Procedure VITEK 2 Integrated System Decontaminating the VITEK 2 instrument Ce NOTE All decontamination must be done with a 10 bleach solution using good laboratory practices 1 Remove and dispose of any remaining accessories kit disposables 2 Wipe down all exterior surfaces 3 Referring to the VITEK 2 User s Manual p n 510731 x perform
126. NNECTION LOCATION Power Cable Lower Left Side Panel standard universal IEC power connector UPS Interface Left Corner Panel 9 pin RS 232 Computer Interface Left Corner Panel 25 pin RS 232 TL VITEK 2 amp VITEK 2 XL System Service Manual 2 3 Rev 0100 Chapter Two System Setu D Oo UJ n Oo V IH3S Is Y3LNI Hd Z MALIA S LOWSY Waqo NI 3NOHd31l31 9O01VNV GSLYOIGS0 OL TVNH3IX3 N N C3 TIvuva H3lNIHd LANYSHL gt A p H3lN3O NOILVTISALSNOO SGYOO H3MOd Ov 3MIM OT cETSBT VAOOFT X SS098TI Sdn X SLO98T Figure 2 2 Cabling Diagram One VITEK Z Instrument VITEK Z amp VITEK 2 XL System Service Manual 2 4 Rev 0100 Chapter Two System Setu E aZ a x B D g w lt So SE ew Io Oo Or D AL ADEM Lu O i tc STATION POWER CQND1 TIONER 70Q0VA UPS 700V fier 700VA TO DEDICATED ANALOG TELEPHONE LINE N x zi z N x QHO0O9 Haoa 2 iN EEE ee LT gt Of 1961 OT EEIDBI we E 1B6132 19 HE R CORDS 3 AD Poy CONSTELLATION CENTER 4 Figure 2 3 Cabling Diagram Three VITEK Z Instruments VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 2 5 Chapter Two System Setu AL Mone TO DEDICATED ANALOG TELEPHONE LINE 2 6 x S8 c N S E o9 ag J D x NE ug 4 m Q H H im
127. OAD CARD UNLOAD CARD will change the status of the card in a specified location from a status of either Sequencing or Terminated to Completed With a status of Completed the card will be ejected when that position is aligned with the reader Example UNLOAD CARD 29 UNLOAD UNLOAD will change the status of ALL the cards in the Carousel to Completed With a status of Completed all the cards will be ejected when they are at the reader position ZEROSLOT ZEROSLOT will change the status of the card in a specified location from a status of either Sequencing Terminated or Completed to Empty Example ZEROSLOT 9 If a card still exists in the specified carousel position it will be necessary to use the CARO command to gain access to the card and then remove it by hand Another option is Cleaning the Carousel See VITEK 2 Users Manual ZEROSLOTS ZEROSLOTS will change the status of ALL the cards in the carousel from either Sequencing Terminated or Completed to Empty After typing the command it will first display WARNING About to Zero the Carousel A Map and ask Do you wish to continue Y N If Y is entered the status of all cards in the carousel will be changed to Empty If a card still exists in any position of the carousel it will be necessary to use the CARO command to gain access to the card and then remove it by hand Another option is Clea
128. OUSEL SEALER EJECTOR HOME Vacuum Vertical Motor Left Transport Pulley Motor Right Transport Pulley Motor Front Transport Pulley Motor Back Transport Pulley Motor Left Transport Paddle Pulley Motor Right Transport Paddle Pulley Motor Front Transport Paddle Pulley Motor Back Transport Paddle Pulley Motor Diluter Pivoting tilt Pulley Motor Diluter Pump Motor Pipettor Direct Drive Drum Motor Pipettor Tip Motor Pipettor Pivoting Rotor Pulley Motor Pipettor Pump Motor Pipettor Vertical Pulley Motor Autoloader Motor Fluorescence Shuttle Motor Card Stacker Motor Reader Cam Motor Carousel Motor Sealer Motor Card Ejector Motor HOME will home the current motor See the MN command IN IN will move the current motor the specified number of steps See the MN command Example VTK2 A gt IN 50 6 44 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Six Troubleshooting OUT OUT will move the current motor the specified number of steps See the MN command Example VTK2 A gt OUT 50 MOTOR OFF MOTOR_OFF will turns the current motor off See the MN command MOV MOV is specifically used to move the reader motor in a positive or negative direction and requires a specified number of steps To move a card completely through the reader the reader motor will make 1500 steps For example to move the reader motor clockwise toward the carousel type MOV 1500 To move the reader motor counterc
129. OWHYSHL Ajddns sam0g 3a LHM 8 Ld X18 Ltd LVLSOWYSHL LVLSOWYSHL Figure B 21 Power Supply Cabinet Diagram VITEK 2 amp VITEK 2 XL System Service Manual B 26 Rev 0100 Appendix B Schematics and Diagrams AC Power Supply Board PWR SUPPLY 1 PWR SUPPLY 2 TOROID PRIMARY TOROID SECONDARY js af 3f amp x z C m aja jz 34 3 C Jv dla la S gt ASSY NO 530718 3 2 a 2p SERIAL NO f Jej 28 i AC POWER DISTRIBUTION i Q PEM 1 GND A D B C HTR A VAC PMP HTR By S 2 J1 Figure B 22 AC Power Supply Board TX Optical System Cross Section Emitter LED Emitter Ceramic Substrate Emitter Aperature Y Sample Well Detector Aperature ya Detector Photodiode Detector Ceramic Substrate Emitter Output SIDE VIEW Sample Well Figure B 23 TX Optical System Cross Section VITEK 2Z amp VITEK 2 XL System Service Manual B 27 Rev 0100 Appendix B Schematics and Diagrams FL Optical System Cross Section 3mm Bore Xenon Flashlamp Elliptical Reflector coated plastic Detector Board Silicon Photodiodes 445nM Bandpass Filter 365nM Bandpass Filter Lens 5mm UV Cold Mirror UV Cold Mirror Beamsplitter Sample Well Cover Glass L Optical Shuttle 365nM Reflector Solid Reference Figure B 24 FL Optica
130. Pin TP Ribbon Cable TX Detector 10 Pin TP W14 Ribbon Cable 4 Wire Harness Pin TP i Ribbon Cable Bardcode Reader J4 HOB A DC PS JG Flashlamp A Board bain For 60 Only AMP 4 pin not 120 Flashlamp Figure B 4a Head Control Board A 60 B 6 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Appendix B Schematics and Diagrams Head Control Board B FL Optics TX Emitter W12 l optional W J2 26 Pin TP 16 Pin TP Ribbon Cable W16 Ribbon Cable w17 Dallas Touch 2 Wire Memory a Harness 3 Head Control W7 B d BCB 34 Pin TP oar TX Cable HCB Detector u B u wi 5 For 120 Only 24 Pin TP Ribbon Cable niei S W14 Hibbon Cable Head W2 Ribbon Cable Bardcode Motor Reader Mire J4 HcB B DC PS Flashlamp vs de e Board Figure B 4b Head Control Board B 120 VITEK 2 amp VITEK 2 XL System Service Manual B 7 Rev 0100 Appendix B Schematics and Diagrams B 8 C1 1 a hi xi EN E 3g a a Cu E I Tue pe a buc imr mur p pis iin LZS8XSBRS352 E31 D 11 CL ou Tt Lr ILA LEG TR AFT B2 ero yeu z n 3 L La TL y E gs V tC B j ji aly pi EM wr uM a LA ov J Wiz d L ue assy NO SZ0712 __ s s E F1 F2 F3 1A Figure B 4c HCB Board Illustration VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Appendix B Schematics and Diagrams DC Power Supply Board
131. Processing Power Fail System will park iil has signaled a POWER FAIL Warnings until power is restored 143 Processing The Uninterruptible Power Warnings Supply has a Low Battery continued D 6 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Appendix D Error Code Text ALARM MESSAGE DESCRIPTION OF ERROR SOURCE OF MESAGE MINOR ERROR MAJOR 145 Optical Error Fluorescence Calibration Failure Fluorescence Validation Failure SYS_TASK or USER LCD Check Log File for details 146 Initialization Error Vacuum System Failure The vacuum sealer SPN board was not auto detected during system boot This will only occur if DML vacuum_en 1 and the vacuum sealer SPN board was not auto detected 147 Initialization Error Card Sealer Failure The vacuum sealer SPN board was not auto detected during system boot This will only occur if DML sealer_en 1 and the vacuum sealer SPN board was not auto detected Pipettor Failure The pipettor SPN board was not auto detected during system boot This will only occur if DML pipetter_en 1 and the pipettor SPN board was not auto detected Dispenser Failure The diluter SPN board was not auto detected during system boot This will only occur if 148 Initialization Error 149 Initialization Error DML diluter_en 1 and the diluter SPN board was not auto detected 150 Processing Error Dispenser Failure During pipettor diluter processing if the diluter SPN
132. RM Add info regarding VK2PRM A 199 0073 02 03 99 B FREINER Alignment procedure add 120 info T add new bar code alignment add CEU minor updates and clarifications NEW I98 0003 01 02 97 J GRUBER Create new alignment procedure for Vitek 2 instrument E 32 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Appendix F Fluorescence Optics Calibration Appendix F Fluorescence Optics Calibration CE NOTE The following text of this appendix is for INFORMATION PURPOSES ONLY Always refer to the Official Release Document for the approved Alignment Procedures See Document Control for the approved drawings VITEK 2 amp VITEK 2 XL System Service Manual F 1 Rev 0100 APPLICATION NEXT USED LTR ASSY ON DRAWN CHECKED APPROVED APPROVED APPROVED APPROVED APPROVED APPROVED APPROVED F 2 bioM rieux Inc C SER MASTER COPY PCN wL99 0050 1 BF I 20799 D SEE MASTER COPY PCN 199 0398 1 oH Oy 8790 E SEE MASTER COPY PCN 199 0482 4 DAH LIIA2J99 Dy ao ALNE Brent D Freiner Ray Shelton Don Hellmann John Bryant Appendix F Fluorescence Optics Calibration REVISIONS DESCRIPTION APPROVED FILENAME 530601E DOC proprietary rights are included in the information disclosed herein Recipient by accepting this document agrees that neither this document nor the information disclosed herein nor any part thereof shall be repro
133. Rev 0100 Chapter Five Component Installation MOUNTING SCREW HOLES PEAK DETECTOR SHOWN REMOVED FROM UNIT Figure 5 38c Peak Detector Assembly Removed Installation 10 11 12 5 60 Carefully install the peak detector assembly into the reader optics frame while routing the peak detector ribbon cable Install the mounting screws attaching the peak detector assembly to the frame Connect the peak detector ribbon cable to the head controller board Also connect the peak detector ground cable to the card reader frame Install the reader ledge on the frame and tighten the three captive screws Ensuring the drive belt is in the proper position on the rollers position and tighten the motor so the belt tension is the same as noted earlier Open the optics to check the belt tension and rotate the motor shaft and pulley checking the force required Perform Steps and 2 of the Fluorescence Lamp Cassette Assembly Replacement Installation Procedure Perform Steps and 2 of the Fluorescence Auto Cal Assembly Replacement Installation Procedure Re install the Diluter Cover including the saline bag and then re connect the drain tube Close the top access doors Ensure the instrument is ready to be turned ON and verify the system operation If a new lamp was installed type SFL TOTAL FLASHES 2O at the diagnostics prompt After turning the VITEK 2 instrument ON perform Fluorescence Optics Calibration Procedure
134. Rev 4 FSTEPS Steps into well 12 Liquid calibrations 1 Solid calibrations 9 DAC offset calibrations 1 Software offset calibrations 1 Total Number of Lamp Flashes 2744180 Flash sector erase cycles 16 Calibrations Targets Ref Channel Data Channel Low DAC Data Channel Low SOFT Data Channel High SHUTTLE Data Channel High POT target cal val target cal val XXXXXX XXXXX val XXXXXX Cal val target cal xxxx 3500 60 175 10 2 5 10 50 100 3800 50 Target Shuttle Calibration Values shuttle finger print Channel 2 Channel3 Channel 4 Channel 5 Channel6 Channel 7 target target target target target target 2839 3117 3104 3139 3040 2742 Liquid Calibration Setting Ref Pot Channel 2 Channel 3 Channel 4 Channel5 Channel 6 Channel 7 Time Date pot dac pot off dac pot off dac pot off dac pot off dac pot off dac pot off 141 139 94 7 141 107 18 139 117 70 141 103 40 140 84 25 140 35 49 Tue Dec 22 07 24 53 1998 Current Settings Ref Pot Channel 2 Channel 3 Channel4 Channel5 Channel6 Channel 7 Time Date pot dac pot off dac pot off dac pot off dac pot off dac pot off dac pot off 145 139 129 9 141 146 21 140 148 71 141 145 45 141 120 28 139 74 54 Thu Jul 01 09 59 40 1999 Figure 6 22 FL STATUS Installed Yes indicates that the Fluorescence optical interrupt was detected on po
135. ST NO009 7 PSEALZ O S is N RM 110 AST N010 TO JA321205 Ss N Te 3 110 AST NO11 82 1 13 235 Ss pz Tis LILO AST P515 83 qT3 2353 S P3 Tox Ili e AST P5T6 Figure 6 50 WELLMAPS Figure 6 50 shows an example of the WELLMAPS and the details are explained below Card Type Indicates the numeric card type Cycle Indicates the maximum number of times that card will read before it ejects Pip Vol Indicates the volume in micro liters that the Pipettor will pipette Class Indicates I for identification S for susceptibility O for neither Group Indicates N for gram negative P for gram positive O for neither Flex Indicates T if this card was entered through the software flex panel and F if not 6 56 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Six Troubleshooting Well Map Definition Indicates which Optic will read the referenced well 0 well will not be read well read by Transmittance 1 2 well read by Transmittance 2 4 well read by Transmittance 3 Not Available 3 well read by both Transmittance amp 2 5 well read by both Transmittance 1 amp 3 Not Available 6 well read by both Transmittance 2 amp 3 Not Available 7 well read by both Transmittance 1 2 amp 3 Not Available 8 well will be read by the Fluorescence Optics F well will be read by all the Transmittance amp Fluorescence Optics Name Indicates the card name ALIGNMENT Descript
136. SealerssStat lO neare T a A 4 28 Reader Incubator Processing System s sssssssoeersssssssseeeresssssssseerrssssssseceressssssssee 4 30 P Wired Ber eme T o T 4 30 VITEK 2 amp VITEK 2 XL System Service Manual i Rev 0100 Carousel am Eee OPosasesemis nan are T eR das 4 3 Carousel TneuDafOT sire etis eer ipd E dale Sn ue sactadenten eecedbece 4 32 ISCader25 VStCIIIa donet adiecto dalisia a dett daha laid hath ee tola iai dedos 4 34 Maste Colecon tat lOS ire oett apod a tior e dtes eftt 4 30 oyster ECL OTIC S eror deem ane dane tance D MR EEDlIS DUM MEIN 4 4 BCB Bodbilssdbiasetsct ate rtasturtocdiid a din casas eue nia poeta ciantertaas semaines 4 44 Head Control BOSE eben Mele utu obe pU uu enun bond Moi nU ee 4 49 Sample Prep Node BOE ertet etre ta pde tarn en omui pet ede eund en eque pug E 4 5 DC Power Supply BOard ctt reino tuo beatae ag cuta aed aee ed cuu bes aree ag ecu Deinen 4 63 Power Supply Drawer ASS iii secs te tlet tas touctab tanec de eea Ru Ee DAT as eR AR d LEARN eU DA DNE 4 64 CHAPTER FIVE COMPONENT INSTALLATION eee e eee eee eee eee nnne 5 1 Laser Bar Code Scanner Cautions and Warnings ccccccccccccessseseeeeeeceeeeaaeeeseeeeess 5 2 ISepait IN OLS ia Sonshine bees han ah cee ie ea eg ee te eae a al 5 3 Moltase Test POYLSo rese cipe s usto stus Pa vas redeo tub waaay aste nd dr eo tad tod bo uoc tet as 5 4 Electrical Component and Circuit Board Replacements
137. Status Indicates the status of the carousel and reader There are 10 status Rev 0100 0 OK indicates a good condition and the carousel is functioning normal Paused indicates that the carousel has been halted by the user through the instrument firmware Terminated indicates that carousel movement has failed Q Carousel Jam indicates the reader is not running due to a carousel jam Load Jam indicates the reader is not running due to an autoloader failure UnLoad Jam indicates the reader is not running due to an unload into stacker jam Q Processing Jam indicates the reader is not running due to a reader or optical failure VITEK 2 amp VITEK 2 XL System Service Manual 6 37 Chapter Six Troubleshooting 0 Max Down Tim indicates the reader has been jammed for over 24 hours and all cards are terminated Q Fatal Jam indicates the firmware is lost and power to the instrument needs to be cycled Booting indicates the initialization of the instrument SEQ STATUS RESET SEQ STATUS RESET zeros the Total Cycles Total Retries and Total Failures in SEQ STATUS If SEQ STATUS RESET is entered WARNING SEQ A Status Non Volatile Values will be changed will be displayed and will ask Do you wish to continue Y N If Y is entered Total Cycles Retries and Total Failures will be set to 0 SEQ PAUSE SEQ PAUSE will stop the carousel processing Cards will not be read SEQ HESUME SEQ RESUME will restart the carousel proces
138. TEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Table of Contents CHAPTER ONE ORGANIZATION OF THE MANUAL eee eee eee eeene 1 1 T ttOOUC HOT us ooo iccdoro stem p itibag edd edite ee paso d dosis es peas neto tb ats eu diesdss Pub ta ord remus OEu dede 1 1 Organization of the Manual teet eee ta Fete eeu eaa ddl reda eaae anda Fuge 1 1 TY POs rapuic CODVODLBOBIS area eer ehideboe ai avt oleis des RD Lee Rd ei CAR ua ean ate es 1 4 CHAPTER TWOrS YS DEINE SE EUD enie a aae 2 1 Preparations For Unpacking the VITEK 2O Integrated System io eeepc ewes 2 UT Ae Ka Proe eae tats tatters boob utei ties eb settee is cai NU dede E e 2 Installatiot PrOCOQUte cete rises tot orent aT redes neveu PROS odes su dis 2 2 Communication Configuration and Association sssseeesssssssseeeresssssssseerrrsssssssees 2 7 Remote Draenoste S356 Lp oen ebd ei aer Rut ehu id dias ania bw de ON uut obe Rua EAR OSA USE 2 11 Verify Proper Operation and Alignment of VITEK 2 e 2 13 IPIS e MIC ANIONS M mr a E 2 18 Instrument Physical and Electrical Requirements eeeeeeeeeeese 2 19 CHAPTER THREE SYSTEM OVERVIEW ssssssscscscctccstestsadscecscasticascsdscssstcaccacsssdsdsseass 3 1 Unit Desen pio mires vation eee ee ee cee eee 3 1 SYSE OPEO Diria a aE a 3 2 User Interface Syste Mena o a a dee aw ee fupe eae 3 4 Load Unload S aON wise cinsaceassancsneseradressitandeen sah iaseacia
139. TY commands See Figure 6 45 VTK2 A mac Existing Macros CMD netsends cur node 30000 1 CMD1 netsends cur node 30000 1 NODE cur node CCB netsends 8 20000 121 1 2 CCJ netsends 8 20000 122 1 0 DIL CYCLE dil fill dil empty DIL SCAN n dil a 8 mot 9 loop 21 pr Pos a moveto a pr sv adc 2 out 25 cr wait 10 inc a pr air sv adc 2 motof DIL CHECK n dil cmd 65 INIT KILL KILL B CODE loopx 1 15 a i cmdl1 156 a bar SAVE ALIGNMENT spnvar show all adgn SHOW ALIGNMENT spnvar show all an RESTORE ALIGNMENT spnvar show all afn SEAL TEST test sealer FIX SPN PARAMS SPN PARAM DEFAULTS SPNVAR SHOW ALL pdfn DILBERT dil fill dil down wait 10 dil empty TX TEST b dm1l log en dml log en 1 a debug all TRN 7 unkill calwave a kill cr tx go dml log en b TX GO screen dump 5 pr Initial Read cr readwave a cr tx burn a 112 3400 50 60 O0 cr pr Final Read cr readwave a FL TEST fl test autodetect fl init cal ref 3500 50 cal offset 10 2 0 FL CAL eshuttle cal gain 3000 50 hshuttle cal softoffset F1 warm lamp 50 screen dump 3 eshuttle readrow 1 1 1 hshuttle F2 warm lamp 50 screen dump 3 hshuttle readrow 1 1 1 INT NOISE fl opt int 0 a fl sema hits warm lamp 100 b fl sema hits a pr Errors pr b cr Percent Used 60 Figure 6 45 MAC INIT The INIT macro is executed each time the instrument is powered on This macro is similar to the Aut
140. Using the center Philips head screw adjust the entire pipettor assembly in or out as needed to center the pipettor tip over the test tube in position 9 of the cassette Verify the diluter plate did not rotate or sag then tighten the allen head set screw securely 7 8 12 Loosen the Allen head set screw located behind the diluter mounting plate just enough to allow in and out movement without sag 7 8 13 Loosen the two Phillips head screws in the front holding the diluter plate to the intermediate support Now adjust the assembly left or right as needed to center the diluter shot tube over a test tube in position 9 of the cassette Verify the diluter plate did not rotate before tightening securely the two Phillips screws 7 8 14 Press the Space Bar to end the PIP POINT command and get the Prompt gt back 7 8 15 Atthe Prompt type PIP INIT DIL INIT and hit Enter This will reset both the pipettor and diluter to their normal states E 20 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Appendix E Alignment Procedures 8 Vacuum Filler 8 1 VITEK Rev 0100 Chamber down position The vacuum chamber O ring gasket should just touch a boat when properly aligned During operation the software will move the chamber down farther and compress the foam washers under the drive nuts a preset amount Note amp VITEK 2 It is important that the mechanical phasing of the drive screws be correct before at
141. Vacuum Dispenser Pipettor Dilution Mode Boats Cleaning Bar Code Reader C2 CD FS eO 1 r3 CD 5 wn O O r3 Carousel Cleaning E Audible Alarm Enable Optics Cleaning Audible Alarm Volume Visual Alarm Enable Keyclick Volume Screen Contrast Figure 4 4 User Interface Flow Diagram VITEK 2 amp VITEK 2 XL System Service Manual 4 5 Rev 0100 Chapter Four System Components Uninterruptable Power Source UPS The UPS is connected to a 9 pin communications port located on the left rear corner of the instrument via a RS232 cable See Figure 4 5 for the location of the port connection In the event of a power failure the UPS will signal the VITEK 2 instrument If the power failure lasts longer than 5 seconds the instrument will go into a power failure mode At this point no new cassettes can be loaded into the instrument If there are previously loaded cassettes in the transports it will continue to process and load the cards for up to 20 minutes or when the UPS sends a battery low All of the cards in the carousel will continue to be read until the UPS battery 1s exhausted If cards remain in the transport after 20 minutes or a battery low the transports will pause and the remaining cards should be considered terminated After power is restored the cassettes must be retrieved by using the move boat command UPS COMMUNICATION PORT S i E at j L T WORKSTATION ET a COMMUNICATION PORT
142. Vertical Motor Home Figure 6 36 SPN SENSORS for Node 4 Diluter SPN Home Home Home Home Figure 6 37 SPN SENSORS for Node 5 Pipettor VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Six Troubleshooting Jo Sealer Flag clear J15 Chamber Motor Home JLG Chamber Encoder clear Figure 6 38 SPN_SENSORS for Node 6 Vac Seal SPN Js Stacker Motor Home des Cam Motor Home WS Optical Shuttle Motor Home J4 Loading Door closed Jo Front Access Panel closed J14 Card Sensor clear URS Autoloader Motor Home Jl Stacker empty MES Stacker Tray present Figure 6 39 SPN SENSORS for Node 7 9 Reader A B TOB Incubator Cover closed 39 2 Carousel Motor x S Ejector Motor Home J14 Caro Top Index blocked JAG Caro Bottom Index blocked Figure 6 40 SPN SENSORS for Node 8 10 Carousel A B VITEK 2 amp VITEK 2 XL System Service Manual 6 43 Rev 0100 Chapter Six Troubleshootin MOTORS MN MN will address a specified motor It is necessary to specify the motor name after this command MN H will list all of the instrument motor names See Table 6 3 CE NOTE The reader motor is connected to the head controller board and not accessible through a node Instead the MOV amp DISABLE commands are used Table 6 3 Addressing Motors MN VACUUM LEFT RIGHT FRONT BACK LPADDLE RPADDLE FPADDLE BPADDLE TILT DPUMP DRUM TIP ROTOR PPUMP VERT AUTOLOADER SHUTTLE STACKER CAM CAR
143. Wh Sample Well Cover Glass P c Optical Shuttle 365nM Reflector Solid Reference Lens 5mm UV Cold Mirror UV Cold Mirror Beamsplitter 365nM Bandpass Filter Figure 3 26 Fluorescence Optics Cross Section 3 20 VITEK Z amp VITEK 2 XL System Service Manual Rev 0100 Chapter Three System Overview Transmittance Optics The transmittance optics use visible light to directly measure organism growth These optics are based on an initial light reading of a well before significant growth has begun Periodic light transmittance samplings of the same well measure organism growth by how much light is prevented from going through the well The optics uses light emitting diodes LEDs that produce light at 660 and 568 nM and silicon photodetectors to capture the transmitted light The system 1s self calibrating to 100 transmission through air Figure 3 27 shows an illustrated cross sectional view of the transmittance optics S NOTE The optics should be cleaned periodically Emitter Emitter Ceramic Substrate E og Emitter Aperature Sample Well TOP VIEW 2 Detector Aperature MEAM Detector Photodiode Em Detector Ceramic Substrate Emitter Output SIDE VIEW Sample Well Figure 3 27 Transmittance Optics Cross Section VITEK Z amp VITEK 2 XL System Service Manual 85 Rev 0100 Ch
144. X5 1 4 VITEK 2Z amp VITEK 2 XL System Service Manual Rev 0100 Chapter Two System Setu Chapter Two System Setup Preparations For Unpacking the VIT EK 2 Integrated System Inspect the shipping container for external damage If damage to the shipping container has occurred verify that the VITEK 2 integrated system has not been damaged If damage to the VITEK 2 integrated system has occurred file a claim with the shipper and notify bioM rieux Inc Check the packing list and verify that all required items are included in the shipment Verify there is suitable bench space for the VITEK 2 see Vitek 2 specifications Verify that the bench is capable of supporting the VITEK 2 Verify the bench is level to within 2 ter NOTE The packaging materials and shipping container should be retained for future transportation needs if necessary 4 WARNING The VITEK Z instrument weighs approximately 109 kg 240 lbs At least 2 people are required to lift or move the instrument A WARNING The VITEK Z XL instrument weighs approximately 145 kg 320 Ibs At least 2 people are required to lift or move the instrument WARNING When lifting the instrument it is essential that only the left and right hand hold pockets on the base pan are used Otherwise severe damage can occur See Figure 2 1 for hand hold location WARNING The fastening straps may have sharp edges Use extreme caution when handling the stra
145. a MEM MEM MEM MEM MEM MEM MN MEN MEN NN NNNM MN MM NNNM NNNM MM NNNM NENNEN NNNM MEM MN NEN MEM MEMINI o dm I O oO me o Appendix F Fluorescence Optics Calibration THiS INDEX GISTs IHE REVISION STAIUS OF THE SHEETS QE IHIS DRAWING VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Appendix F Fluorescence Optics Calibration 1 REFERENCE DOCUMENTS 1 1 510731 VITEKe2 User s Manual 1 2 530600 VITEKe2 Alignment Procedure 1 3 TSTP530120 VITEK 2 Fluorescence Optics Test Procedure 2 REQUIRED CONSUMABLE SUPPLIES 2 005080 1 QC F Calibration Kit 2 2 3 12 x 75mm Plastic Test Tubes This kit consists of three Vitek 2 cards covered with BOPP tape with a fluorescence calibration card bar code label applied and three vials of SuM 4MU solution PROTECT LIQUID FROM LIGHT WHEN NOT IN USE INSURE THAT THE LIQUID HAS REACHED ROOM TEMPERATURE BEFORE USING USE THE CALIBRATION KIT ONLY ONCE 30 Black Test Card Fixture 371233 3 INTRODUCTION PERFORM CALIBRATION PROCEDURE WITH ALL PANELS INSTALLED AND ALL DOORS CLOSED WAIT ONE HOUR FROM INSTRUMENT POWER UP PRIOR TO PERFORMING CALIBRATION 3 1 If the operational status of the instrument is unknown type the command inst defaults atthe DML prompt to reset all the system variables to their default state 3 2 Check the optical shuttle alignment using the procedure outlined in the Vitek 2 Alignment Procedure F 4 VITEK 2Z amp VITEK 2 X
146. able set by LCD BIAS INC and J gr NN LCD BIAS DEC LIM M 5 4 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation Electrical Component and Circuit Board Replacements This section of chapter five lists the recommended replacement and installation procedure steps and locations of the electrical and circuit board component parts when performing component and or circuit board removal or replacement Power Switch Replacement The VITEK 2 instrument power switch is located on the left side rear area of the cabinet base Power to the instrument is supplied from a power cord connected to a UPS The UPS is plugged via the lab facilities wall outlet Refer to Figure 5 1a for an illustration of the power switch front Figure 5 1b shows the access cover which needs to be removed before gaining access to the power switch for removal Removal 1 Turn the switch to the off position and unplug the power cord 2 Note the voltage on the power switch and with a flat blade screw drive open the fuse cover 3 Remove the fuse block and set aside Remove the rear access cover to expose the rear of the power switch 5 Squeeze the plastic retainers or tabs on each side of the p
147. acement parts of the incubator assembly consists of 2 Carousel Fans Carousel Heater Assembly Carousel Quadrant Removal and installation of the carousel motor and drive belt can be found in the Card Handing System section of this chapter Bottom Carousel Fan Replacement Refer to Figure 5 30 for the location of the bottom fan Removal 1 Open the rear instrument cover and the rear access cover for the incubator to expose the heater fan 2 Label and disconnect the fan cable from the SPN board Note the fan position 3 Remove the screws flat washers and lock washers attaching the bottom fan to the top incubator assembly FAN MOUNTING PLATE BOLTS EACH SIDE FAN MOUNTING SCREWS BOTTOM FAN Mar me e Figure 5 30 Bottom Carousel Fan Replacement VITEK 2 amp VITEK 2 XL System Service Manual 5 49 Rev 0100 Chapter Five Component Installation Installation 1 Place the fan into the incubator housing as noted from removal Air flow should be from outside the cabinet to inside the carousel 2 Install the lock washers flat washers and screws to attach the bottom fan to the incubator assembly 3 Connect the fan cable to the SPN board 4 Install the covers to the incubator carousel area and the instrument covers Ensure the instrument is ready to turn ON and verify fan is working Forthcoming Design Change Figure 5 31 shows an example of the upcoming molded incubator assembly Th
148. al Motor ccccccssssssssseccccceseeeesseseeccccesseeesseeeeeeceeenaas 5 27 Dieubator NIOLOE s ansia tx M nee es ar A 5 29 Reader Head MOLO perrie pen Nro ted ea uh uta an NE On ted tu Uh ban man sigoumieeaes 5 31 Gear MOILOr RSeplace ie sse duoi otc is RS e puer LE is npe eens a acaancet ati nee dep de 5 33 Auto Loader Motor Replacement ssec pra tenner ieee onan estet oes 5 33 Card Ejector Motor Replacement aine ed pon eas oto P re v EE ne e estt 5 34 Cam MOtotr Replacement ooo tor P obo voa eese oa p tec a eee pase eats 5 35 Stacker Motor Replacement win coctatesstavad r tuo oe metuat eoe omen doen iata 5 37 Direct Drive Deum MOLPOE sa curse te a be Rt ou usd sui tuteste qua epe obe uaa us 5 38 Instrument Positioning Sensors Switches 5 40 Optical Switch Assembly Sensors dusenccesudcisenr keit tes ai oo agotado tese ven ea cepe Di T Saee sali 5 40 Pipettor Hall Effect proximity Sensor ssssssseeeeeeenneeeeeenen nennen 5 42 Retlectiy e sensor Replacement enren ni utis et ote ieee 5 44 ii VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Sd CDODSS ITO een ae En meer ry See Pat en Ree ent oc etude oe ee Peer oer 5 46 Transport Assembly Component Replacement ccceecccsecccecceceeeeeeeeeeeeeeeeeaeeeeees 5 47 Transport Paddle Drive Bele occasion caste wnnopacdeneaddenyiienddatitestbeidaaidaaansesdesmanendaatnlesiains 5 48 Incubator Asse mOl y vicio opera dissident dome ti as ateacess riui pt Une
149. all parameters relating to the Vacuum SPN Board it is necessary to first enter N VAC to make it the current board and then enter SPNVAR SHOW P See Figure 6 44 WIRA2 AX gt m Vac VTK2 A gt spnvar show p NV data Stored at Thu dul 15 09 25 49 1999 posee Vacubealer 5 Debug Flags P 255 130 Sealer On Time 10th secs P 35 dl Sealer Off Time 10th secs P 1 5 Log Sealer Preheat Time secs P 7 133 Sealer Up Offset P 0 134 Sealer Down Offset P O Laa Vac Encoder Limit P 40 L36 Vac Speed P 70 1333 Vac Touch Speed P 25 T39 Vac Down Offset P TOO 140 Vac Read Mult P T JEAN Vac Read Offset P 130 142 Vac Hold Time 2 5 143 Vac Mode Point P 30 144 Vac Down Slope P 65 LAS Vac Down Increment P 10 146 Vac Up Slope P 65 147 Vac Up Increment P 4 148 Nac Prop Cad Offset IPI 15 Press any key to continue Figure 6 44 SPNVAR SHOW P Parameters for Vac Seal SPN SPNVAR SHOW ALL SPNVAR SHOW ALL will list all SPN board alignments parameters and information just like SPNVAR SHOW except no node needs to be addressed The same flags are used See SPNVAR SHOW 6 48 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Six Troubleshooting MACROS MAC MAC will list all macros contained in instrument memory A macro is a small program that allows multiple commands to be combined into one For example DIL CYCLE is a macro that will execute the DIL FILL and DIL EMP
150. all the belt and then secure the bracket Reconnect the wires to the carousel SPN board as tagged Reinstall the right hockey table plate Reinstall the two carousel quadrants Reinstall left rear panel and close the top panel door Ensure the instrument is ready to be turned ON and verify the system operation After turning ON verify alignments See Appendix E Alignment Procedure a cs PS Forthcoming Design Change Figure 5 17b shows an example of the upcoming molded incubator assembly The incubator motor replacement will be easily achieved through back access F INCUBATOR ASSEMBLY CAROUSEL ISPNBOARD ae 5 B 3 7 Figure 5 17b Molded Incubator Assembly 5 30 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation Reader Head Motor Refer to Figure 5 18 for an example of the reader head motor Removal 1 Open the top panel door and remove the side cover to expose the reader head assembly 2 Tag and disconnect the motor wires attached to the reader SPN board 3 Open the optics and press on the belt where the optics sit Make a mental note of the belt tension Also turn the motor shaft and pulley of the reader head motor and make a mental note of the force required to turn it by hand When re assembling the belt will need to be adjusted accordingly 4 Loosen the timing belt motor and push it upward adding slack to the belt 5 Loosen and remove the four mo
151. allation Solid State Relay Replacement There is more than one solid state relay installed in the instrument 2 60 unit 3 120 unit One for each Reader Incubator and one for the Vacuum Pump This procedure will be common to all the solid state relays installed in the instrument The access to the vacuum pump solid state relay is from the rear panel of the instrument Access to the incubator heater solid state relay is gained by first removing the rear panel of the instrument and then by removing the incubator chamber rear access cover Figure 5 5 shows a typical solid state relay Removal m Remove panels to access the solid state relay for replacement 2 Remove the relay shield by placing a flat tip screw driver between shield and relay then prying the shield off Disconnect and tag all wires going to the relay 4 Note the relay position and remove the screws and washer from each end of the relay 5 Remove the relay and discard UJ EU e UTD A A y Ec x X WF WIRING z Call 3 SOLID STATE RELAY RELAY SHIELD Figure 5 5 Solid State Relay Replacement 5 10 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation Installation 1 Place the relay into position on mounting plate as noted from removal 2 Install washers and screws to attach relay to mounting plate 3 Reconnect the tagged wires back to the proper points on the relay 4 Place relay shield over the relay
152. ally Cg NOTE Cards can be ejected on command through the workstation or through the instrument diagnostics screen WARNING Ejected cards cannot be reinserted into the VITEK Z instrument Ensure that all card processing has been completed before commanding a card to eject WARNING Do not reinsert cards in waste collection tray once they have been removed 4 40 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Four System Components System Electronics The internal electronic architecture of the VITEK 2 integrated system is a distributive control system comprised of two types of microprocessor based controller boards connected with a serial network Instrument electrical power is comprised of a power supply cabinet arrangement serving all internal power consumption requirements The VITEK 2 system electronics include the following primary internal components Bay Controller Board BCB Head Controller Board s Sample Prep integrated Network SPN Boards DC Power Supply Board Power Supply Cabinet 9 9 9 9 VITEK 2Z amp VITEK 2 XL System Service Manual 4 4 Rev 0100 Chapter Four System Components Figure 4 43 and Figure 4 44 shows a block diagram and location of the PC boards inside the VITEK 2 and VITEK Z XL instruments Vitek 2 PC Board Top Level 60 Unit Workstation Carousel A Bay Controller Board BCB SPN Board Head Control Board HCB
153. alyses by continually monitoring the growth of organisms inside the wells of the test cards Two different types of optics perform this function fluorescence optics and transmittance optics VITEK 2 amp VITEK 2 XL System Service Manual 3 19 Rev 0100 Chapter Three System Overview Fluorescence Optics The fluorescence optics detect the growth of organisms indirectly It detects a chemical byproduct of their growth rather than the organisms themselves This chemical called a fluorophore absorbs light at a wavelength of 365 nM and immediately re emits the light at a different wavelength 445 nM A xenon flash tube and optical filters are used to create the specific wavelength of light and a fluorescence detector captures light re emitted by the fluorophore The biochemical system in these wells is designed to produce this substance in direct proportion to the growth of the organisms The amount of re emitted light produced therefore provides an excellent growth indicator The fluorescence optics calibrate to a known external 4 MU bioM rieux prepared standard and periodically self check and adjust calibration against a internal phosophorescent reference Figure 3 26 shows an illustrated cross sectional view of the fluorescence optics 3mm Bore Xenon Flashlamp Elliptical Reflector coated plastic Detector Board Silicon Photodiodes 445nM Bandpass Filter 365nM Bandpass Filter T es es Se J A 7
154. and pressing ENTER will disable the sealer so it will not operate when cards are processing For proper instrument operation it is imperative that the sealer is enabled prior to exiting DML To accomplish this use the command SEALER EN 1 or INST DEFAULTS AUTOLOADER AL INIT AL INIT initializes the autoloader to its autoloader home sensor If the cycle is completed without errors no message will be displayed AL CYCLE AL CYCLE performs an autoloader cycle 6 24 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Six Troubleshooting TRANSMITTANCE TX STATUS TX STATUS displays the current condition of all the transmittance optics installed See Figure 6 18 TX STATUS VTK2 A tx status Led reads per step 3 Number of HI values pitched 0 Number of LO values pitched 0 Cool time between each read 10 Cool time between each calibration bit 100 First scan point Steps into well 2 steps Scans across the well 16 scans Calibration error range 25 counts Total data points readings per well 48 Channel DAC Values Wave Status Target Cal LED Delay 1 2 Ai 4 Bu 6 FN 8 TXA1 OK 3400 60 2135 2245 2089 2143 3019 2331 2207 2184 TXA2 OK 3400 60 O 2465 1644 3043 2672 0 2731 1822 Figure 6 18 TX_STATUS Status Indicates if the Transmittance Optics has a status of OK functioning or BAD not functioning LED Delay Ind
155. and bases along with wiring for board connection see Figure 5 24 for an example Table 5 5 lists the optical switch assembly sensor wiring configuration Table 5 5 Optical Sensor Pin and Wiring PIN SIGNAL WIRE COLOR 1 5VDC Detector White 2 Negative Emitter Black 3 Positive Emitter Red 4 Ground detector Green 5 Sense Out Detector Blue Removal 1 Open the door or remove the access cover of the instrument to access the optical sensor 2 Disconnect and tag all cables from the SPN board to where to optical sensor attaches Note the mounting position 3 Remove the screw and lock washers holding the sensor and remove the sensor from the instrument 5 40 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation OPTICAL SENSOR OPTICAK SENSOR Figure 5 24 Example Optical Switch Assembly Sensor Installation 1 Place the new optical switch assembly sensor into position and install the mounting screws 2 Reconnect the cables to the SPN board connectors that were previously removed 3 Install or close any access doors or covers previously removed 4 Ensure the instrument is ready to turn ON and verify sensor operates properly See Table 5 5 for wiring information 5 Verify alignments See Appendix E Alignment Procedure Optical Switch Assembly Sensors part number 530119 1 Transport Paddle Switch Assy Qty
156. apter Three System Overview The Transport System positions an identification sample tube beneath the Pipettor System The pump assembly rotates so that the pipette tip is over the ID suspension test tube The pipette tip is lowered into the suspension The displacement pump draws the preprogrammed amount of suspension from the tube The displacement pump assembly raises the pipette tip out of the tube The Transport System moves the cassette placing the adjacent susceptibility sample tube under the pipette tip The pipette tip 1s lowered into the test tube and the pump dispenses the suspension into the tube where it mixes with the saline previously dispensed by the Dispenser System The vacuum transducer will verify that the fluid transfer has been properly performed A volume of air is then slowly bubbled through the tip to mix the inoculum Finally the contaminated pipette tip is released by the pipettor pump assembly and left in the same sample tube for disposal The user loads up to 350 pipette tips into the drum Firmware will prompt the operator when the drum is approaching the empty level or the expiration date of 30 days Vacuum Station The Vacuum Station fills the wells of the card with an inoculum using vacuum displacement The Transport System places a cassette and boat under the vacuum chamber The vacuum chamber lowers onto the boat forming the lower half of the vacuum chamber Figure 3 17 shows the vacuum chamber The Vacu
157. apter Three System Overview Waste Collection Station s Once testing a card is complete the card will be removed automatically from the carousel by the card ejector 1t will advance through the reader system and then is deposited into a waste container Here the stacker push plate pushes the card out of the way so the next card to complete can be ejected into the collection tray These cards are collected at the Waste Collection Station for removal from the VITEK 2 and disposed of The VITEK 2 120 includes two Waste Collection Stations The system will send a message to the user interface panel when the station container approaches the full level The station container can then be removed from the instrument and emptied Each Waste Collection Station will collect and hold up to 60 cards for disposal Access to the Waste Collection Station is made by a door on the front of the VITEK 2 instrument Figure 3 28 shows the waste collection station waste collection tray and test cards STACKER PUSH PLATE Figure 3 28 Waste Collection Station 3 22 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Three System Overview Figure 3 29 shows a card being ejected into the waste collection tray You can eject cards by command or automatically by setting an option in the System Configuration window of the workstation WARNING Ejected cards cannot be reinserted into the VITEK 2 Make sure that all card process
158. ard 3 Remove the drum from the instrument Only empty the drum of all pipette tips 1f the drum needs to be replaced 4 Perform the Display Assembly Removal Procedure Steps 3 5 and set the display assembly aside 5 Supporting the pipettor assembly remove the mounting screws holding the pipettor assembly to the instrument frame Refer to Figure 5 45a and 5 45b for the location of the screws 6 Carefully maneuver the pipettor assembly off of the guide post and then out of the instrument 7 Setthe pipettor assembly aside to return for repairs or exchange MOUNTING SCREWS CABLE Figure 5 45a Pipettor Assembly Location old design VITEK 2Z amp VITEK 2 XL System Service Manual 5 71 Rev 0100 Chapter Five Component Installation i a ml i z m 3MOUNTING i SCREWS _ DRUM REMOVED GUIDE POST e Figure 5 45b Pipettor Assembly Location new design Installation 9 E Carefully install the pipettor assembly into the instrument and install the mounting screws to secure the assembly to the frame Connect the flat ribbon network cable to the SPN Board and clips as noted from the removal Perform the Display Assembly nstallation Procedure Steps 1 3 Re install the Diluter Cover including the saline bag and then re connect the drain tube Close the top access doors Ensure the instrument is ready to be turned ON and verify the system operation After turning the VITEK 2 instrument O
159. ariables are scrolled on the screen To find a specific command type CMDS pattern and press ENTER To find a specific variable type VARS pattern and press ENTER Entering a question mark 7 after a command or variable will display a short definition or help text of that command For example by typing TX STATUS and pressing ENTER a short description of the command TX STATUS will be displayed See Figure 6 4 Words Example Four VIK2 A gt tx status 7 IX STATUS Displays the Transmittance Status Figure 6 4 Words Example Four TRANSPORTS There are four transports in the VITEKe2 instrument that circulate 1 4 boats clockwise around the basepan There are several commands and variables used in DML to verify status and interact with the boat transport system They are BOAT STATUS BOAT PAUSE BOAT RESUME BOAT ADVANCE BOAT PLAN BOAT STATUS RESET SBOAT COUNT SBOAT SIM LOAD and TRANS 6 6 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Six Troubleshooting BOAT STATUS BOAT_STATUS indicates the position of each boat installed in the instrument the total number of cycles each boat has made around the instrument the total number of recovered jams on each boat the total number of unrecovered jams on each boat the status of each boat and if a paddle is currently engaged with a boat See Figure 6 5 BOAT_STATUS VTK2 A gt BOAT STATUS Current Spoti SPOT 6 0 Total Cycles 40 Retries 0 Failure
160. assette Status CM5 R01 03 A 0 Slot Status Array 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 9 Pip Accession ID Iso Card Type Organism Id Ancillary Test Modifier Pro Track dier Ies RE 1 0101398300002413 0 Ze eae ts 1 lt O 76128430001 0927 0 een 6 ae 2 1 010 b3 98300002415 0 qe 93 e 1 0761284300009728 0 Se Os cme 1 0101398300002369 0 Sx Mo ME Os 1 0761284300010144 0 Os 4 1 0101398300002368 0 Or NE An g 1 0761284300009727 37 Oe Ae zs D uw 1 0101398300000807 i 23 Oe oF e 5i 1 0761284300009726 37 Lys 0 72 Gs 1 0101398300002374 23 Top Gx 1 0761284300009725 18 Lae OS feos 1 0101398300002373 1 aes 4 308 1 0761284300009724 0 Te Ooz lis 3 0 Figure 6 12 TOUCH RD BOAT 6 14 VITEK 2 amp VITEK Z XL System Service Manual Rev 0100 Chapter Six Troubleshooting TOUCH SEARCH The TOUCH SEARCH command searches for all the touch devices 1n the instrument To perform this command type TOUCH SEARCH and press ENTER The output text will include Touch Serial Number This is the BCB serial number and should always be detected unless there is a short in the circuitry By positioning a cassette in front of the button memory reader and executing the same command the cassette button memory should also be detected When the cassette button memory is detected the text will include 64Kbit Touch Memory See Figure 6 13 TOUCH SEAR
161. at and cassette reach the card loading station the cards will be transferred from the cassette into slots by the autoloader in to a 60 position carousel Here they are incubated at a temperature of 35 5 1 C 95 9 F 1 8 F S NOTE The carousel is divided into four sections so that it can be easily removed for periodic cleaning VITEK 2 amp VITEK 2 XL System Service Manual 3 15 Rev 0100 Chapter Three System Overview Figure 3 21 shows the Autoloader AUTO LOADER d OPEN CAROUSEL SLOT a a m Figure 3 21 Carousel Loading Station As the carousel rotates each card moves into the reading position every fifteen minutes A card ejector pushes the card onto a drive belt where it is moved through the reader optic station After the reading cycle is complete the card returns to its slot in the carousel where it continues to be incubated until its next read cycle Figure 3 22 shows the Reader Optics Station drive belt Figure 3 23 shows the Reader Card Ejector 3 16 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Three System Overview DRIVE BELT Figure 3 22 Reader Optics Station Drive Belt Figure 3 23 Reader Card Ejector back cover removed VITEK 2Z amp VITEK 2 XL System Service Manual 3 17 Rev 0100 Chapter Three System Overview Incubator Heater Assembly The carousel contains a heater and two circulating fans used to incubate the test cards
162. ates the gain setting on the reference channel It has a value range from 1 to 512 It will typically increase over time as the lamp ages Channel 2 7 Each channel has a DAC offset typically 135 145 The POT gain value range is from 1 to 255 The software offset limit is less than 150 VITEK 2 amp VITEK 2 XL System Service Manual 6 29 Rev 0100 Chapter Six Troubleshootin FL HISTORY FL_HISTORY displays the fluorescence calibration history since the last liquid calibration See Figure 6 23 FL_History VTK2 A gt fl_history Liquid Calibration Setting Ref Pot Channel 2 Channel 3 Channel4 Channel5 Channel6 Channel 7 Time Date pot dac pot off dac pot off dac pot off dac pot off dac pot off dac pot off 141 139 94 7 141 107 18 139 117 70 141 103 40 140 84 25 140 35 49 Tue Dec 22 07 24 53 1998 Pot Gain Calibration History Ref Pot Channel2 Channel3 Channel 4 Channel5 Channel 6 Channel 7 Time Date pot dac pot off dac pot off dac pot off dac pot off dac pot off dac pot off 143 139 132 10 141 152 23 139 156 73 141 152 46 140 124 28 140 80 57 Thu Jul 01 11 40 15 1999 145 139 129 9 141 146 21 140 148 71 141 145 45 141 120 28 139 74 54 Wed May 19 07 03 07 1999 143 140 113 9 141 132 20 140 134 71 141 129 45 141 106 28 139 58 52 Sat Apr 24 12 07 13 1999 141 140 100 9 141 116 20 140 122 72 141 112 43 141
163. atics and Diagram Carousel A SPN Board Incubator Heater ncubato Incubator Yam uM Carousel Moon Incubator S Temperature y Cover Switch ensor RLY2 Bottom Sensor Top SW25 MT15 K2 MT16 J19 Blank Blank J8 J4 Nd Carousel A J12 Blank SPN Board 530 04 Blank J15 J9 Blank TO Reader A SPN Board 120 i A6 60 Upper Fan Right Transport SPN Bd 60 1 O A11 120 dis Pod DaS R S B28 DC Power Supply Bd 3 ERERCIEN 60 amp 120 _ os a Lower Fan Incubator B27 J6 J2 J16 J5 J14 J3 Ejector Carousel Ejector Carousel Carousel Carousel Motor Motor Home Home Index Top Index Bottom B25 B26 Switch Switch Sensor Sensor SW23 SW24 MT13 MT14 Figure B 13a Carousel A SPN Board B 20 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 S Appendix B Schematics and Diagrams Carousel B SPN Board 120 Only Incubator Heater Incubator Solid State inet Temperature Carousel Relay ncu ator S Temperature Cover Switch ensor RLY2 Sensor Top SW25 Bottom MT15 K2 MT16 J18 J11 J1 J19 Blank Blank J8 J4 one Carousel B SPN Board 530704 J12 Blank Blank J15 J9 Blank TO x Upper Fan Reader B SPN Board A12 120 J13 Heater oe C
164. ave a pump failure that must be repaired VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Appendix E Alignment Procedures T VITEK 2 Rev 0100 Pipettor The Rotor home Vertical home and Rotor down sub sections are all interdependent Be sure to check each of these when performing one of these alignments 7 1 7 2 7 3 Tip home The end of the tip should be flush with the tip opening in the snout housing Caution Do not step tip inward further than flush with the housing damage may occur 7 1 1 Atthe Prompt type ALIGN TIP HOME andhit Enter This starts the tip home alignment routine 7 1 2 Following the prompts on the screen adjust the tip position until it is flush with the snout housing Press the H key when done to verify the proper position during this alignment Readjust 1f necessary 7 1 3 Press Enter when done to save the adjustment The pipettor will now move to its normal default state located next to drum Drum check This verifies the drum can move and stop reliably at each of the three finger locations 7 2 1 Tilt the drum up to allow the fingers to be observed and empty drum of any straws if necessary 7 2 2 Atthe Prompt type DRUM CYCLE andhit Enter This cycles the drum through one of its three possible positions 7 2 3 Verify the drum moves freely and the finger adequately blocks the straw slot consistently in the bottom of the drum Repeat
165. backward in position Remove any boat and cassette that may be in front of the touch memory contacts before continuing 5 1 2 Position the contact mounting block s front edge so that it is 17 5mm 690 from and is square to the front face of the base pan center mount 5 1 3 Tighten the screw holding the touch memory contact block 5 2 Touch memory check 5 2 1 Manually place and position an empty boat in the front left corner of the instrument Next place a cassette with button memory installed into the boat 5 2 2 Move the boat to the right by hand verifying that the cassette depresses the touch memory contacts as it moves past Stop the cassette when it 1s centered with the touch memory contact block 5 2 3 Atthe Prompt type TOUCH SEARCH andhit Enter The instrument will try to read the touch memory in the cassette and report its findings Verify the phrase 64K BIT TOUCH MEMORY 1s included in the report displayed on the terminal If not verify the cassette is centered properly with the contact block and or the block is aligned properly 5 2 4 Remove the cassette from the boat and at the Prompt again type the command TOUCH SEARCH andhit Enter Verify the phrase 64K BIT TOUCH MEMORY is no longer included in the report displayed on the terminal VITEK 2Z amp VITEK 2 XL System Service Manual E 13 Rev 0100 Appendix E Alignment Procedures 6 Diluter The Tilt home position sub section mus
166. be displayed Refer to Chapter Four Vacuum Station for the Vacuum Chamber Pneumatic process VAC STAT Displays the status of the vacuum system This includes ambient PSI See Figure 6 14 VIKZ A gt vac stat PSI 13 9 A D Counts Ooarse 205 Pine 2 55 Prop setpoint 1 RPF 0 Figure 6 14 VAC_STAT VITEK 2 amp VITEK 2 XL System Service Manual 6 21 Rev 0100 Chapter Six Troubleshootin VAG DUMP VAC DUMP displays information from the last vacuum cycle See Figure 6 15 The numbers displayed are readings from the pressure transducer and are used in a calculation based on the setting given when performing CAL VAC Therefore all the readings are relative with the exception of the down and up slope The normal pump down rate is 40 to 60 psi second and the normal return rate 1s 40 to 60 psi second VIK A gt vac dump Starke peris LosT Hold ps7 Stabe dq Ends 9 End psas 1944 Time Down 27 Ups 25 Cycler 58 Prop valve bingo POE Lov Time 6 origianl method Down slope 0 48 Down slope 0 48 Up elopese 0 01 Figure 6 15 VAC DUMP VACUUM EN VACUUM EN enables disables the vacuum component This is a variable that is stored in non volatile memory To determine its value it is necessary to enter PR before the command If a 1 is displayed the vacuum is enabled Typing VACUUM_EN 0 and pressing ENTER will disable the vacuum so it will not operate when cards are processing For proper instrument operation it is
167. be still in the carousel Incubator Temperature SEQ 60 Incubator failed initialization Controller Failure Motor Sensor Failure SEQ 60 Ejector failed initialization Motor Sensor Failure SEQ 60 Cam failed initialization Motor Sensor Failure SEQ 60 Cam failed init cycle Motor Sensor Failure SEQ 60 Stacker failed initialization continued Unload Failure Incubator cover is off Unknown Card Type at Slot Communication Failure Reader Error Occurred Reader Error Occurred D 3 Appendix D Error Code Text E ALARM MESSAGE MINOR MAJOR 69 69 Initialization Errors Motor Sensor Failure SEQ 60 Autoloader failed initialization 70 70 Initialization Errors Motor Sensor Failure SEQ 60 Carousel failed initialization 71 71 Initialization Errors Motor Sensor Failure SEQ 60 Carousel failed Quad search 1 T2 72 _ Initialization Errors Motor Sensor Failure SEQ 60 Carousel failed Quad search 2 73 Initialization Errors Motor Sensor Failure SEQ 60 Carousel failed Quad search 3 74 74 Initialization Errors Motor Sensor Failure SEQ 60 Carousel failed Quad search 4 75 Initialization Errors Incubator Temperature SEQ 120 Incubator failed initialization Controller Failure ps 76 76 lInitialization Errors IMotor Sensor Failure ISEQ 120 Ejector failed initialization hoe T Initializatio
168. board location has a individual jumper configuration connection to determine the specific function or operation the board will perform The SPN board design and distributed control allow the boards to be placed close to the systems they are controlling By means of the jumper connection the board is specialized for the control of stepper motors optical sensors and general purpose I O The SPN board dedicated to the vacuum and sealing functions is the only unique SPN board in the instrument Figure 4 52 shows a typical SPN board mounted inside the instrument MOUNTED SPN BOARD Figure 4 52 Instrument Mounted SPN Board VITEK 2 amp VITEK 2 XL System Service Manual 4 5 Rev 0100 Chapter Four System Components The VITEK 2 60 contains 7 SPN boards and the VITEK 29 120 contains 9 SPN boards The SPN provides the following instrument interface and control functions Left amp Front Transport System Right amp Back Transport System Diluter System Pipettor System Filler System Card Seal System Reader System two are included in the VITEK 2 120 Carousel System two are included in the VITEK 2 120 9 9 9 9 9 9 Tables 4 2 and 4 3 shows the Sample Prep Node board SPN jumper configurations for the VITEK 2 60 and VITEK 2 120 to setup specific SPN board operation Table 4 2 Sample Prep Node Board SPN for the VITEK 20 60 SPN BOARD P N 530704 1 Ls Des LL BID DESCRIPTION JUMPERS POSITION BCB JP2 JP9
169. ce back light Figure 4 62 shows the DC Power Supply Board and Figure 4 63 shows a layout diagram Figure 4 62 DC Power Supply Board DC POWER SUPPLY sero 3 MMi ba CUL m epp T li i me ae T is jam gts Figure 4 63 DC Power Supply Board Layout VITEK 2 amp VITEK 2 XL System Service Manual 4 63 Rev 0100 Chapter Four System Components Power Supply Drawer Assy The VITEKe2 instrument power drawer houses and supplies the required AC and DC voltages for instrument operation The power supply drawer is located inside the base of the instrument behind the flipdown bottom access door See Figure 4 64 BOTTOM ACCESS DOOR POWER SUPPLY DRAWER a 4 4 TURN Figure 4 64 Power Supply Drawer Assembly The power supply drawer houses the AC voltage distribution for the vacuum pump and incubator heater s The DC voltages feed the DC power distribution board Figure 4 65 shows the wiring diagram for the instrument power supply drawer 4 64 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 System Components Chapter Four Djo co L2 N L1 THA NHO 13 LHM Z d 1d L d SS3NUVH AlddNS H3MOd OV I Sd MOVd LV14d HOIA 94 GLYLELZL LL OF 9L GLYLELZLHLL OL X18 b bd LHM d la agy
170. cision resistors This design enables the cards to be held at an average temperature of 35 5 1 C 95 9 F 18 F Air inside the incubator is circulated by a fan above the heater assembly across the heater to a second fan which pushes the heated air through a series of holes on a hockey table plate through the carousel card slots and back up to the fan above the heater The carousel motor rotates the carousel inside the incubator Figure 4 35 shows the incubator heater and components THERMISTOR i 3 NE T j 5 LI e J Figure 4 35 Incubator Heater and Components VITEK 2Z amp VITEK 2 XL System Service Manual 4 33 Rev 0100 Chapter Four System Components Reader System The reader system of the instrument performs the card positioning identification and susceptibility analyses by continually monitoring the growth of organisms inside the wells of the test cards After the card ejector pushes the card out of the carousel onto the reader belt and card guide the reader transports the card through the various optical systems and then returns it to the incubator Two different optical systems perform the analysis of organism growth within the test wells transmittance optical system and fluorescence optical system Figure 4 36 shows the location of the optics system and components of the instrument a READER EN E dw m FLUORESCENCE OPTICS SHOWN OPEN m Ea 568 TRANSMITTANCE
171. connected to the instrument via an RS232 cable C 2 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Appendix D Error Code Text Appendix D Error Code Text 4 ALARM MESSAGE MAJOR 2 Processing Errors 3 Processing Warnings Hardware Errors 5 Processing Errors 6 Processing Errors 7 Processing Errors 8 Initialization Errors 9 Initialization Errors 10 Processing Errors Initialization Error pu Initialization Error i Initialization Error ia Initialization Error 15 Hardware Error 16 Processing Error 17 Processing Error VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 ALARM MESSAGE MINOR DESCRIPTION OF ERROR SOURCE OF ERROR Currently available for use Card Transport System Failure Boat management and the transport system failed The instruments transport system is currently halted Cassette loading door is open When a boat is ready to advance from the cassette loading station the load door must be closed A warning will be generated if the boat is ready to advance and the load door is open for more that minute BCB is running fast or slow The vacuum sealer SPN board has failed to perform a vacuum cycle during cassette processing Internal Clock Vacuum System Failure Card Sealer Failure execute a sealer on command during cassette processing Load Failur
172. could find that card to unload SEQ Max retries on the Stacker while unloading a card SEQ Recovering from a Fluorescence Card jam failure SEQ Failure to unload a Fluorescence Card during a jam SEQ Failure to move a Fluorescence Card during a jam from carousel into the head FLR Cal Failure to calibrate the reference channel during liquid calibration ENV TASK Head B incubator state has a failure condition FLR Cal Failure to calibrate the offset during Load Failure Unload Failure Unload Failure Unload Failure General Failure Unload Failure Reader Error Occurred Fluorescence Calibration Failure Incubator Temperature Controller Failure Fluorescence Requires Liquid Calibration liquid calibration Fluorescence Process Failure we Could not find the first edge of the card while reading the Fluorescence Card SEQ Failure to unload card during Fluorescence jam SEQ We have tried to move the carousel but the incubator door is open Reader Error Occurred ISEQ Snaking Error Reader Error Occurred ISEQ Max recover attempts during a Cam jam Unload Failure SEQ Unload failure while attempting to recover from Cam jam SEQ Could not find matching wellmap to card before reading card SYS Over 100 ENQs sent with no ACK received process Card could be still in the carousel SEQ Could not find Transmittance card to process Card could
173. crews make sure the drive gear engages the rack enough to remove backlash but not tight enough to produce binding 4 Connect the motor wires to the Incubator SPN board as previously noted 5 Install or close any access doors or covers previously removed 6 Ensure the instrument is ready to turn ON 7 Verify the motor is operating properly and verify alignment See corresponding section See Table 5 4 for wiring information Cam Motor Replacement Refer to Figure 5 21 for the location of the cam motor Removal Open the top panel doors of the instrument Disconnect the drain tube from the Diluter Cover and then unscrew and move the Diluter Cover including the saline bag to the side 2 Carefully pry the Reader SPN board from the standoffs and push the board aside allowing access to the cam motor 3 While supporting the cam motor on the inside of the reader head loosen and remove the cam motor assembly s two mounting screws 4 Carefully lift the cam motor assembly from reader head 5 Loosen and remove the four mounting screws attaching the motor to the motor mount bracket Note the motor orientation to the bracket 6 Measure and note the distance of the tray drive gear mounted on the motor drive shaft 7 Loosen the set screws and remove the gear from the motor shaft 8 Discard the motor VITEK 2 amp VITEK 2 XL System Service Manual 5 35 Rev 0100 Chapter Five Component Installation Wwe SS
174. cs The Reader SPN board above the optics will need to be removed from the standoffs and pushed aside allowing access to the emitter side of the TX optics 4 While supporting each of the optics modules one at a time push the clamp lever on the top of each of the TX optics modules and the FL optics module Gently allow the optics to hinge down 5 Press on the belt where the optics sit and make a mental note of the belt tension Also turn the motor shaft and pulley of the reader head motor and make a mental note of the force required to turn it by hand When re assembling the belt will need to be adjusted accordingly 6 Unscrew the three captive screws from the reader ledge and remove the ledge from the reader frame 7 Note the placement of the timing belt on the reader head Loosen the timing belt motor and push it upward adding slack to the belt 8 Remove the belt partially by pulling it over the upper right corner of the roller plate assembly Then with the optics opened maneuver the belt around and down so it comes off the TX optics The belt will still be threaded around the fluorescence and the rest of the reader head 9 Close each of the optics modules until the clamp lever locks in place 10 Remove the two mounting screws attaching the TX optics module s you need to replace from the reader head assembly 11 Carefully slide the TX optics module s from the reader 12 Set the optics module s aside to return for repairs o
175. d 3 Reinstall the diluter motor assembly onto the diluter dispenser assembly 4 Install the drive belt on the pulleys Slide the motor to remove the slack in the drive belt Position and tighten the motor so the belt tension is the same as noted earlier Rotate the motor shaft and pulley checking the force required If the belt tension is too tight it will loose motor steps while performing a diluter cycle 5 Reconnect the wires to the diluter SPN board as tagged 6 Close large access door 7 Ensure the instrument is ready to be turned ON and verify the system operation 8 After turning ON verify alignments See Appendix E Alignment Procedure 5 24 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation Pipettor Vertical Pulley Motor Refer to Figure 5 14 for an example of the pipettor vertical pulley motor Removal 1 Open the large access door to expose the pipettor system assembly 2 Tag and disconnect the motor wires attached to the pipettor SPN board 3 Press on the middle of the timing belt and make a mental note of the tension Also turn the pulley and motor shaft and make a mental note of the force required to turn it by hand The belt will need to be adjusted accordingly after the replacement motor is installed 4 Loosen and remove the four mounting screws attaching the motor to the vertical motor mount Note the motor orientation to motor mount
176. d This number can be used in conjunction with FLASH LOG TAIL to find the logged lines in the same time frame Figure 6 32 shows a example of FLASH LOG GREP VTK2 A FLASH LOG GREP PIP 0252 LOG 00 00 00 01 112 FBOOT Time Mon Nov 30 10 27 06 1998 Rotterdam x 0353 LOG 02 02 23 22 117 PIP DIL responce error 0x94 Pipetter PT reading with fluid was too low 0356 LOG 02 02 23 23 190 PIP DIL Error terminating card 0761243300004396 0492 LOG 10 05 31 40 197 PIP DIL responce error 0x50 Diluter max timeout exceeded 0495 LOG 10 05 31 40 290 PIP DIL Error terminating card 0761243300004408 0496 LOG 10 05 32 10 512 PIP DIL responce error 0x50 Diluter max timeout exceeded 0499 LOG 10 05 32 10 605 PIP DIL Error terminating card 0761243300004505 Figure 6 32 FLASH LOG GREP 6 40 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Six Troubleshooting SAMPLE PREP NODE BOARDS NODE STATUS NODE_STATUS will display all SPN Board node numbers location status and version If the status of SPN Board is DISABLED then it has not been detected by the instrument Figure 6 33 shows a example of NODE_STATUS P Node Status Temp F Seq Num Seq Num Zero Errors CS Errors Version 2 Left Transport ENABLED 103 124 123 0 0 01 61 18 11 1997 3 Right Transport ENABLED 103 189 204 0 0 01 61 18 11 1997 4 Diluter ENABLED 103 88 87 0 0 01 61 18 11
177. d during removal of motor After applying threadlocking adhesive place set screws of motor pulley over flat spots of shaft and tighten set screws securely 2 Mount the drum motor assembly to the pipettor drum cam plate 3 Connect the motor wires to the pipettor SPN board 4 Reinstall the drum assembly 5 Close the pipettor drum lid and the front door 6 Ensure the instrument is ready to be turned ON and verify the system operation 7 After turning ON verify alignments See Appendix E Alignment Procedure VITEK 2 amp VITEK 2 XL System Service Manual 5 39 Rev 0100 Chapter Five Component Installation Instrument Positioning Sensors Switches The positioning sensor switch replacement and installation procedures are grouped together due to the consistency of their use in the instrument The specific location of the sensors switches will require the user to open or remove panels to access the area they serve Most sensors switches will be positioned in the closest proximity to the system they are to monitor The VITEK 2 instrument has the following types of sensors switches Optical Switch Assembly sensors Hall Effect proximity sensor Reflective sensors Snap Acting switch 9 9 9 Optical Switch Assembly Sensors All photoelectric optical sensors for the most part operate identical The only change would be in the physical construction of the specific sensing arrangement All have mounting screws
178. der head assembly 7 Loosen the two captive screws on the base of the reader frame 8 Gently lift the reader assembly from the instrument and set on a flat table top surface 9 Perform the TX Optics Replacement Removal Procedure Steps 4 11 and set the TX optics aside to install in new reader head assembly 10 Perform the FL Auto Cal Assembly Replacement Removal Procedure Steps 2 4 and set the auto cal assembly aside to install in new reader head assembly 11 Perform the FL Optics Peak Detector Assembly Replacement Removal Procedure Steps 9 10 and set the FL optics and peak detector aside to install in new reader head assembly 12 Using a chip extractor remove the SPN chip from the Reader SPN board and set the chip aside to install in the new reader head assembly NOTE Use anti static precautions 13 Set aside the reader assembly to be returned for exchange or repair if required 5 62 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation READER HEAD ASSEMBLY FRAME MOUNTING CAPTIVE SCREWS Figure 5 40 Reader Head Assembly Captive Screws Located Inside Reader Head Installation l Match the flat corner of the SPN chip pulled from the old reader head assembly with the flat spot on the Reader SPN board socket of the replacement reader head and snap it in place NOTE Use anti static precautions 2 Perform Steps 1 and 2 of the FL Optics Peak Detector Assembly Replacem
179. dirt onto either glass Clean only with lens paper if necessary 13 2 1 Open the Fluorescence Optical Shuttle to allow you to view its movement 13 2 2 Atthe Prompt type ALIGN SHUTTLE and hit Enter Note The red LED on the shuttle should turn on during this alignment 13 2 3 Following the prompts on the screen first move the shuttle in or out as needed to center the reflector glass dark glass with the interrupt LED 13 2 4 Press Enter when done to save this adjustment 13 2 5 Now following the prompts on the screen move the shuttle in or out as needed to center the solid reference standard glass mirrored glass with the interrupt LED 13 2 6 Press Enter when done to save this adjustment 13 2 7 Carefully close the Optical Shuttle using the latch to avoid possible damage to the optics VITEK 2 amp VITEK 2 XL System Service Manual E 29 Rev 0100 Appendix E Alignment Procedures 14 Stacker E 30 14 1 14 2 14 3 Stacker Selection If aligning a 60 then skip this sub section If aligning a 120 this sub section is required 14 1 1 Fora 120 atthe Prompt type CAROUSEL A and hit Enter This will redirect all stacker alignment commands to Stacker A You may complete the rest of this section to align Stacker A then return back to this point 14 1 2 For a 120 after Stacker A has been aligned type CAROUSEL B and hit Enter to redirect all stacker alignme
180. ds each card in the carousel once every fifteen minutes When the card is complete a duration determined by card type and dictated through the software the card travels through the reader system into the waste collection tray at the front of the instrument The stacker push plate fully extends placing the card between the card stop of the tray and a spring loaded stacker rack completing the card cycle Figure 4 37 shows the various components of the optical system of the reader DRIVE BELT READER TIMING ROLLER PLATE MOTOR BELT ASSEMBLY Figure 4 37 Reader System VITEK 2Z amp VITEK 2 XL System Service Manual 4 35 Rev 0100 Chapter Four System Components Transmittance TX Optical System Transmittance TX optics use visible light to directly measure organism growth These optics are based on an initial light reading of a well before significant growth has begun Periodic light transmittance samplings of the same well measure organism growth by how much light is prevented from going through the well The TX optical system is an eight channel configuration meaning it can read eight wells in a column rows 1 8 top to bottom for a total of 64 wells per card The emitter uses LEDs for the light source at present wavelengths of 660 nM TX1 and a 568 nM TX2 The detector captures the LED light using silicon photodiodes The emitter and detector housings are hinged for ease of servicing or access to the optics area Up to three TX
181. duced or transferred to other documents or used or disclosed to others for manufacturing or for any other purpose except as specifically authorized in writing by bioM rieux Inc SIZE DRAWING NO T J 990604 11 24 97 11 24 97 bioM rieux Inc 1 12 98 1712799 595 Anglum Road 1 20 98 1 20 98 Hazelwood MO 63042 2320 USA 1 21 98 1 21 98 TITLE 1 21 98 1214989 VITEK Z FLUORESCENCE OETICS 1 21 98 1400798 CALIBRATION PROCEDURE MEN i Ron Robinson 1 13 98 SCALES FURL NIA AN SHEET d f VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 INDEX OF ACTIVE SHEETS ERR ELLE ELE EEE ELLE EEE 1 H 5 43 x e I O urbes o gt X oe c I 5 5 H D MY Pr S s i M T D n n SS B EE ri Ei m E E i S i EE EE D B i nm MM e munis m Bana SS S SS a l a BE I O S HR m hal o o HI ee E EE EE al gt c E E aa D Z SS SS M A SM L M e AL i SS SS SS SS SS L L L SS a e a L e e l H H m Alas m uw G EF I E RR T RR RR RR RR RR E I UR RR RR SS eS RR UR RR RR RR RR RR RR RR RR RR RR RR RR RR RR RR e RR ERR RR RR RR RR eens Wee i e A x
182. dy to be turned ON and verify the system operation After turning the VITEK 2 instrument ON perform Alignments See Appendix E Alignment Procedure APP od ri WARNING Laser Bar Code Scanner is a laser light Do not stare into the beam 5 78 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation Cassette Button Contacts Replacement Refer to Figure 5 51a and 5 51b for the cassette button contacts location Removal 1 Open the front covers of the instrument 2 Tag the wiring for the cassette button contacts 3 Disconnect the wiring from the spade terminals 4 Remove mounting screw s holding the contacts 5 Set the cassette button contacts aside for repair or exchange MOUNTING SCREW B ipa BUTTON CONTACTS RE Figure 5 51a Cassette Button Contacts Replacement old design WIRING il a F z a J s m r 7 inl BUTTON MEMORY MOUNTING SCREW DEVICE READER 1 Each Contact Figure 5 51b Cassette Button Contacts Replacement new design VITEK 2 amp VITEK 2 XL System Service Manual 5 79 Rev 0100 Chapter Five Component Installation Installation 1 Mount cassette button contacts and tighten mounting screw s 2 Reconnect wiring to cassette button spade terminals 3 Turn the VITEK 2 instrument ON 4 If the cassette button contacts are the new design verify operation If the cassette button contacts are the old design p
183. e Raise paddle by hand if necessary to place boat in this position 3 3 2 Atthe Prompt type ALIGN BTRANS andhit Enter This starts the back transport alignment routine 3 3 3 Following the prompts on the screen position the boat as requested and adjust the back transport so the boat 1s just barely touching the right side rail Do not force the boat into the rail under pressure from the paddle 3 3 4 Press Enter when done to save the adjustment If the paddle does not look centered in the boat pocket after completion of this alignment then recheck alignment belt tension or transport itself for problem VITEK 2 amp VITEK 2 XL System Service Manual E 9 Rev 0100 Appendix E Alignment Procedures 3 4 Right Transport E 10 When the right transport is properly aligned the paddle will cause the boat to just touch the back rail The free play of the boat between the back rail and the paddle just is removed 3 4 1 3 4 2 3 4 3 3 4 4 Place an empty boat in the back right corner of the base pan Note Raise paddle by hand if necessary to place boat in this position Caution It is important that the boat be squared against the back rail both rear feet touching back rail when the alignment is completed Atthe Prompt type ALIGN RTRANS and hit Enter This starts the right transport alignment routine Following the prompts on the screen position the boat as requested and adjust the right
184. e Bay Controller Board jumper configuration for HDR8 Figure 6 49 gives an example of the JUMPER command The asterisks in the far right column indicates if a jumper is installed for that specific location To set the BCB fora VITEK 2 60 jumper 0X2000 must be removed To set the BCB for a VITEK 2 120 jumper 0X2000 must be installed VTK2 A JUMPER Jumpetrt Optromns usa OxOTQ0 Skrp INIT Macro during BOOT 00200 4 LCD Display rs installed 0x0400 Development System Overide Dx0800 LCD Display Type 5001 or 1013 0x1000 ZERO the NV RAM during BOOT Ox2000 Vitek II 60 or 120 0x4000 Skip FLASH CRC Check during BOOT Ox8000 Abort jump to FLASH Code Figure 6 49 JUMPER WELLMAPS WELLMAPS will lists all cards that the instrument knows how to process When the instrument leaves manufacturing it has a very limited knowledge of specific card wellmaps therefore the operator is instructed to enter new cards in the Work Station flex panel entry before trying to process them Once entered that card type will not need to be entered again unless the BCB and Work Station hard drives are replaced simultaneously VITEK 2 amp VITEK 2 XL System Service Manual 6 55 Rev 0100 Chapter Six Troubleshooting If the operator tries to process a card that 1s not listed in WELLMAPS it will return the cassette back to the load unload station An alarm message number 122 unknown card type will occur and the instrument will au
185. e Boat management has failed to load cards into the incubator Generic load failure message The pipettor has failed initialization during system boot The diluter has failed initialization during system boot Pipettor Failure Dispenser Failure The vacuum sealer SPN board has failed to Dispenser Failure Failed diluter check while filling and dispensing saline Other related error messages may occur The vacuum system has failed initialization during system boot The sealer system has failed initialization during system boot 1 of the 4 paddle transport systems has failed initialization during system boot Vacuum System Failure Card Sealer Failure Card Transport System Failure Card Transport System Failure 1 of the 4 paddle transport systems has failed initial position forecast during system boot The critical system clock used to time stamp all card reading data points was a negative number during power up When a cassette is loaded and it will require use of the diluter a check is performed to verify the Internal Clock Dispenser Failure presents of a shot tube If the shot tube is not detected this error message will be generated During pipettor diluter processing if the diluter SPN board fails the diluter fill command and no retries can be made the card will be terminated and an error message will be generated Dispenser Failure continued D 1 Appendix
186. e Transmittance group See Figure 6 2 Words Example Two Note The entire group name does not have to be entered DML Groups Keywords diagnostics HCB Network SPN Transmittance VTK2 A gt words trans Transmittance READWAVE OPT_INT_BURN TX_STATUS STX3 MASK SLED BIAS A2 SLED BIAS B2 STX1 MAX DAC STX ERROR SAX SO STX AIR SPR SCAN VTK2 A gt VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Boat DATA Flash Fluorescence Host Communication Motor Sequence Sound System Touch TX BURN TX DATA BURN CALWAVE VALWAVE SIX AD VAI STXZ MASK SLED DELAY SLED BIAS AS SLED BIAS Bo STX2_MIN_DAC STX_READS SIX COOL LIME TX SIEPS INTO WELHLL SREADS ACROSS WELL SLED BIAS A1 SLED BLIAS BRI STXT MEIN DAC STX2 MAX DAC ST HI STX CAL COOL TIME Figure 6 2 Words Example Two 6 5 Chapter Six Troubleshootin To search for commands and variables beginning with a specific text pattern type WORDS followed by a space a carrot and a pattern For example typing WORDS SEQ and press ENTER will list all the commands and variables beginning with SEQ See Figure 6 3 Words Example Three VTK2 A words seq osedquence SEQ RESUME SEQ PAUSE SEQ STATUS SRO STATUS RESEI oSEO STATE VIKS A Figure 6 3 Words Example Three CMDS and VARS are used the same way as WORDS If CMDS is typed the entire list of commands are scrolled on the screen If VARS is typed the entire list of v
187. e currently in the carousel Carousel Reader Error Occurred Cam Error Card is still under the cam General Failure ICam Error Max retries on cam Communication Failure Host Communications Only 40 of heap remains should be host error Communication Failure DATATASK Could not find any more data that had not been sent Data has been lost Flash Rollover Tip Level Low SYS_TASK Back ground checking thinks the straw level is low Diluent Level Low SYS_TASK Back ground checking thinks the diluent level is low Incubator Temperature is HIGH ENV_TASK The average incubator temperature is high ENV_TASK The average incubator temperature is low Fluorescence Calibration Failure IFLR Cal Optical Shuttle failed to home Fluorescence Calibration Failure FLR Cal The Offset Calibration Failed luorescence Calibration Failure FLR Cal Optical Shuttle failed to extend Fluorescence Calibration Failure FLR Cal Optical Shuttle failed to home after the finger print Incubator Temperature ENV TASK Head A incubator state has a Controller Failure failure condition Fluorescence Calibration Failure FLR Val Optical Shuttle failed to home before a validation luorescence Calibration Failure FLR Val Reference Channel failed calibration luorescence Calibration Failure FLR Val Offset Calibration failed Fluorescence Calibration Failure FLR Val Optical Shuttle failed to extend before high end validation luoresc
188. e instrument was cold the heater may time out before this 1s accomplished To verify use the incu stat command If the heater drive is 096 perform an init heater or a cold and monitor the temperature 7 Verify vacuum by connecting a tee fitting to a Absolute Pressure Gauge Carefully disconnect the small vacuum line coming from the pressure transducer on the Vac Seal SPN board and connect it to one end of the tee Connect the other end of the tee to the same fitting that the tubing was originally attached Square a boat against the back left transport rails From the diagnostics window type vac cycle and press ENTER This runs a standard vacuum cycle Verify the chamber runs through a complete cycle and the 0 89 0 04 PSIA specification is met If it is not perform the Vacuum Transducer Calibration procedure found in Appendix E Alignment Procedure 8 Process engineering test card and verify proper alignment and operation of instrumentation Refer to Appendix E a If not already displayed open the Work Station Diagnostics window b Verify change the cassette mode to cassette only From the User Interface main menu select Utilities Configuration Cassette Mode and Cassette Only c Verify change the dilution mode to automatic From the User Interface main menu select Utilities Configuration Dilution Mode and Automatic d Setup engineering test cards tubes and liquid in a cassette as shown in Figure 2 12 VITEK Z amp VITE
189. e is in a menu screen and is unattended for more than three minutes or by pressing the previous screen key of the user interface from the main menu 4 2 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Four System Components The Status field can display following conditions OK Subsystem in the instrument are working normally Warming Indicating the incubator has not reached its operating temperature Messages Indicating that there is an error message in the queue that needs to be viewed and resolved Pressing the message button on the user interface will display the first messages Pressing the down arrow will display any other message that may exist All messages must be viewed or the message status will remain Errors Indicating that the message has been viewed but has not been resolved This status can be cleared only by resolving the condition that generated the original message Cleaning Indicating that boats and or carousel quadrants have been removed for cleaning Figure 4 2 shows the VITEK 2 instrument Status screen 08 09 C3 Status Warmin MAX Available Slots 53 C Cassette Name ABC Dilution Mode Automatic E 0 o 1 4 1 2 3 4 ENECEENN o 0 O Q 4 Figure 4 2 VITEK 2 Instrument Status Screen If a Halted screen 1s displayed instead of the Status scree
190. e prompt you would see on your diagnostic terminal is referred to as Prompt gt throughout the procedure The actual prompt you see will vary by instrument Throughout this procedure commands which must be typed on the keyboard are found as bolded all caps in quotes Do not type the quotes when entering commands It is also not necessary to type in all caps Lower case commands work the same Example ALIGN DIL FLUID Keys on the keyboard which must be pressed will be found as bolded capitalized text in single quotes Example H key Enter key Other highlighted text will be bolded to bring attention to it Throughout the procedure as well as prompts and text from the diagnostic terminal the words out and in are used relating to alignment Out is used to indicate direction away from the home sensor for that particular motor In is used to indicate direction towards the home sensor for that particular motor General Recommendations During many motor alignments the H key is used to home the motor and return to the aligned position This can be quite useful in checking your alignment while you are doing it and 1s recommended in most cases Reference Documents 510731 Vitek 2 user s manual 530602 Jumper document VK2PRM Firmware adjustments VITEK 2 amp VITEK 2 XL System Service Manual E 5 Rev 0100 Appendix E Alignment Procedures 1 6 Required Tools Material e Data Diagnostic Reade
191. e top carousel fan replacement will be easily achieved through the top access and the bottom fan through access from the back FAN WIRING FAN MOUNTING SCREWS Each Side Figure 5 31 Molded Incubator Assembly 5 50 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation Carousel Heater Assembly Replacement Refer to Figure 5 32 for the location of the carousel heater assembly Removal Open the rear instrument cover and the incubator rear access cover to expose the heater assembly 2 Tag and disconnect the wiring cables to the incubator heater 3 Open the top right access cover to gain access to the carousel and remove the incubator access cover from the carousel 4 Remove each quadrant 4 from the carousel per the Carousel Quadrant Removal procedure Then turn the instrument OFF and disconnect the power 5 Remove the left and right hockey table plate and corresponding hardware from inside incubator 6 Locate and remove the screws flat washers and lock washers attaching the heater assembly to the carousel incubator housing 7 Remove the heater assembly and set aside for return repair or exchange INCUBATOR REAR VIEW COVER REMOVED 2 CAROUSEL HEATER ASSEMBLY Figure 5 32 Carousel Heater Assembly Replacement Installation 1 Place carousel heater assembly into position in the incubator Be sure fan is positioned so that air flow 1s blowing downward across the
192. eeeeaaas B 25 Workstation Connector Board sion pde bi et Ln tele Resin iuuenis B 25 Power supply Cabinet Did erat ccs eteeide oae nectare a ete ER TM Bab B 26 AC Power SUP DIV DOG si inn bte ibed v ubt eciam tedv eq buit dedisc uite cad B 27 TX Optical Systems Cross SecHODl aoi oer ELI ED eecha trie iude os eOp REAL OIN Dose Spe pede UE B 27 PL Opticals ystems Cross SCHON ecciesie gatis eer eisdem debe M Uno Dua iUc B 28 Vacuum Chamber Pipine Didra oee Dite dn ot xe ei ri dd E B 29 APPENDIXC GLOSSARY conesa Fosse gab oa o equa a Fa Re epa aeo o Rea a Casse ga oae equa a Fass epa b enace C 1 APPENDIX D ERROR CODE TEX FE ascssissscasssssaswssccsswsbsehsasessccsssaniedsasensasauwabseteaseasss D 1 APPENDIX E ALIGNMENT PROCEDURES eee eee eee ee eee eene ee eee ees ooaos E 1 APPENDIX F FLUORESCENCE OPTICS CALIBRATION F 1 APPENDIX G INSTALLATION CHECK LINT cccccssscsssssssssssssssssccssssees G 1 iv VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter One Organization of the Manual Chapter One Organization of the Manual Introduction This Service Manual contains information on the operation installation maintenance and repair of the VITEK ZPand the VITEK 2 XL integrated systems This information is intended to provide an understanding of how these instruments perform possible causes of malfunctions and how to isolate and correct performance p
193. ence Calibration Failure FLR Val Failed to calibrate to the finger print Fluorescence Calibration Failure FLR Val Optical Shuttle failed to home after finger print failed Incubator Temperature is LOW rji continued VITEK Z amp VITEK 2 XL System Service Manual Rev 0100 Appendix D Error Code Text 4 ALARM MESSAGE MAJOR 42 Optical Error 43 Optical Error 57 Processing Errors 58 Processing Errors 44 Processing Error nem pee pe pee pee a Optical Error Hardware Errors 5 Optical Error gt Optical Error fed pem Processing Warnings 59 Processing Errors 60 Processing Errors 61 Host Communication Errors 62 Processing Errors 63 Processing Errors 64 Initialization Errors 65 Initialization Errors 66 Initialization Errors 67 Initialization Errors 68 Initialization Errors cc VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 ALARM MESSAGE MINOR DESCRIPTION OF ERROR SOURCE OF ERROR Fluorescence Calibration Failure FLR Val Optical Shuttle failed to home after finger print Fluorescence Calibration Failure FLR Init Optical Shuttle failed initialization Fatal error when loading cards into the reader via the read head with DML clear fails and we can not find the card SEQ Unloading a card and
194. ent Installation Procedure 3 Perform Steps 1 and 2 of the FL Auto Cal Assembly Replacement nstallation Procedure 4 Perform Steps 1 7 of the TX Optics Replacement nstallation Procedure 5 Carefully place the reader head assembly into the instrument and mechanically align the reader head to the carousel and stacker 6 Tighten the two captives screws to secure the reader head assembly in the instrument 7 Perform Steps 1 3 of the Lamp Power Supply Replacement nstallation Procedure 8 Perform Steps and 2 of the FL Lamp Cassette Assembly Replacement Installation Procedure 9 Connect all wiring cables disconnected from the removal and install the Reader SPN board on the standoffs 10 Re install the Diluter Cover including the saline bag and then re connect the drain tube 11 Close the top access doors 12 Ensure the instrument is ready to be turned ON and verify the system operation 13 After turning the VITEK 2 instrument ON perform Alignments and Fluorescence Optics Calibration See Appendix E amp F VITEK 2Z amp VITEK 2 XL System Service Manual 5 63 Rev 0100 Chapter Five Component Installation Reader Head Assembly Drive Belt Replacement Drive belt replacement can be accomplished without removing the reader assembly from the instrument Refer to Figure 5 41 for the location of the reader head drive belt Removal l 2 While supporting each of the optics modules one at a time push the clamp
195. ents Diluter SPN Board Diluter Sensor J1 Diluter Pump Motor B23 oa a a a J4 ae J19 J18 J11 J8 J1 F J12 Blank Diluter Diluter pure Howie SPN Board Switch m 530704 J9 Blank L4 DC Pwr Supply Bd Tos x AS J13 ie Pipetter SPN Bad S amp D Z J2 J14 J16 J3 EM J6 Blank Blank Blank Blank Diluter Tilt Diluter Tilt Home Switch SW22 Motor B24 Figure 4 55 Diluter SPN Board 4 56 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Four System Components Pipettor SPN Board Pump Home Switch SW14 Vertical Motor B14 Blank Blank Blank Blank Blank Blank J19 J18 J11 J8 J4 J1 Vertical P pettor PN Boar d S E d J12 Pipettor SW10 Snout Board J9 Blank 530720 x TO A3 Diluter SPNBd Q m Sra DC mod ly B L2 Supply Bd Z J14 J16 J6 Blank Blank J3 J2 Tip Home Switch SW13 Figure 4 56 Pipettor SPN Board VITEK 2 amp VITEK 2 XL System Service Manual 4 57 Rev 0100 Chapter Four System Components Reader A SPN Board Flourescence Optical Interrupt Stacker Tray Board 530722 Stacker Home Switch SW19 Stacker Cover Sensor 120 MT18 Stacker Motor B22 Present Switch SW20 J1 J4 J1
196. eplaced E Tag and disconnect the cables attached to the SPN board Note the mounting position of the board With a flat tip screwdriver gently pry the board from the standoffs holding the SPN board into place 4 Note the jumper configuration and remove the SPN board EXAMPLE SPN BOARD REMOVAL FROM STANDOFF SCREW DRIVER SASS LAS LN LT p P p SPN BOARD i STANDOFF Figure 5 9 SPN Boards Replacement VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation Installation 1 Configure the jumper for the system the replacement SPN board 1s to control Refer to the old board or Table 5 2 for the correct jumper configuration 2 Place SPN board into the proper position noted from the removal of the old board and gently push board onto the standoffs 3 Connect the cables to the SPN board as tagged from the removal of the old board 4 Install the SPN chip from the old board or replace with a current version SPN chip 5 Install the access covers removed for replacement 6 Ensure the instrument is ready to turn ON and verify proper operation Refer to Table 5 1 for any voltage readings and test point information 7 From the diagnostic terminal confirm the following are displayed during the instrument initialization NOTE If the instrument has completed initialization before the screen could be reviewed use FLASH_LOG_BOOT command BOOT Boat Management System is OK
197. eplacement Installation 1 Place HCB board into the proper position noted from the removal of the old board and gently push the board on the standoffs 2 Connect the cables to the HCB board as tagged from the removal of the old board 3 Move the Diluter Cover including the saline bag back into place and secure Reconnect the drain tube 4 Close the access panels 5 Ensure the instrument is ready to turn ON and verify proper operation Refer to Table 5 1 for any voltage readings and test point information 5 14 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation Sample Prep Node SPN Board Replacement This procedure is common to all the SPN boards located inside the instrument All SPN boards are interchangeable except the Vacuum Sealer Board Each SPN board will be mounted as close to the module as possible The instrument is designed for easy access either by removing panels or access through hinged doors This allows for easy serviceability and replacement of SPN boards SPN Board Jumper Configuration Each SPN board is designed to perform the operational process of the system it 1s assigned To accomplish the configuration of the particular system the SPN board is to control the jumper configuration must be set to allow the SPN board to function to that system Table 5 2 and Table 5 3 below lists the SPN board jumper location for the VITEK 2 60 and the VITEK 2 120 The node
198. eq Task Dark current on FLR B Optical Controller Failure Seq Task Dark current on TX1 B Optical Controller Failure Seq Task Dark current on TX3 B Optical Controller Failure Seq Task Dark current on TX2 B Fluorescence Calibration Failure Warm Lamp has detected a Noisy Flash Lamp The fluorescence is approaching calibration limits Transmittance Calibration Failure Transmittance Calibration Failure Optical Controller Failure Reader Error Occurred Card Transport System Failure Load Failure SeqTask Reference channel or internal 2 volt was out of range Tx BurnIn Calibration Failure Tx BurnIn Optical Interrupt Failure Optical Interrupt not functional before reading card read the wrong card Unload all cards After a cassette has passed through the diluter and pipettor processing section the front transport performs a check home If the step loss is greater then 50 steps all the cards in that cassette will be terminated After cards have been loaded into the incubator the back transport performs a check home If the step loss is greater than 50 steps the reader will be signaled to unload all the cards that were loaded from the cassette continued VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Appendix D Error Code Text MESSAGE MAJOR 233 Processing Error 234 235 Processing Warnings Processing Warnings 237 Processing Warn
199. er locks in place and reconnect the ribbon cable Install the motor and mount bracket assembly with the mounting screws Do not tighten the screws Place the drive belt over the drive motor pulley Slide the motor and mount to remove the slack in the drive belt Position and tighten the motor so the belt tension is the same as noted earlier Open the optics to check the belt tension and rotate the motor shaft and pulley checking the force required Perform the Fluorescence Auto Cal Assembly Replacement nstallation Procedure Steps 1 and 2 Reader Head Roller Plate Assembly Replacement The roller plate replacement can be accomplished without removing the reader assembly from the instrument Bad bearings would create the need for replacing the roller plate assembly Refer to Figure 5 41 for location of the roller plate Removal 1 Tag and disconnect the accessible ribbon cable plugged into the TX optics 2 While supporting each of the optics modules one at a time push the clamp lever on the top of each of the TX optics modules and the FL optics module Gently allow the optics to hinge down 3 Press on the belt where the optics sit and make a mental note of the belt tension Also turn the motor shaft and pulley of the reader head motor and make a mental note of the force required to turn it by hand When re assembling the belt will need to be adjusted accordingly 4 Close each of the optics modules until the clamp levers lock
200. erform Alignments See Appendix E Alignment Procedure Sealer Hot Wire Assembly Replacement WARNING The Sealer Station contains a wire that is heated during the sealing operation The proper precautions should be taken Refer to Figures 5 52 and 5 53 for the Sealer Hot Wire Replacement Removals 1 Open the top covers of the instrument Disconnect the drain tube from the Diluter Cover and then unscrew and move the Diluter Cover including the saline bag to the side 2 Note the position of the Sealer Hot Wire mounting and remove the mounting screws 3 Disconnect the wiring from the Sealer Hot Wire Assembly and remove the assembly from the instrument r NICHROME HEATED WIRE TRANSFER TUBE F CARD 1 SEALER STATION Figure 5 52 Sealer Hot Wire Assembly 5 80 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation MOUNTING SCRE Figure 5 53 Sealer Hot Wire Mounting Screws Installation 1 Place the Sealer Hot Wire Assembly into the instrument 2 Install the mounting screws to the Sealer Hot Wire Assembly Align to the noted position from removal and tighten the mounting screws Connect the wiring as noted from the removal 4 Ensure the instrument is ready to be turned ON and check the instrument operation 5 Perform the alignment procedure for the Sealer Hot Wire Assembly See Appendix E Alignment Procedure 6 Re install the Diluter C
201. es to their production default values When the INST DEFAULTS command is executed WARNING Setting ALL Instrument VARIABLES to there default setting Do you wish to continue Y N will be displayed Pressing Y will default the instrument settings ter NOTE If any variables have been changed on a instrument during troubleshooting INST_DEFAULTS followed by a COLD should always be executed prior to leaving DML VITEK 2 amp VITEK 2 XL System Service Manual 6 51 Rev 0100 Chapter Six Troubleshooting The parameters changed are Development mode is turned off Range of motion is enabled Door cassette sensors are enabled Dilutrou mode 1s set to Automattic Bar code is enabled Pipettor is enabled Sealer is enabled Autoloader is enabled Transmittance 2 is enabled Fluorescence is enabled Audible alarm is enabled Bu rr irt is disabled COMP STATUS Boat management is enabled Real load mode is enabled Cassette mode is set to SCS Temperature alarm is enable Diluter is enabled Vacuum is enabled Stacker is enabled Transmittance 1 is enabled Transmittance 3 is disabled Communications is enabled Visual alarm is enabled COMP_STATUS indicates the number of cycles performed on the Vacuum Sealer Pipettor and Diluter and if any failures have occurred It displays the version of bar code reader the number of Power Fail and Low Battery signals from the instrument UPS the quantity of saline dispenses and
202. et it aside 3 Tag and disconnect the motor wires attached to the pipettor SPN board 4 Press on the middle of the timing belt and make a mental note of the tension Also turn the pulley and motor shaft and make a mental note of the force required to turn it by hand The belt will need to be adjusted accordingly after the replacement motor is installed 5 Loosen and remove the two mounting screws attaching the motor assembly to the pipettor vertical slide 6 Remove the timing belt and the pipettor pulley assembly 7 Loosen and remove the four mounting screws attaching the motor and the stepper motor mount Note the motor orientation to motor mount 8 Measure and note the distance of the drive pulley mounted on the motor drive shaft 9 Loosen the pulley set screws and remove from the motor shaft 10 Discard the motor WH Ny ER Ux T 7 a M gt a 7 E i TES i Pr at LA Er L Ew i PIPETTOR PIVOTING PULLEY MOTOR Figure 5 15 Pipettor Pivoting Pulley Motor Top View 5 26 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation Installation l aod pepe A Install the motor pulley on the motor shaft to the distance measured during removal of motor After applying threadlocking adhesive place set screws of motor pulley over flat spots of shaft and tighten set screws securely Install the four mounting screws attaching the motor to the stepper motor mount
203. f the vacuum chamber assembly The pneumatic components and vacuum pump make up the rest of the vacuum station The vacuum chamber is a formed plastic designed to cover the cassette and rest on the boat surface The vacuum chamber has a seal surrounding it s bottom which when lowered makes contact with the boat surface completing the chamber CE NOTE The seal on the vacuum chamber should be cleaned periodically with a disinfectant and warm water Figure 4 27 shows the top section vacuum chamber seal VAGUUM CHAMBER te Figure 4 27 Vacuum Chamber Seal 4 24 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Four System Components Figure 4 28 shows the pneumatic diagram for the vacuum chamber dWAd WNNOVA INVeHOVICG OILVINNANd S YAENVHO NNNOVA Pi Z l l ONIENL NNNIYA YSONASNVYL 1 67 dJovdsuns SNITV3s i HVO8 Od 3unssaud 1vog Nds aLMmosav l GION310S ea S ONILOV LOSUIC AVM Y s u3sWvHo dtum m WANIYA NI j Ld H3 NI ANWA TVNOILHOdOMd al TV2lLdO Hali uiv y 4 G P 4 BRE ld Vl e H3002N3 YJgWYH2 INnnovA Te SYSAMO1 8 SASIVY YOLOW 9NIdd3 1S 4 ONISNL WANOWA ZN COC C A l 4 25 Figure 4 28 Vacuum Chamber Pneumatic Diagram VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Four System Components The transport system delivers a cassette to the vacuum station for filling the test cards with the inoculum sol
204. g position of the pump and remove the screws and lock washers holding the pump into place Note pump bracket can be loosened and turned such that the pump can easily be removed 5 Remove the pump U DILUTER PUMP ASSEMBLY MOUNTING SCREWS Figure 5 43a Air Pump Location VITEK 2 amp VITEK 2 XL System Service Manual 5 67 Rev 0100 Chapter Five Component Installation AIR PUMP ES MOUNTING f BRACKET 7 SCREWS SALINE BAG COMPARTMENT T AP Figure 5 43b Air Pump Mounting Location Installation 1 Place pump into the proper position noted from the removal of the old pump and install the mounting screws and lock washers 2 Connect the cables and plastic tubing to the pump as tagged from the removal of the old pump 3 Re install the Diluter Cover including the saline bag and then re connect the drain tube 4 Close the top access doors 5 Ensure the instrument is ready to turn ON and verify proper operation 6 Perform Alignments See Appendix E Alignment Procedure Diluter Dispenser Assembly Replacement The design of the instrument permits the user to remove and install the complete dispenser assembly if problems are noted This design makes for efficient change outs Cem NOTE Take care not to contaminate disposable Refer to Figure 5 44a and Figure 5 44b for the dispenser assembly when performing the replacement procedures 5 68 VITEK 2 amp VITEK 2 XL System Service Manual Rev 01
205. g the timing belt as previously noted around the rollers Install the eight screws but do not tighten Install the three springs Tighten the eight screws securing the plate assembly to the linear way rails While supporting each of the optics modules one at a time push the clamp lever on the top of each of the TX optics modules Gently allow the optics to hinge down 8 Manipulate the belt up and over the optics and reposition the belt around the roller plate assembly 9 Carefully close each of the optics modules until the clamp lever locks in place ensuring the drive belt is 1n the proper position on the rollers 10 Install the reader motor bracket to the roller plate assembly and place the timing belt around the pulley 11 Position and tighten the motor so the belt tension 1s the same as noted earlier Open the optics to check the belt tension and rotate the motor shaft and pulley checking the force required 12 Reconncet the TX optics ribbon cable oS a 5 66 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation Air Pump Replacement See Figure 5 43a and Figure 5 43b for the air pump location Removal 1 Open the top access doors of the instrument 2 Disconnect the drain tube from the Diluter Cover and then unscrew and move the Diluter Cover including the saline bag to the side Tag and disconnect the cables and tubing attached to the air pump 4 Note the mountin
206. gnostics connection between the Work Station and the VITEK Z NOTE The communications cable from the instrument to the Work Station should not be connected at this time 1 From the Command Terminal of the Work Station type vt2setup and press ENTER A series of options will be displayed See Figure 2 5 ter NOTE The command vt2setup is case sensitive as well as all commands within vt2setup VITEK 2 set up LIODUV COnELOUT ataon tnstrunment association subsystem control 2 3 Q quit setup Figure 2 5 VITEK 2 Setup Screen Options VITEK 2 amp VITEK 2 XL System Service Manual Dy Rev 0100 Chapter Two System Setu 2 In VITEK 2 Setup type 1 and press ENTER for tty configuration A device configuration window will be displayed similar to Figure 2 6 Device Configuration Device name lt Q gt to return device product logical modem baud data stop name name name getty control rate parity bits bis tty WIFE EU disable no 9600 none 8 1 Eryl BE tty disable no 9600 none 8 1 be VIK i Z enable no 9600 none 8 1 eyo VTK Ely enable no 9600 none 8 i bier VLK tty4 enable no 9600 none 8 1 ttyb VTK pb enable no 9600 none 8 1 be S YS tty6 enable no 9600 none 8 1 ty ndo QD enable no 9600 none 8 1 pos OS tty8 enable no 9600 none 8 1 Figure 2 6 Device Configuration Window 3 Type the device name that needs to be configured i e tty2 and press ENTER Follow the prompts to define the corresp
207. he Bay Controller board also can capture a user invoked backup of all the alignment settings The BCB is located under the top left instrument cover mounted to the underside of the cover An EMI shield is mounted around the board serving as its outer cover Figure 4 45 shows the BCB location in the instrument TOP LEFT DOOR BCB CIRCUIT BOARD Figure 4 45 Bay Controller Board BCB Location EMI Shield Removed The BCB is a Motorola MC68332 based computer board and is responsible for the following instrument functions Controls for the optical systems and the associated data collection Non volatile memory holding up to 2700 card hours of data User interface control Controls for card movement within the reader and incubator Laser bar code scanner Interface to the cassette button memory device Communications with the SCS including firmware updates Communications to the workstation computer Master control to the SPN network 9 9 9 9 99 9 9 4 44 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Four System Components Figure 4 46 and 4 47 show the instrument system electronics and the connections to the BCB Vitek 2 System Electronics LCD Assy 2 i w13 oM ooo osten aes 2 Harness 2 Wire w8 a Ribbon Cable Ribban Cable Harness Reader n SPN P6 P1 ne 10 Pin TP Ribbon Cable DB25 Conn Bay Co ntro l er H Board BCB SCS I F 14 Pin TP Dilute
208. he boat throughout the process stations of the instrument Figure 4 7 shows a loaded cassette and boat TEST TUBES TEST CARDS CASSETTE Figure 4 7 Loaded Cassette and Boat 4 8 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Four System Components Cassette Load Unload Station Cassettes are placed onto boats and removed from them at the cassette load unload station The station consists of a sliding cassette loading door a green LED indicator light a queuing cassette reflective sensor and a door locking mechanism Cassettes are loaded onto a boat through a open door at the load unload station A green LED below the station is illuminated when the instrument is ready to accept a cassette When the cassette is loaded onto the boat the queuing cassette reflective sensor detects the presence of the loaded cassette The operator closes the cassette loading door the door lock solenoid initiates and the green LED will go out At this point test card processing automatically initiates The cassette loading door remains locked whenever a boat is moving through the Load Unload Station Table 4 1 shows the LED status light information Once the cards have been processed and loaded into the incubator the boats return the cassettes containing processed patient isolate tubes to the Load Unload Station for removal from the system The cassette will be parked at the cassette loading door with the door unlocked and the o
209. he corresponding slots in the cassette 3 5 If not already place the instrument into Cassette Only mode by pressing UTILITIES CONFIGURATION CASSETTE MODE CASSETTE ONLY on the User Interface Menu 3 6 Open the load door put the cassette into the Vitek 2 and close the load door The instrument will immediately begin processing the cassette During this time the instrument will run the vacuum cycle twice this is normal The calibration cycle takes approximately 15 minutes VITEK 2 amp VITEK 2 XL System Service Manual F 5 Rev 0100 Appendix F Fluorescence Optics Calibration 3 7 At the conclusion of the calibration the cards will be ejected into the stacker waste tray Any failures will be indicated on the LCD display If the calibration was successful the instrument will emit a series of tones Remove the ejected cards Be sure to leave the instrument in the same mode as you found it Cassette Only or Smart Carrier F 6 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Appendix G Installation Check List Appendix G Installation Check List Place VITEK 2 in its permanent location Verify all outlets for proper grounding and then properly connect all cables except for the instrument communications cable This will be done after configuring the tty serial ports See Figure 2 2 to 2 4 Place the Smart Carrier Station SCS in its working location and connect it to a power outlet Do not
210. hecking how the alignment looks on one complete quad you may find it necessary to readjust to give the best overall alignment for all 15 slots Readjust as necessary 1f this 1s the case Example When verifying alignment of the 15 slots in a quad you notice that the slots range from being centered to off in only one direction left or right this system should be readjusted It is desired that the range in bottom of slot alignment be such that they appear off center by approximately the same amount left and right from the center as the 15 slots move past the autoloader opening Press Enter when done to save the adjustment VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Appendix E Alignment Procedures 11 Cam 11 1 Cam Selection If aligning a 60 then skip this sub section If aligning a 120 this sub section is required 11 1 1 For a 120 atthe Prompt type CAROUSEL A and hit Enter This will redirect all cam alignment commands to Cam A You may complete the rest of this section to align Cam A then return back to this point 11 1 2 For a 120 after Cam A has been aligned type CAROUSEL B and hit Enter to redirect all cam alignment commands to Cam B You may complete the rest of this section to align Cam B 11 2 Cam Stroke The Cam is properly aligned when it will stop just short of pressing on the edge of a test card that is setting in the carousel slot in front of the reader head
211. his is to ensure that the scanned test card is loaded in the correct slot as indicated by the button memory Figure 4 14 shows an illustration of the laser bar code scanner as it scans a test card CARD SEPARATOR BAR CODES LASER BAR CODE SCANNER LASER BEAM Figure 4 14 Laser Bar Code Scanner Scanning Test Card Button Memory Reader The button memory reader is a device that the instrument uses to read the test card information stored by the Smart Carrier Station SCS on the button memory chip of the cassette This non volatile memory device contains the patient test and carrier specific information for the system The button memory reader is located at the cassette scan Station 4 14 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Four System Components Figure 4 15 shows the button memory reader in the instrument BUTTON MEMORY DEVICE READER Figure 4 15 Button Memory Reader Contacts The button memory reader has two spring loaded contacts that make contact with the arriving cassette button memory chip contacts When the VITEK 2 is set up in the Smart Carrier Cassette Mode and the button memory device has been programmed at the Smart Carrier Station the information is read from the button memory chip If the location of the cards found by the bar code reader and card separator match what is on the button memory it transfers all the button memory information to the flash memory on the Bay Con
212. icates time in milliseconds that the channel LEDs are activated while reading a card Channel DAC Values Indicates the LED intensity to calibrate to the Target Cal 3400 0000 indicates that the channel is not functioning properly Led reads per step Indicates the number of times the LED is flashed per stop across the well Number of HI values pitched Indicates the number of high flashes ignored in the algorithm Number of LO values pitched Indicates the number of low flashes ignored in the algorithm Cool time between each read Indicates a delay between flashes measured in milliseconds Cool time between each calibration bit Indicates a delay between calibration measured in milliseconds First scan point Steps into well Indicates how many steps are made into the well before the first flash 1s taken Scans across the well Indicates the number of stops across the well Total data points readings per well Indicates the number of flashes per well 16 stops across the well multiplied by 3 reads flashes per stop equals 48 flashes per well VITEK 2 amp VITEK 2 XL System Service Manual 6 25 Rev 0100 Chapter Six Troubleshootin READWAVE The READWAVE command reads the transmittance optics It is necessary to enter the optics number after the command For example READWAVE 1 will read the Transmittance Optic 1 or READWAVE 2 will read the Transmittance Optic 2 SCREEN DUMP
213. il the sealer home sensor detects the bottom of the sealer flag SEAL ON SEAL_ON causes the hot wire motor to lowers the sealer wire until the sealer home sensor detects the top of the sealer flag and then current 1s applied to heat the sealer wire SEAL OFF SEAL OFF stops the current to the sealer wire and then causes the hot wire motor to raise the sealer wire until the sealer home sensor detects the bottom of the sealer flag SEAL STAT SEAL STAT displays the current and voltage of the sealer If the sealer wire is heating the current and voltage will fluctuate See Figure 6 16 SEAL STAT VTK2 A seal on VTK2 A gt seal stat Current 8 47 Voltage 1 59 VTK2 A AGAIN seal stat Cur emit ul Voltage 0 00 VERA Poe AGAIN seal stat Current 8 47 Voltage 1 41 VTK2 A 1084 seal off Figure 6 16 SEAL STAT VITEK 2 amp VITEK 2 XL System Service Manual 6 23 Rev 0100 Chapter Six Troubleshootin TEST SEALER TEST_SEALER turns the sealer element on momentarily and displays the current and voltage Normal amperage should be 8 5 0 1 amp See Figure 6 17 TEST_SEALER VIK2 A gt TEST SEALER Sealer Current 8 4 7 Voltage 1 72 Figure 6 17 TEST_SEALER SEALER EN SEALER_EN enables disables the sealer component This is a variable that is stored in non volatile memory To determine its value it is necessary to enter PR before the command If a 1 is displayed the sealer is enabled Typing SEALER_EN 0
214. ile attempting to unload a card Fluorescence Calibration Failure When fluorescence validation with a card FLR CAL card fails Fluorescence Calibration Failure FLR Val Soft Offset Failed Communication Failure 180 Host Communication Errors D 8 More than 250 Commands are in the Q for the APL continued VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Appendix D Error Code Text 189 IHardware Errors 190 IHardware Errors 191 Hardware Errors FLASH Memory Failure 192 Hardware Errors FLASH Memory Failure 193 Hardware Errors FLASH Memory Failure 194 Hardware Errors FLASH Memory Failure 195 Hardware Errors FLASH Memory Failure 196 Hardware Errors FLASH Memory Failure 197 Hardware Errors FLASH Memory Failure 198 Hardware Errors FLASH Memory Failure 199 Fatal Errors Call bioMerieux 200 Fatal Errors Call bioMerieux 201 Hardware Errors Optical Controller Failure 202 Hardware Errors Optical Controller Failure 203 Hardware Errors Optical Controller Failure 204 Hardware Errors ptical Controller Failure 205 Hardware Errors Optical Controller Failure 206 Hardware Errors Optical Controller Failure rmo U 71 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Incubator Temperature is HIGH get_cassette_info Incubator Temperature is
215. imperative that the vacuum is enabled prior to exiting DML To accomplish this use the command VACUUM EN 1 or INST DEFAULTS SAVE INSIDE TEMP AVE INSIDE TEMP displays a three minute running average of the instruments inside temperature in C Because this command begins with a it is a variable and has a value assigned to it To determine its value it is necessary to enter PR before the command If the average inside temperature is 33 C or higher a message will occur and cards can not be processed until the problem has been resolved This average temperature can also be accessed through the User Interface by selecting Utilities Diagnostics Temperature NOTE The inside temperature thermistor is mounted to the top of the vacuum assembly 6 22 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Six Troubleshooting SEALER SEAL INIT SEAL_INIT initializes the Sealer Initializing the sealer includes using the hot wire motor assembly to position the sealer wire in its home position and then returning to its idle position The sealer home position is determined when the sealer home sensor detects the bottom of the sealer flag If the cycle is completed without errors no message will be displayed SEAL DOWN SEAL DOWN causes the hot wire motor to lower the sealer wire until the sealer home sensor detects the top of the sealer flag SEAL UP SEAL UP causes the hot wire motor to raise the sealer wire unt
216. in the same orientation as removed Reinstall the motor assembly to the pipettor vertical slide Install the drive belt on the pulleys Slide the motor to remove the slack in the drive belt Position and tighten the motor so the belt tension 1s the same as noted earlier Rotate the motor shaft and pulley checking the force required Reconnect the wires to the pipettor SPN board as tagged Reinstall the display assembly Close large access door Ensure the instrument is ready to be turned ON and verify the system operation After turning ON verify alignments See Appendix E Alignment Procedure Vacuum Assembly Vertical Motor Refer to Figure 5 16 for an example of the vacuum assembly vertical motor Removal l Open the top panel door and the large access door to expose the vacuum assembly 2 Loosen and remove the 4 screws securing the vacuum belt drive plate to the upper bearing mount 3 Tag and disconnect the necessary wires and connectors and then slide the plate assembly behind the vacuum chamber 4 Tag and disconnect the motor wires attached to the vacuum sealer board 5 Place a boat against the left and back side rails of the base pan 6 Press on the middle of the timing belt and make a mental note of the tension Also turn the pulley and motor shaft and make a mental note of the force required to turn it by hand The belt will need to be adjusted accordingly after the replacement motor is installed 7 Man
217. ing has been completed before ejecting a card Figure 3 29 Card Ejection CS NOTE The waste collection door should remain closed when cards are not being removed from the station CS NOTE The Waste Collection Station should be emptied whenever a new cassette 1s loaded into the instrument CS NOTE Once cards are removed from the Waste Collection Station they should never be reinserted This could cause jams VITEK 2 amp VITEK 2 XL System Service Manual 3 03 Rev 0100 Chapter Four System Components Chapter Four System Components Chapter Four is designed to familiarize the user with the five major systems of the VITEK 2 instrument Information from the previous chapter explained the product flow through the various stations of the instrument In this chapter we provide more detailed descriptions of the individual component parts of each system and their functions The VITEK 2 60 and the VITEK 2 120 Integrated Instruments are made up of the following systems Interface System Card Transport System Card Preparation System Reader Incubator Processing System s System Electronics 9 9 9 9 VITEK Z Interface System The VITEK Z Interface System is made up of the following primary internal components User Interface Keypad and Screen Uninterruptable Power Source UPS Workstation Computer User Interface Keypad and Screen The keypad and screen are located on the front of the instrument and
218. ings 236 ICard Sealer Failure Processing Errors ALARM MESSAGE MINOR Grouping Error at Slot Can not unload cards waste tray is not functional No cards found VITEK Z amp VITEK 2 XL System Service Manual Rev 0100 DESCRIPTION OF ERROR SOURCE OF ERROR The vacuum sealer SPN board has failed to execute a sealer off command during cassette processing Get Cassette Info SS where S and S are together SEQ 120 unload card but the stacker installed 1 functional 0 Instrument status is cleaning Carousel in cleaning mode while attempting to load cards After cassette was loaded into the instrument both the bar code reader and the card separator did not detect any cards Appendix E Alignment Procedures Appendix E Alignment Procedures te NOTE The following text of this appendix is for INFORMATION PURPOSES ONLY Always refer to the Official Release Document for the approved Alignment Procedures See Document Control for the approved drawings WARNING WARNING WARNING WARNING gt e e p Place boats back in the 1 4 5 and 6 Transport position prior to ALIGN_MODE_OFF Do SAVE_ALIGNMENTS prior to leaving instruments Do ALIGN MODE OFF prior to leaving instruments Perform BOAT ADVANCE after ALIGN MODE OFF VITEK 2Z amp VITEK 2 XL System Service Manual E 1 Rev 0100 Appendix E Alignment Procedures APPLICATION REVISIONS
219. installed which use gears The motor assembly 1s identical for each of these different tasks 9 9 9 Auto Loader Motor Card Ejector Motor Cam Motor Stacker Motor qty 2 for 120 Auto Loader Motor Replacement Refer to Figure 5 19 for the location of the auto loader motor Removal Open the top panel door and remove the side cover to expose the motor you are replacing 2 Tag and disconnect the motor wires attached to the Reader SPN Board 3 Move the auto loader rack by hand to expose the bottom two pan head screws securing the motor Note the motor orientation to the auto loader guide 4 Loosen and remove the four mounting screws attaching the motor to the back of the auto loader guide 5 Measure and note the distance of the tray drive gear mounted on the motor drive shaft 6 Loosen the hex screw and remove the gear from the motor shaft 7 Discard the motor AUTOLOAD R RACK Figure 5 19 Auto Loader Motor VITEK 2Z amp VITEK 2 XL System Service Manual 5 33 Rev 0100 Chapter Five Component Installation Installation 1 Position the tray drive gear on the motor shaft to the distance measured during removal and tighten screw securely 2 Mount the replacement motor onto the auto loader guide in the same orientation as removed When tightening the motor mounting screws make sure the drive gear engages the rack enough to remove backlash but not tight enough to produce binding Connect the motor wires to
220. ions on the use of the following commands may be found in the VITEK 2 Alignment Procedure ALIGN MODE ON ALIGN MODE OFF ALIGN FTRANS ALIGN BTRANS ALIGN LTRANS ALIGN RTRANS ALIGN BARCODE ALIGN DIL PUMP ALIGN DIL FLUID ALIGN DIL DOWN ALIGN VERT ALIGN PIP PUMP ALIGN ROTOR HOME ALIGN ROTOR DOWN ALIGN TIP HOME ALIGN TIP EXT PIP_POINT ALIGN VAC DOWN CAL VAC ALIGN SHUTTLE ALIGN CAM ALIGN AL ALIGN MOT ALIGN CARO TOP ALIGN CARO BOTTOM ALIGN STACKER VITEK 2 amp VITEK 2 XL System Service Manual 6 57 Rev 0100 Chapter Six Troubleshootin VITEK Z Reader General Troubleshooting Table 6 4 represents general troubleshooting information to be utilized ONLY by an authorized VITEK 2P instrument service representative All safety and hazard information must be clearly understood and exercised anytime the instrument is serviced Table 6 4 General Instrument Troubleshooting Information MALFUNCTION GENERAL TROUBLESHOOTING ACTIONS 1 AC power to instrument Verify AC power switch is in the ON position has failed Verify the AC line cord 1s properly connected to the power source Verify proper voltages at the power source Check AC power switch fuses in the RFI Filter Check the AC voltage selector of the RFI Filter Check fuses in AC Power Supply assembly Check AC power cord for damage Verify proper functioning of AC power switch on the instrument Check output side of RFI filter for proper AC voltage Replace filter
221. is warranty for any defect arising from abuse of the Product failure to operate and maintain the system in accordance with the Product manual including repair service alteration or modification of the product by any person other than service personnel of bioM rieux Inc or use of modified changed or previously used disposables Limited Warranty for Reconditioned Products bioM rieux Inc warrants Reconditioned Products to the original purchaser for a period of ninety 90 days after the date of installation under normal use against defects 1n material and workmanship and defects arising from failure to conform to specifications applicable on the date of installation provided bioM rieux Inc is promptly notified by the purchaser either in writing or by telephone The liability of bioM rieux Inc is limited to repair of the Reconditioned Products or at its own discretion and option to their replacement by another Reconditioned Product bioM rieux Inc shall 1n no case be liable under this warranty for any defect arising from abuse of the Product failure to operate and maintain the system in accordance with the Product manual including repair service alteration or modification of the product by any person other than service personnel of bioM rieux Inc or use of modified changed or previously used disposables THE WARRANTY OF BIOM RIEUX INC SET FORTH ABOVE AND THE OBLIGATIONS AND LIABILITIES OF BIOM RIEUX INC THEREUNDER
222. ix Troubleshooting TESTINT TESTINT will cycle the optical interrupts for the Fluorescence Transmittance 1 and Transmittance 2 optics between the on and off states Transmittance 3 not available at this time If the digits under the 0 1 2 are not changing between 0 and 1 then the corresponding optical assembly will need to be cleaned or replaced See Figure 6 25 TESTINT WARNING This command should only be used when cards are not processing or a SEQ PAUSE is invoked VTK2 A gt testint Scanning Duart Input Portis 290m3 DUART A Spare Spare DX Ae o TX A 2 qo Fol FLUOR A O e O N OW Hia a 0 Level ON O Figure 6 25 TESTINT VITEK 2 amp VITEK 2 XL System Service Manual 6 31 Rev 0100 Chapter Six Troubleshootin READROW READROW will perform one set of fluorescence readings See Figure 6 26 for READROW with a homed shuttle WARNING This command should only be used when cards are not processing or a SEQ PAUSE is invoked vTK2 A gt readrow 1 1 1 RAW data Reading i 2 3 4 5 6 7 8 Reading 1 PLO 34 40 36 46 9 g1 250 Reading 2 23393 10 1 3 J L1 12 12 25 Reading 3 2294 12 135 9 16 11 19 Z2 Reading 4 3342 10 14 9 13 9 T1 292 Reading 5 3334 8 13 12 1 3 ital 11 202 Reading 6 O09 10 14 8 14 10 16 2 Reading 7 Du qu 10 13 LT 19 E2 16 293 Reading 8 Daa 12 13 8 13 11 li 252 Reading 9 3417 2 145 7 10 9
223. kg 30 Ibs ter NOTE The power supply cabinet can be exchanged as a complete unit or individual parts can be ordered and replaced Removal 1 Open the base cabinet door to access the power supply cabinet front 2 Rotate the I 4 turn fasteners on the power supply cabinet located on the front base section of the instrument counter clockwise Figure 5 3 Pull and slide the power supply cabinet out of the base section of the instrument 4 Replace non functioning part or entire Power Supply Drawer Assembly Figure 5 4 U ES NOTE If replacing entire assembly ship the old one back to bioM rieux for repair BASE CABINET DOOR POWER SUPPLY DRAWER I C 1 4 TURN FASTENERS Pi Figure 5 3 Power Supply Drawer Assembly 5 8 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation FAN ZN MOUNTING cov MET 4 MOUNTING SCREW HOLES Figure 5 4 Power Supply Drawer Assembly amp Internal Components Installation 1 Place the power supply base in the base slot and slide the Power Supply Drawer Assembly fully in the base until it stops flush on the front base Tighten the 1 4 turn fasteners to secure the power supply in place 2 Ensure the instrument is ready to turn ON and verify voltages as necessary per Table 5 1 3 Shut the base cabinet access door VITEK 2 amp VITEK 2 XL System Service Manual 5 9 Rev 0100 Chapter Five Component Inst
224. l Rev 0100 Chapter Six Troubleshooting PIP GET PIP_GET performs a pipette of a specified volume It is necessary to enter a value after the PIP_GET command The value should be between 100 and 300 For example PIP_GET 100 will perform a pipette of 100 ul of liquid If the cycle is completed without errors no message will be displayed Pip_get includes Initializing the pipettor See pip_init Rotating drum so a pipette tip falls into drum slot Extending taper pin to insert into pipette tip Verifying the presence of pipette tip by performing vacuum check using pressure transducer Engaging solenoid to retract horizontal slide The rotor motor rotating the pipettor snout a pre aligned number of steps counterclockwise so the pipette tip 1s in the down position The vertical motor lowering the pipette tip into a pre existing volume of liquid in a test tube The pipettor pump extracting the specified amount of liquid The vertical motor raising the pipette tip from the test tube Verifying presence of liquid in pipette tip by performing pressure check with pipettor pressure transducer PIP PUT PIP PUT performs a dispense of already pipetted fluid If the cycle is completed without errors no message will be displayed Pip put includes The vertical motor lowering the pipette tip into a test tube with pre existing liquid The pipettor pump evacuating the liquid from the pipe
225. l System Cross Section 365nM Bandpass Filter B 28 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Appendix B Schematics and Diagrams Vacuum Chamber Piping Diagram INVeHOVICG OILVINNANd z H3gINVHO WANOVA i ems l l ONISR L NNNIYA YSONASNVYL Goe dJovdsuns 9NNYIS i HVO8 Od J3yNSSIYd 1vog NdS aLmosav l dIONJTOS AS NIL Y LOSUIC AYM uz u3sWvHo Ben a WANIYA NI f M Ld H3 NI ANWA TVNOILHOdOMd vas TV2lLdO Hali uiv y 4 EHtr 4 RS ld Vl H3002N3 YAEWVHD INnnovA Mee SYJM0O1 9 SASIVY YOLOW 9NIdd3 1S 4 ONISNL WANOWA Figure B 25 Vacuum Chamber Piping Diagram B 29 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Appendix C Glossar Appendix C Glossary BCB Bay Controller Board the main microprocessor in the instrument Boat See cassette carrier Cassette carrier The tray like device that carries the cassette around the instrument It forms the bottom half of the vacuum chamber and will help capture any spills It is removable for cleaning Carousel The rotating incubator section which holds up to four quads of cards Card Sealer Melts and seals the transfer tube that delivered the inoculum to the card from the test tube using a hot wire Cassette The card and tube carrier that is loaded with sample and up to 15 cards before being inserted into the instrument It can contain button memory that is used to
226. lacement motor is installed 4 Loosen and remove the three screws securing the transport motor assembly to the basepan 5 Remove the timing belt and the transport motor assembly 6 Loosen and remove the four mounting screws attaching the drive motor bracket to the motor Note the motor orientation to motor bracket 7 Measure and note the distance of the drive pulley mounted on the motor drive shaft 8 Loosen the pulley set screws and remove from the motor shaft 9 Discard the motor Installation 1 Install the motor pulley on the motor shaft to the distance measured during removal of motor After applying Vibra Tite threadlocking adhesive place set screws of motor pulley over flat spot of shaft and tighten set screws securely 2 Mount the motor to the drive motor bracket using the four mounting screws in the same orientation as removed Reinstall the transport motor assembly onto the basepan Install the drive belt on the pulleys Slide the motor to remove the slack in the drive belt Position and tighten the motor so the belt tension 1s the same as noted earlier Rotate the motor shaft and pulley checking the force required Reconnect the wires to the SPN board as tagged Install access doors or covers removed earlier Ensure the instrument is ready to be turned ON and verify the system operation After turning ON verify alignments See Appendix E Alignment Procedure cen sce M Diluter Pulley Motor Refe
227. les onto the SPN chip without having to realign the instrument See the SPNVAR SHOW and SPNVAR SHOW ALL command for related information TX TEST macro TX TEST is a macro that will test the transmittance optics It is necessary to enter the optics number after this command For example TX TEST 1 for transmittance optic 1 and TX TEST 2 for transmittance optic 2 WARNING This command should only be used when cards are not processing or a SEQ PAUSE is invoked 6 50 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Six Troubleshooting SYSTEM COLD COLD will reboot the instrument This command is prioritized by the data manager If there is any process that has a higher priority it will perform those tasks first before rebooting HARDCOLD HARDCOLD immediately does a reboot without allowing the firmware to perform higher priority tasks The COLD command should always be used otherwise data from processing cards could be lost ALARMS The ALARMS command displays the current instrument alarms from the message error alarm queue CLEAR ALARMS CLEAR_ALARMS will clear all the alarms from the message error alarm queue Note If the user interface screen is displaying the alarms when this command is executed the alarms will remain in the queue MESSAGES MESSAGES will display all the historical alarms since the last power up of the instrument INST DEFAULTS INST_DEFAULTS will set all instrument variabl
228. leshooting Status Empty Indicates that the boat does not contain a cassette There are 7 statuses 4 Empty indicates that the boat does not contain a cassette Loaded indicates that the boat is processing a cassette Completed indicates that the boat has completed processing its cassette and is waiting to have the cassette removed at the load unload station Removing indicates that the boat is being removed from the instrument for cleaning Inactive indicates that the boat is not installed in the instrument Paused indicates that the boat has been halted by the instrument firmware due to a jam with a different boat This condition will also display if a manual boat pause command is given Jammed indicates that boat movement has failed and halted User intervention is necessary Paddle 1 4 Indicates that paddle 1 front and paddle 4 right are engaged on the boat in SPOT 1 0 See Figure 6 6a VITEK Z Boat Spots positions and Figure 6 6b VITEK Z XL Boat Spots positions BACK 3 LEFT 2 RIGHT 4 FRONT 1 Figure 6 6a VITEK 2Z Boat Spots positions BACK 3 LEFT 2 RIGHT 4 FRONT 1 Figure 6 6b VITEK 2 XL Boat Spots positions 6 8 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Six Troubleshooting BOAT PAUSE BOAT PAUSE sends a pause command to each active boat This 1s an interaction command and will stop the transports until a resume command
229. lockwise toward the waste collection tray type MOV 1500 WARNING The motor phases are locked after the MOV command is given T ci When finished with this command the operator MUST type DISABLE to disable the lock DISABLE DISABLE is used specifically used to unlock the reader motor phases after the MOV command has been given VITEK 2 amp VITEK 2 XL System Service Manual 6 45 Rev 0100 Chapter Six Troubleshootin FIRMWARE VER VER will display the installed versions of the BCB BOOT and SPN firmware Figure 6 41 shows an example of the ver command VTK2 A gt ver Aw PBCB REV E SAR Flash version BOB 024261Feb T9 1999 compitatcion Limes 09559201 BOOT Versions 04 034 Mar 30 1999 K k SPN Kk Best Transport DlaeL Wo cLlr9o9T Right Transporti Oneri uSeu5l 1997 Dilute r Obok eal Prpettor 01 01 l19 Il 1997 Vacusealer 0l 59 29 10 1997 Header At 0l o0l 15 11 2997 Carousel A l6l 19 11 1997 Figure 6 41 VER Version Information Flash Version Indicates the Bay Controller Board firmware version This firmware can be updated by using the FILE REQUEST command or from the User Interface main menu by typing 3476 and pressing ENTER BOOT Version Indicates the boot firmware version written on the EPROM chip located on the Bay Controller Board SPN Indicates all the firmware versions of the SPN board controller chips FILE REQUEST FILE REQUEST will transfer a file from the Work Station
230. long with its associated help text Because the text output is extremely long and scrolls off the screen it is recommended that a capture file be enabled prior to executing the MANUAL command Once a capture file is enabled type MANUAL and press ENTER It will take several minutes for the MANUAL command to complete and a instrument prompt to reappear Stop the capture file and review as necessary Bytyping WORDS and pressing ENTER the entire list of commands and variables in DML will be displayed in group form Prior to scrolling off the screen Press any key to continue will be displayed To escape from the scroll press the q key 6 4 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Six Troubleshooting To search for a specific command or variable type WORDS pattern and press ENTER The pattern is the text of the command being searched For example typing WORDS VAC and pressing ENTER will display all DML commands and variables containing VAC See Figure 6 1 Words Example One IIK A words vac SPN VAC_CYCLE VAC_INIT CAL VAC System SVACUUM_EN VTK2 A gt VAC UP VAC DOWN VAC STAT VAC DUMP ALIGN VAC DOWN N VAC Figure 6 1 Words Example One Words are categorized into 16 groups shown below To search for commands and variables in a specific group type WORDS followed by a space a comma and the eroup For example typing WORDS TRANS and pressing ENTER will list all commands in th
231. ls total Calibration 3 800 RFU t5 with 5uM 4 MU in CHES pH 9 6 Lamp Life 30 million flashes minimum Self checking and calibrating using internal reference Reads each card once every 15 minutes 60 cards maximum for VITEK 2 120 cards maximum for VITEK 2 XL Up to 1 liter of fluid in drip pan Operating Ambient temperature 20 C to 30 C measured within 5cm of instrument 68 F to 86 F Humidity 40 to 80 non condensing Altitude up to 2000 m Indoor use only VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Two System Setup Instrument Physical and Electrical Requirements PHYSICAL Dimensions CHARACTERISTICS VITEK 2 Height 67 cm 26 3 in e Width 100 cm 39 4 in Depth 71 cm 27 7 in VITEK 2 XL Height 67 cm 26 3 in Width 140 cm 55 1 in Depth 71 cm 27 7 in Clearance 5cm 2 in minimum on all sides 50cm 20 in minimum above the top of the cabinet doors Weight VITEK 2 110 kg 240 Ib Left and right side lift pockets 2 people min VITEK 2 XL 145 kg 320 Ib Left and right side lift pockets 2 people min ELECTRICAL Voltage Selection REQUIREMENTS Externally selectable at universal power switch fuse block Input voltages e 100 120 VAC amp 200 240 VAC 50 60 Hz Maximum Current VITEK 2 4amps 120VAC or 2 amps 240 VAC VITEK Z XL 5 2 amps 120 VAC or 2 8 amps 240 VAC Nominal Current VITEK 2 1 5 a
232. maps in the flash The instrument may not have any wellmaps now Get Cassette Info Inoculum source is more than 2 tubes away Get Cassette Info The BarCode reader and card sensor saw acard but SCS did not Get Cassette Info The SCS says that a card is there but the BarCode reader and card sensor do not continued D 5 Appendix D Error Code Text ALARM ALARM MESSAGE DESCRIPTION OF ERROR SOURCE OF DE EE MINOR ERROR MAJOR 122 Processing Errors Unknown Card Type at Slot Get Cassette Info could not find a matching wellmap to target card type 123 Processing Errors Card has expired at Slot pm expired 124 Processing Errors E information has errors as Get Cassette Info SCS says to dilute into an T Slot card 125 Processing Errors Get Cassette Info SCS says pipette into card but the card is type T 126 Processing Errors been processed SEQ Current Validated Optical System do not 127 Processing Errors Reader Error Occurred match the card type Optics have failed 128 Processing Errors An optical system is not available Get Cassette Info No valid optical systems for card type in slot exists for target card type 129 Processing Diluent Level Low Boat Management has verified the diluent level Warnings and it is too low for the current cassette 1
233. mine which operations are to be performed on the individual slots within each cassette Once the data is transferred the instrument marks the cassette memory as read in preparation for the next station cycle A security check of this information is provided by comparing the card information on the cassette memory to what is read by the laser bar code scanner Figure 3 11 Computer Work Station 3 8 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Three System Overview Dispenser Pipettor Station Inoculum Preparation System The Dispenser Pipettor Station automates the preparation of inoculums for susceptibility cards This station also ensures that companion ID and susceptibility cards are processed from the same specimen which provides a significant workflow advantage Figure 3 12 shows the location of the Dispenser Pipettor Stations PIPETTOR E i DISPENSER STATION T EIL Figure 3 12 Dispenser Pipettor Station Dispenser System The Dispenser System dispenses 2 33 ml 2 63 ml of sterile saline solution into the test tube of each susceptibility card in a cassette This system consists of a 1 000 ml bag of sterile saline a fixed volume dispensing chamber Dispensing Tube two optical sensors a mechanical control system and volume tracking firmware to determine when the saline bag and dispensing assembly needs replacing See Figure 3 13 for the location of the dispensing chamber Before
234. mps 120VAC or 0 75 amps 240 VAC VITEK Z XL 2 75 amps 120 VAC or 1 75 amps 240 VAC Power e VITEK 2 150 watts nominal 480 watts peak VITEK 2 XL 200 watts nominal 480 watts peak e VITEK 2 512 BTU HR nominal e VITEK 2 XL 682 BTU HR nominal VITEK 2 amp VITEK 2 XL System Service Manual 2 19 Rev 0100 Chapter Two System Setu ELECTRICAL Power Fail REQUIREMENTS External UPS backup 700VA minimum con t Automatic power down mode using external UPS provided signals power fail battery low 2 20 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Three System Overview Chapter Three System Overview Unit Description The VITEK 2 is a fully automated bacteriological testing system This design integrates sample preparation incubation and optical measurement systems into a single instrument for use in the identification and susceptibility testing of microorganisms Automation provided by the VITEK ZP includes preparation of the patient isolate transfer of fluid to the test card loading the card into the optical reader incubator and disposing of the card once the test is complete This instrument is comparable to the existing Vitek susceptibility test methods Enhancements to the optical system provides multi wavelength capability Figure 3 1 shows the VITEK 2 60 integrated system instrument Figure 3 2 shows the VITEK 2 120 integrated system instrument
235. n this indicates that there 1s a movement error condition in either the transport or reader carousel and that portion of the instrument has stopped processing The Halted screen will display which section has the halted condition transport or reader how many minutes the halted condition has existed how many messages are in the message queue and it will display a GO button to be pressed after the problem is corrected The messages need to be viewed and the condition needs to be resolved before the GO is pressed Figure 4 3 shows the instrument Halted screen VITEK 2 amp VITEK 2 XL System Service Manual 4 3 Rev 0100 Chapter Four System Components 4 4 Instrument Halted Reader Processing Transport Halted Minutes 1 Messages Pending 0 Figure 4 3 Instrument Halted Screen VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Four System Components All of the functions used on the VITEKe2 instrument are available through the menu system The system is composed of a Main Menu and a set of five submenus as shown in Figure 4 4 User Interface Flow Diagram VITEK 2 Main Menu Display Instrument QC Status Cassette Setup Batch Load Utilities Resolve Bar Code Errors Maintenance Move Boat Diagnostics Configuration Change Diluent Temperature Cassette Names Change Pipette Tips Instrument Names Optics Shutdown Schedule QC Status Cleaning Cassette Mode
236. n Errors IMotor Sensor Failure ISEQ 120 Cam failed initialization 78 Initialization Errors IMotor Sensor Failure ISEQ 120 Cam failed init cycle 19 80 MTM De DESCRIPTION OF ERROR SOURCE OF ERROR 79 Initialization Errors IMotor Sensor Failure ISEQ 120 Stacker failed initialization Motor Sensor Failure SEQ 120 Autoloader failed initialization 80 Initialization Errors 81 Initialization Errors IMotor Sensor Failure ISEQ 120 Carousel failed initialization 82 82 Initialization Errors Motor Sensor Failure SEQ 120 Carousel failed Quad search 1 83 83 Initialization Errors IMotor Sensor Failure SEQ 120 Carousel failed Quad search 2 84 84 Initialization Errors IMotor Sensor Failure ISEQ 120 Carousel failed Quad search 3 85 85 Initialization Errors Errors Motor Sensor Failure ISEQ 120 Carousel failed Quad search 4 86 Processing Errors Card has expired at Slot SEQ After the carousel has been jammed for 24 hours all cards will be expired 87 Fatal Errors Restart System SEQ Nested carousel jamware cant get back out of it Sequence task will generate this error when a fatal load error occurs when loading cards into the reader via the read head with DML Boat management signals sequence task to prepare for auto loading before cards can be L88 Processing Error Load Failure 89 Processing Error Load Failure loaded into the incuba
237. n Failure Fluorescence Requires Liquid Additional cards were found with Additional cards were found with A cassette was loaded with QC D 007 cards but the pattern did not match 011111111110 Can not unload cards waste tray untransmitted data VAL FLR was just processed Internal settings are approaching calibration limits Network Transport were not installed and should be SYS Task makes a call to verify the all SPiN Variables SYS Task makes a call to verify the all SPiN Variables SYS Task makes a call to verify the all SPiN Variables SYS Task makes a call to verify the all SPiN Variables SYS Task makes a call to verify the all SPiN Variables SYS Task makes a call to verify the all SPiN Variables SYS Task makes a call to verify the all SPiN Variables SYS Task makes a call to verify the all SPiN Variables SYS Task makes a call to verify the all SPiN Variables SYS Task makes a call to verify the all SPiN Variables FLR POS Failure to calibrate the reference channel during FLR POS FLR POS Failure to calibrate the offset during FLR POS Fluorescence Calibration Failure FLR POS Optical Shuttle failed to extend A cassette was loaded with QC D 007 cards and other types of cards were found in the cassette SEQ 120 Waste tray is not installed while attempting to unload a card Can not unload cards waste tray SEQ 120 Waste tray 1s full wh
238. n the diluter home sensor detects the flag on the diluter block Verifying the air read of the dispensing tube using the diluter sensor assembly Engaging the diluter solenoid allowing the saline to begin filling the dispensing tube Detecting the saline at the tip of the tube using a optical sensor Disengaging the solenoid stopping the flow of saline The diluter motor rotating the dispensing tube a pre aligned number of steps clockwise so the dispensing tube is in the down position Activating the diluter pump so it forces air out of the tube at a controlled rate Initializing the diluter Returning dispensing tube to its idle position DILUTER EN DILUTER_EN enables disables the diluter component This is a variable that is stored in non volatile memory To determine its value it is necessary to enter PR before the command If a 1 is displayed the diluter is enabled Typing SDILUTER EN O and pressing ENTER will disable the diluter so it will not operate when cards are processing For proper instrument operation it is imperative that the diluter is enabled prior to exiting DML To accomplish this use the command DILUTER_EN 1 or INST DEFAULTS PIPETTOR When a pipettor alarm occurs review the flash log See flash log later in this chapter Within the log and near the alarm message there should be a detailed line with a description of a prep failure a get failure or a put failure A PREP failure will occur du
239. n the instrument The boats provide overflow areas to capture liquid spillage and a sealing surface for the vacuum fill cycle The boat normally remains in the system but is removable for cleaning CASSETTE LOADING DOOR LED INDICATOR ar LOADED CASSETTE Figure 3 6 Load Unload Station Cassettes are loaded into a boat through an open door at the Load Unload Station see Figure 3 6 A green LED below the load unload station is illuminated when the instrument is ready to accept a cassette Once the cassette 1s loaded onto the boat and the operator closes the cassette loading door the door locks and the green LED will go out At this point test card processing automatically initiates The cassette loading door remains locked whenever a boat is moving through the Load Unload Station Once the cards have been processed and loaded into the incubator the boats return the cassettes containing processed patient isolate tubes to the Load Unload Station for removal from the system The cassette will be parked at the cassette loading door with the door unlocked and the operator notified by the flashing load unload LED The operator can then remove the cassette and dispose the processed test tubes The boat will remain in place for the next cassette or it will advance to make room for the next processed boat to come forward to the unload station VITEK 2Z amp VITEK 2 XL System Service Manual 3 5 Rev 0100 Chapter Three System Over
240. n will go through the necessary steps after an instrument has been aligned either in part or completely This section will have to be performed after completion of alignment prior to the instrument being used 15 1 Firmware Configuration The firmware must be taken out of alignment mode after it is aligned Failure to do so will result in the instrument not operating correctly 15 1 1 Consult latest revision of document VK2PRM for variable adjustments prior to next step 15 1 2 Atthe Prompt type SAVE ALIGNMENT and hit Enter This will save a copy of the alignments for all nodes SPN boards to the Bay Controller Board BCB 15 1 3 Atthe Prompt type ALIGN MODE OFF and hit Enter This disables alignment mode and reboots 15 1 4 Wait for completion of the reboot before using the instrument VITEK 2Z amp VITEK 2 XL System Service Manual E 31 Rev 0100 Appendix E Alignment Procedures REVISION HISTORY REV PCNNO DATE BY DESCRIPTION D 100 0035 2 02 00 S HIGGINS Change to the following 4 1 8 Press the R key three times to move the boat so the card separator is at card positon 4 Verify correct position by looking at reported position on the diagnostic terminal C 199 0482 11 19 99 D HOPPER Numerous changes are being implemented to this assembly drawing and related test procedures See attached data summary sheets for details B 199 0274 05 17 00 J P Add info regarding VK2P
241. nd a shot tube before it can be properly aligned 2 2 1 Insert a shot tube into the diluter assembly referring to the user s manual as needed for instructions Note Tubing is not required for alignment purposes 2 2 2 Insert straws into the drum referring to the user s manual as needed for instructions 2 2 3 Insert all quads into the instrument referring to the user s manual as needed for instructions Firmware Configuration The firmware must be set to the proper diagnostic mode before you can align most parts of the instrument Failure to do so will result is some alignment commands not working correctly or not working at all 2 3 1 Atthe Prompt type ALIGN MODE ON and hit Enter Answer Y when prompted This configures the instrument for alignment and reboots 2 3 2 Wait for completion of the reboot before continuing 2 3 8 For a 120 atthe Prompt type CAROUSEL A or CAROUSEL B andhit Enter depending on which carousel cam autoloader or stacker you will be aligning Carousel A is the one closest to the center of the instrument and Carousel B is the one on the right closest to the load door VITEK 2 amp VITEK 2 XL System Service Manual E 7 Rev 0100 Appendix E Alignment Procedures 3 Transport System E 8 Alignment mode must be enabled for this section to be performed properly Note During transport alignment you will be stepping boats against the exterior rail of the base
242. ndsadaceaiabualandeegersioaeaatamecadscendabediands 3 5 Cassette S Ca SCAT OM a oe oet Eee eua teure idc das vou toeSaainlonedean Pedes ncatbuuluadeoaccexatys 3 6 Dispenser Pipettor Station Inoculum Preparation Systemy ssssss 3 0 NIOHUTHSSTEOHOTI Sos oicsodh E etted d nee en Mere ene Dn ater rea re ener hat 3 12 Card SCAICE tan OM Goose ertet ooo bectop tia fade Eoo eI SIDES nae A 3 14 Autoloader amp Reader Incubator Station S cc ccc cceccseccceecceescessseesseessseeseeeseees 3 15 Waste Collect On Station S Joner cased otic eS a tle ne Mech sels N 3 22 CHAPTER FOUR SYSTEM COMPONENTS eere eee eee eee eee eee eee eee eee ee ee e eee eee 4 1 VITEK 2 Interface Di SIE TD sd o cdd eb i pt eee wea 4 UserIntertace Keypad amd SCreem edocet terrea Ue rueda pense pu teem eevee 4 Umnterr ptable Power Source UPS area ao Rail EE RU pne et Ee s iR Sa Road et a vou gEs 4 6 Work Staton eai E 4 7 Card Transport SY SEIL 2 noeud dete Ebert ptt re EE ated du osa SUV seen 4 7 Cassettes and BD Odo nobi sued e eet EE Dea lap E T ETE ie 4 8 cassette boad Elmlodd Stano o2 oes adita oo tao Rad amado asians 4 9 Transport ASSemibHe Sore tere Mee voe rab rud bonas ida iens uuu Rede usage 4 10 Card PreparatiOn SY Ste II sei taatiaeincet io ea dese Li T 4 12 Cassete Sca S EILUOTE duros a 4 12 Dispenser zPIDettoroSEatilOTE eot Dieu tei e arto mend Dra eic dando ld Cose cades 4 17 V ACUI SAO enre a EEE 4 23 Card
243. ng Install the four mounting screws on each of the mounting feet to secure the vacuum pump in the instrument Connect all wiring and tubing disconnected from the removal Install the left side access cover on the instrument Install the rear access cover on the instrument Close the top access doors that were opened earlier Ensure the instrument is ready to be turned ON and verify the system operation 0 After turning the VITEK 2 instrument ON perform Alignments See Appendix E Alignment Procedure db M E E 5 76 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation Instrument Cabinet Fans Replacement Refer to Figure 5 49 for the location of the instrument cabinet fans Removal 1 Open the top left and right covers of the instrument 2 Tag and disconnect the wiring connector for the cabinet fan s where attached to the various circuit boards 3 Remove the mounting nuts from finger guards covering the cabinet fan s 4 Note the fan position and air flow arrow then remove the mounting bolts from the fan s and remove the fan s from the instrument 5 Discard the fan s Figure 5 49 Instrument Cabinet Fans Replacement Installation 1 Carefully place the cabinet fan s into the instrument with the proper noted position and air flow arrow from the removal When facing the front of the VITEK Z the left fan should be blowing into the instrument and the right fan sho
244. ning the Carousel See VITEK 2 Users Manual 6 36 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Six Troubleshooting SEQ STATUS SEQ_STATUS shows several status conditions of the carousel and several carousel counter mechanisms Figure 6 29 shows an example of SEQ STATUS VIKZ A amp SEOU STATUS Carousel A Status Total Cycles 74145 Total Retries 392 Total Failures 1 D Carousel Pos Available Slots Fast Read onaking First Read Mode Loading Mode Flush Carousel Lost Time Mode Cycle Time ms Card Retries Cards Gn Stacker Flr Cal Cards Current Flr Cal Cara SPN Version Cara SPN Dash Head SPN Version Reserved Slots 1 Worst Elaspe rs 00r s00 26222 992 Seq Status OK 5000 NOrFODCDCODOOFOOFOAOOOCOCN NN OD y O JH Figure 6 29 SEQ STATUS Total Cycles Indicates how many times the reader has read the cards loaded into the instrument Total Retries Indicates the number of times the carousel was not successful inserting a card into the reader but recovered Total Failures Indicates the number of times the carousel was not successful inserting a card into the reader and could not recover A carousel halted jam Available Slots Indicates the number of slots available for loading cards into the Carousel This is also displayed on the User Interface status screen Cards in Stacker Indicates the number of cards in the stacker Seq
245. not Program the Test Eject Packet DATATASK Could not Program the Test Load Packet DATATASK Could not Program the Test Info Packet DATATASK Could not Program the Card Data Packet Fatal Error Handle was called Minor Error Handle was called Default optical configuration does not match the plug n played TX1 A Default optical configuration does not match the plug n played TX2 A Default optical configuration does not match the plug n played TX3 A Default optical configuration does not match the plug n played FLR A Default optical configuration does not match the plug n played TX1 B Default optical configuration does not match the plug n played TX2 B continued D 9 Appendix D Error Code Text ALARM MESSAGE MAJOR 207 Hardware Errors 208 Hardware Errors 209 210 I on z z C s 1 un 211 Processing Warnings Optical Error 217 213 Processing Warnings 214 215 Processing Warnings Processing Warnings 216 218 IHardware Errors 220 IHardware Errors 222 IHardware Errors 224 IHardware Errors 26 Processing Warnings Optical Error 22 228 Optical Error 229 Hardware Errors 230 Processing Errors 217 Hardware Errors 219 Hardware Errors 221 Hardware Errors 223 Hardware Errors 225 lOptical Error 2 Processing Errors ALARM MESSAGE MINOR Pr
246. nt commands to Stacker B You may complete the rest of this section to align Stacker B Home Offset The home offset is properly aligned when the stacker pusher does not bottom against the stacker assembly 14 2 1 Atthe Prompt type MN STACKER and hit Enter 14 2 2 Next at the Prompt type ALIGN MOT and hit Enter 14 2 3 Following the prompts on the screen move the stacker pusher in or out as needed so the back of the pusher just touches the stacker housing Note Press the H key when done to re home the stacker Verify the back of the pusher does not hit or bottom hard against the stacker housing Readjust if necessary Tray Switch The tray switch is properly aligned when it detects the presence or absence of the tray 14 3 1 Atthe Prompt type N STACKER SPN SENSORS and hit Enter This will switch to the SPN board controlling the stacker and display the status of its sensors 14 3 2 Loosen the two small screws holding the stacker tray micro switch 14 3 3 With the stacker tray fully seated into stacker adjust the micro switch in or out as needed until the terminal screen indicates the stacker tray is present 14 3 4 Tighten the two screws holding the micro switch 14 3 5 Pressthe Space Bar to end the SPN SENSORS command and get the Prompt back VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Appendix E Alignment Procedures 15 Alignment Completion This sectio
247. nt with a button on the VITEK Z Work Verify proper incubator temperature See specification From User Interface Utilities Diagnostic Temperature Verify vacuum level obtained is 0 89 0 04 PSIA by connecting Absolute Pressure Gauge and performing vacuum cycle vac cycle and operation of instrument See current revision of drawing 530600 Perform F steps amp Fluorescence Calibration See current revision of drawing 530601 Py LL PE BL g gd T BB B BBLL DL With diagnostic window opened run engineering test cards and verify proper alignment VITEK 2 amp VITEK 2 XL System Service Manual G 1 Rev 0100
248. ntamination One tube connects from the dispensing tube to the saline bag The other plastic tube connects from the dispensing tube onto the inline air filter to the diluter pump assembly 4 18 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Four System Components Figure 4 20 shows the dispenser assembly front view Figure 4 21 shows the location of the diluter pump assembly from the top of the instrument FILTER H OPTICAL SENSOR BT tial TUBING DISPENSING TUBE ROTATING DISPENSOR MOUNTING BLOCK ASSEMBLY DILUTER PUMP ASSEMBLY Figure 4 21 Diluter Pump Assembly VITEK 2 amp VITEK 2 XL System Service Manual 4 19 Rev 0100 Chapter Four System Components When the instrument is set to automatic mode and a susceptibility card is positioned under the dispenser system by the transport the dispensing tube and mounting block assembly rotate in a counterclockwise direction until the optical sensor flag is sensed by the optical sensor An electrical solenoid is then compressed which causes a push pin to press into the bottom of the dispensing tube Gravity causes the saline from the bag to flow into the dispensing tube When the optical sensor at the tip of the dispenser tube detects the saline the solenoid releases compression and the flow of saline is stopped The diluter motor assembly rotates the dispenser block clockwise at a pre aligned distance over the susceptibility test tube The
249. ntered on the reader head drive mechanism and the card ejector during a carousel slot read movement 10 3 1 Atthe Prompt type ALIGN CARO TOP andhit Enter 10 3 2 Following the prompts on the screen move the carousel left or right as needed so that the carousel slots are centered with the reader head drive mechanism Visually line up the top card guide rail of the reader head with the top of the carousel slot peak of the arch of the slot The alignment software will automatically move to the next slot each time you make an adjustment Tip It is helpful to remove the carousel access cover rear access panel and open up the transmittance and fluorescence optics remove the stacker tray and prop up the stacker latch If desired also move the stacker push arm to the right 10 3 3 After completing alignment press G to check all 60 slots on all four quads Press the Space Bar to stop the slot cycling Note Make sure this 1s done with the carousel moving in a clockwise direction 10 3 4 After checking how the alignment looks on one complete quad you may find it necessary to readjust to give the best overall alignment for all 15 slots Readjust as necessary if this is the case Example When verifying alignment of the 15 slots in a quad you notice that the slots range from being centered to off in only one direction left or right this system should be readjusted It 1s desired that the range in the top of
250. number of the Bay Controller Board BCB on each VITEK ZP attached to the Work Station The third is labeled Name This is the instrument name given to the VITEK 2 by the operator The last is labeled Device This is referencing which serial port the data cables are connected NOTE It may take several minutes to display the VITEK 2 instrument on the Instrument Association window Instrument Association anstr ument name device 1 O0000rIOSB E LEOL dev tty2 2 X JOUOQUJDRCI 9 bubo Ideyv tty4 Figure 2 9 Instrument Association 9 First type the corresponding instrument BCB serial number located in the instrument column and press ENTER Next type 1 4 and press enter to associate this instrument with the first second third or fourth button to be displayed on the VITEK 2 Software Directory window Updating database will appear for a few minutes Press q and ENTER to exit from Instrument Association and press q and ENTER to exit from VITEK 2 Setup 2 10 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Two System Setu 10 Verify the instrument association by pressing the VITEK 2 button on the Main Menu of the Work Station and then select the corresponding instrument button Remote Diagnostics Setu WARNING For security purposes the external modem MUST be turned OFF when not in use by authorized bioM rieux personnel Configure Work Station for External Modem 1 From the W
251. number refers to the number that is used by the BCB to communicate with the SPN board and is provided for reference only Table 5 2 SPN Board Jumper Configuration for the VITEK 2 60 SPN BOARD P N 530704 1 pe JUMPERS I lt BCB gt i o omm od JP3 JP9 1 2 Right Transport i JP4 JP9 JP5 JP9 Diluter on Q2 f Pipettor Vacuum Sealer Reader A Carousel A J JP7 JP9 JP8 JP9 EN I NO SPN BOARD P N 530704 2 NODE INSTALLED JUMPERS BOARDFUNCTION I lt BCB gt 2 JP2 Left Transport 3 JP3 Right Transport 4 JP4 Diluter 5 Pipettor Re UA 6 Vacuum Sealer 7 JP7 Reader A 8 JP8 Carousel A VITEK 2 amp VITEK 2 XL System Service Manual 5 15 Rev 0100 Chapter Five Component Installation Table 5 3 SPN Board Jumper Configuration for the VITEK 2 120 SPN BOARD P N 530704 2 Ww N mn A oo NIA p lt INSTALLED JUMPERS BOARDFUNCTION BCB JP2 Left Transport JP3 Right Transport JP4 Diluter JP5 Pipettor Vacuum Sealer JP7 Reader A JPS Carousel A JP1 Reader B JP6 Carousel B SPN Board Replacement Refer to Tables 5 2 and 5 3 for the jumper configuration for the SPN board your are replacing Figure 5 9 shows a typical SPN board Removal 1 Remove the instrument covers or access panels to expose the SPN board to be r
252. numbered with two numbers separated by a period and followed by a period example 3 1 Rotor home Under each sub section are one or more steps required to perform the adjustment in that sub section Steps are numbered with three numbers separated by periods and ending in a period example 3 1 2 Differences in the alignment process between the Vitek 2 and Vitek 2XL are noted where necessary as 60 for the Vitek 2 and 120 for the Vitek 2XL 1 2 Use of procedure When aligning a previously aligned instrument you may use only those sections or sub sections which are required to make the needed alignment If the alignment in one section or sub section is dependent on another then it is noted Within a section sometimes the first or last sub section may be required even though the remaining sub sections may be performed independently of each other When this is the case the sub section will have required in its heading Please note that sub sections should be performed in their entirety Do not perform individual steps within a sub section It is also recommended in most cases you will want to perform a complete section and not do a sub section alignment by itself Obviously if the instrument has never been aligned or the status is unknown the complete procedure should be followed E 4 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Appendix E Alignment Procedures 1 3 Conventions 1 4 1 5 Th
253. oard 3 Close the top access doors 4 Ensure the instrument is ready to be turned ON and verify the system operation 5 After turning VITEK 2 ON Align the FL auto cal optical shuttle and perform Fluorescence Optics Calibration Procedure See Appendix E amp F 5 56 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation Fluorescence FL Lamp Cassette Assembly Replacement Refer to Figure 5 37 for the location of lamp cassette assembly Ce NOTE The Fluorescence assembly must be replaced as a complete unit Its parts should not be interchanged Removal l Open the top covers of the instrument Disconnect the drain tube from the diluter cover and then unscrew and move the diluter cover including the saline bag to the side 2 The lamp cassette assembly is installed in the lamp power supply assembly 3 Locate the one captive and two mounting screws for the lamp assembly and loosen 4 Using the handle pull the lamp assembly straight up The lamp assembly will slide up a dovetailed mounting on the FL optics module 5 Setthe lamp cassette assembly aside to return for repair or replacement POWER SUPPLY WA al Figure 5 37 Fluorescence FL Lamp Assembly Cassette Replacement Installation 1 Carefully align the dovetail groove on the lamp assembly to the dovetail mount on the FL optics module Slide the lamp assembly down until it is flush with the power supply case 2
254. ocated and the status of the transport system Figure 4 9 and Figure 4 10 shows a transport assembly and components Figure 4 9 Transport Assembly 4 10 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Four System Components HORIZONTAL PADDLE PADDLE HORIZONTAL DRIVE POSITION DRIVE DRIVE BELT PADDLE SHAFT BELT amp MOTOR VERTICAL POSITION DRIVE BELT AND MOTOR ENCODER WHEEL Figure 4 10 Transport Assembly and Motors Each transport consists of a square horizontal drive shaft with a belt driven paddle that moves horizontally by a drive motor A transport home switch sensor is attached to a vertical position plate The paddle checks this sensor before hooking the next boat or in the event of a transport jam This transport home switch assembly 1s the transports reference point for proper stepping and positioning The horizontal drive shaft also rotates which causes the paddle to be in either an up or down position When it is in the up position it is either preparing to hook the next boat or it is in an idle state When it is in the down position the paddle is in a pocket of a boat and is ready for transport Shaft rotation 1s accomplished by a separate drive motor and belt A transport paddle switch sensor mounted to the vertical position plate detects the up down rotation of the paddle An encoder is located on the front and back transports It is a notched wheel between a transport encoder sensor As
255. ocessing Errors 23 Processing Error 232 Processing Error D 10 Optical Controller Failure Optical Controller Failure FLASH Memory Failure Cassette button memory failure The fluorescence is approaching calibration limits Fluorescence Calibration Failure The fluorescence is approaching calibration limits Reader Error Occurred The fluorescence is approaching calibration limits The fluorescence is approaching calibration limits DESCRIPTION OF ERROR SOURCE OF ERROR Default optical configuration does not match the plug n played TX3 B Default optical configuration does not match the plug n played FLR B Could not Erase a Sector During switch bank Get Cassette Info We are in Cassette Only mode but the Touch Memory has SCS Data FLR Finger Print values are are approaching calibration limits FLR POS Final Fsteps was calculated to the Rail FLR POS Final Fsteps is close to the Rail SEQ During an unload the optical interrupt E is not functional SYS TASK Head A was not done a VALFLUOR in more than 5 days LE Head B was not done a VALFLUOR in more than 5 days Optical Controller Failure Seq Task Dark current on FLR A Optical Controller Failure Seq Task Dark current on TX1 A Optical Controller Failure Seq Task Dark current on TX2 A Optical Controller Failure Seq Task Dark current on TX3 A Optical Controller Failure S
256. oexec bat macro that is used in DOS ED ED allows editing of an existing macro Example VTK2 A ED DIL CYCLE Edit DIL INIT DIL _FILL DIL EMPTY saving SETMAC SETMAC can be used to create a macro Example VTK2 A SETMAC PIP CYCLE PIP GET 100 PIP PUT A macro called PIP CYCLE will now be listed with the other instrument macros and can be vied by entering MAC VITEK Z amp VITEK 2 XL System Service Manual 6 49 Rev 0100 Chapter Six Troubleshootin DELMAC DELMAC will delete a specified macro Example VTK2 A gt DELMAC PIP_CYCLE Macro deleted CLEAR ALL MACROS CLEAR ALL MACROS will delete all macros REFRESHMAC REFRESHMAC will restore all default macros SAVE ALIGNMENT macro SAVE_ALIGNMENT is a macro that will save all alignments from the SPN Boards to the Bay Controller Board Failure to enter this command after an alignment has been changed will generate the instrument alarm Hardware Error Internal Data Failure 169 See the SPNVAR SHOW and SPNVAR SHOW ALL command for related information N WARNING Ifa SPN chip is replaced without previously saving the alignment variables to the BCB the corresponding section of the instrument will need to be realigned RESTORE ALIGNMENT macro RESTORE_ALIGNMENT is a macro that will restore all saved alignment variables from the Bay Controller Board to the SPN Boards If a new SPN chip is installed entering this command will reload the alignment variab
257. og line This is when the LOG or ALM occurred referencing a 24 hour clock that starts each time the instrument is turned on The time stamp is displayed in Days Hours Minutes Seconds Milliseconds Following the time stamp is a description of the LOG or ALM FLASH LOGS FLASH_LOGS will list all log messages contained in the flash memory of the Bay Controller Board starting from the earliest logged message it has in flash to the last There are two options with this command FLASH LOGS 0 and FLASH LOGS 1 FLASH LOGS 0 will allow the log messages to scroll without stopping FLASH LOGS 1 will allow the log messages to scroll with page stops The entire log can be captured by a communications software package or by Enable Logging on the diagnostics terminal FLASH LOG TAIL FLASH LOG TAIL will list the number of specified lines staring from the most recent logged messages contained in the flash memory of the Bay Controller Board For example FLASH LOG TAIL 10 will list the last 10 logged messages entered into the flash memory of the Bay Controller Board Figure 6 30 shows a example of FLASH LOG TAIL 10 VTK2 A FLASH LOG TAIL 10 Logs 10 of 902 LOG 12 21 10 36 696 LCD Error Log LOG 12 21 56 53 272 Door closed with new cassette Signaling start SINGLE process LOG 12 21 56 59 288 SPNLOG Motor home failure Right Transport of 20 steps LOG 12 21 57 22 816 CASSETTE LOAD 004 EP Real Vac 1 Seal 1 Mode O0 Cards 3 0A0A0A00000000
258. on and the action required to fix it VITEK 2 amp VITEK 2 XL System Service Manual 1 3 Rev 0100 Chapter One Organization of the Manual Typographic Conventions Following are the terms and visual cues used in this manual to aid in your understanding of the procedures te NOTE This symbol calls attention to especially useful information or instructions WARNING The information or instructions following is critical to the safe operation of the instrument Please read this information carefully The following data entry instructions are used throughout this manual ENTER key An instruction to use this key ALWAYS takes the form press ENTER NOTE On some keyboards this key may be labeled RETURN Function keys Function keys include all control keys the ESCAPE key the CONTROL key and the SHIFT key They are capitalized and appear as press CTRL U Data Entry Data entered into the system via the keyboard is ALWAYS shown in bold Instructions for making a data entry begin with type and conclude with press ENTER An operation involving a selection always begins with Select Single key entries may not require pressing ENTER Such entries begin with press such as press Q Commands From time to time this manual may instruct you to enter a command on an external keyboard An operation involving a command will appear in bold type For example Type motor pump and press ENTER Press Ctrl
259. onding VITEK 2 tty ports for both data VT2 and diagnostic SYS communication as shown in Table 2 2 and Figure 2 7 Also configure ttyO as VT2 for the SCS NOTE Only define the ports for the VITEK 2 and the SCS that are Cg being installed 2 8 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Two System Setu Table 2 2 Proper TTY Connections PHYSICAL LOGICAL PRODUCT LOCATION INSTRUMENT MODULE CABLE PORT NAME NAME Work 1 ttyO Smart Carrier Station SCS 186132 10 VT2 Station Work 2 ttyl Bi directional Computer BCI Station Interface 1 POD 0 tty2 186075 X VT2 1 Installed VITEK 2 Data 1 POD 1 EES 186075 X SYS sgh Installed VITEK 2 Diagnostic 1 POD 2 tty4 amp 186075 X VT2 27 Installed VITEK 2 Data 1 POD 3 tty5 186075 X SYS ee Installed VITEK 2 Diagnostic 1 POD 4 tty6 186075 X VT2 3 Installed VITEK 2 DSA 1 POD 5 tty7 186075 X SYS a Installed VITEK 2 Diagnostic 1 POD 6 tty8 External Modem 186008 1 SYS 1 POD I None Optional remote printer 186062 X 2 POD 0 EEVS Available 2 POD 1 tty10 186075 X VT2 4 Installed VITEK 2 Data 2 POD 2 ttyll 186075 X SYS yen Installed VITEK 2 Diagnostic Device Contiguravion Device name 0 to return device product logical modem baud data stop name name name getty control rate parity bits bits Eey VIZ tty0 disable no 1920
260. op covers and remove the rear access cover to expose the vacuum pump Remove the left end panel of the instrument to gain access to the vacuum chamber and vacuum pump Disconnect the vacuum tubing from the vacuum pump Tag and disconnect all four wires from the vacuum pump solid state relay Disconnect housing connector which attaches the pump to the power supply Remove the four mounting screws securing the vacuum pump plate to the base pan Gently lift and remove the vacuum pump assembly from the instrument through the rear opening and set on a flat table top surface Remove the intake filter from the pump and set aside Note the order of the hardware and then remove the four mounting screws corresponding hardware and vibration isolation bushings that secure the feet of the pump to the vacuum pump plate Set aside the vacuum pump to be returned for exchange or repair 1f required VITEK 2 amp VITEK 2 XL System Service Manual 5 75 Rev 0100 Chapter Five Component Installation can rv SREAR ACGESS COVER REMOVED RELAY HIDDEN MOUNTING SCREWS Figure 5 48 Vacuum Pump Replacement Installation 1 Install the intake muffler into the intake opening of the vacuum pump Use teflon pipe sealent only 2 Using the appropriate hardware and vibration isolation bushings mount the vacuum pump to the vacuum pump plate as previously noted 3 Carefully place the vacuum pump into the instrument through the rear openi
261. optical shuttle fluorometer aperture optical head ultraviolet flashlamp assembly peak and photodiode detector boards in an EMI box and the 600V power supply Figure 4 39 shows the FL optical system components CA Optical Shuttle J Front Surface Fluorometer Aperatures Optical Head Flashlamp Peak Detector amp EMI Box Figure 4 39 Fluorescence Optical System VITEK 2Z amp VITEK 2 XL System Service Manual 4 37 Rev 0100 Chapter Four System Components The FL optical system is a six channel configuration meaning it will read 6 wells in a row rows 2 7 top to bottom for a total of 48 wells per card The emitter is a xenon flash tube and optical filters delivering 10 flashes per reading The fluorophore re emits light from the xenon flash tube and this re emitted light is captured by the fluorescence detector The biochemical in these wells is designed to produce this substance in direct proportion to the growth of the organisms The amount or re emitted light produced by the fluorophore provides the level of growth of the organism From the 10 readings per well the firmware removes the two highest and two lowest numbers and then averages the remaining 6 which becomes the final value for that well on that particular read The fluorescence optics require a initial liquid calibration using 4 MU bio prepared standard Another liquid calibration should follow every 6 months An automatic calibration verification is
262. ork Station computer open the Change Show Characteristics of a tty window From the Main Menu select System System Maintenance and Change Show Characteristics of a TTY 2 Configure tty8 port as shown in Table 2 3 Refer the bioLaiason User Manual for instruction Table 2 3 tty8 Modem Configuration TTYS tty8 Product SYS Unique ID tty8 Login state enable Modem Control es BAUD rate 19200 PARITY none BITS per character Number of STOP BITS 1 Configure US Robotics 33 6 Faxmodem 1 Verify modem is connected to Work Station See Figure 2 2 through Figure 2 4 for cabling diagram 2 Ensure that modem switches 3 5 and 8 are in the down position and all the others are in the up position 3 Turn the external modem ON 4 Opena command terminal window from the Work Station computer From the Main Menu select System System Maintenance Command Terminal OK 5 Atthe dms prompt type Su and press ENTER 6 Atthe password prompt type vitek and press ENTER The cursor should be displayed next to the pound prompt 7 At the pound prompt type kermit c I dev tty8 and press ENTER Kermit will connect to the tty8 port and display a speed of 19200 baud A solid red cursor will also be displayed VITEK 2Z amp VITEK 2 XL System Service Manual 2 11 Rev 0100 Chapter Two System Setu 8 Type at amp f2 amp n10 amp u4 and press ENTER The monitor should display the response OK If there is no re
263. ors 11 Ensure the instrument is ready to be turned ON and verify the system operation 12 After turning the VITEK 2 ON from the Diagnostic window type tx_test X X the number of the Transmittance optics which has been replaced 1 e 1 2 or 3 Verify that the test passed VITEK 2Z amp VITEK 2 XL System Service Manual 5 55 Rev 0100 Chapter Five Component Installation Fluorescence FL Auto Cal Assembly Replacement Figure 5 36 shows the location of the FL auto cal assembly Ce NOTE The Fluorescence assembly must be replaced as a complete unit Its parts should not be interchanged Removal l Open the top covers of the instrument Disconnect the drain tube from the diluter cover and then unscrew and move the diluter cover including the saline bag to the side 2 Tag and disconnect all FL auto cal assembly wires attached to the Reader SPN board 3 Unscrew the small phillips screw securing the auto cal to the FL optics under the FL hinge 4 Carefully remove the FL auto cal assembly from the FL optics 5 Set the FL auto cal assembly aside to return for repairs or exchange FL AUTO CAL ASSEMBLY jams FL OPTICS OPEN Fi hd CLAMP LEVER l il uiii Figure 5 36 FL Auto Cal Assembly Installation Carefully install the FL auto cal assembly to the FL optics and then close module until the clamp lever locks in place 2 Re connect the wires from the FL auto cal assembly to the Reader SPN b
264. otor raising the fully evacuated pipette tip The pipettor pump homing The vertical motor lowering and forcing air through pipette tip to complete mixing cycle The taper pin retracting into the snout therefore pushing the pipette tip off of the pin and dropping into the test tube of mixed liquid Pipettor initializing PIP INIT PIP INIT initializes the Pipettor If the cycle is completed without errors no message will be displayed Pip init includes Using the vertical motor to position the pipettor assembly in its vertical home position and then return to its idle position The pipettor vertical home position is determined when the pipettor vertical flag 1s detected by the pipettor vertical Sensor Using the pipettor rotor motor to rotate the pipettor snout assembly to its home position and then returning to its idle position The pipettor rotor home position is determined when the pipettor rotor flag is detected by the pipettor rotor home Sensor Retracting the pipettor taper pin motor assembly its home position and then returning to its idle position The pipettor taper home position is determined when the taper pin flag is detected by the taper pin home sensor Running pipettor pump motor all the way out until detected by pipettor pump home sensor and then returning to its idle position Checking the ambient pressure using the pipettor pressure transducer VITEK 2 amp VITEK 2 XL System Service Manua
265. over including the saline bag and then re connect the drain tube UJ VITEK 2Z amp VITEK 2 XL System Service Manual 5 81 Rev 0100 Chapter Six Troubleshootin Chapter Six Troubleshooting This chapter contains information to aid in diagnosing problems with the VITEK 2 instrument Refer to the VITEK Z Operators Manual for additional information WARNING POTENTIAL BIOHAZARDOUS MATERIAL Instrument surfaces and contamination test kit components are potentially biohazardous and should be handled according to good laboratory practices Observe universal precautions when operating the instrument and when performing maintenance or troubleshooting Instrument Diagnostics Using Development Macro Language DML Accessing the DML The Development Macro Language DML is a tool used for determining diagnosing and maintaining the VITEK Z instrument The DML can be accessed using three different methods It can be opened through the diagnostic window of the Work Station by a physical connection from the instrument to a PC or by remote communication WARNING Itis imperative that the operator accessing the Development Macro Language DML type all commands with preexisting knowledge of the result Erroneously executing commands or changing variables could have a detrimental effect on the operation of the VITEK 2 instrument Any person accessing the DML should first have the proper training through bioM rieux Inc Acces
266. ower switch holding the power switch to the panel base 6 Gently remove the switch from the panel while feeding the power cable through the opening 7 Tag and disconnect the wires attached to the power switch Power Switch Location Left side base toward back of the unit Fuse Access Slot insert screwdriver blade into slot and twist to open the fuses access cover Switch Mounting Slots Switch Mounting Slots Instrument Base Left Side View Figure 5 1a Power Switch Replacement VITEK 2 amp VITEK 2 XL System Service Manual 5 5 Rev 0100 Chapter Five Component Installation Figure 5 1b Access to Power Switch Installation em Reconnect the wires to the power switch as tagged 2 Gently feed the wiring cable and the power switch into front of the base cabinet mounting opening making sure to position the power switch the same as the one removed 3 Push firmly on the power switch until the plastic retainer tabs on the back of the circuit breaker snap firmly into place 4 Install the fuse block in the power switch housing for the correct voltage as noted before Close fuse cover Reconnect the power cable to the instrument s power connection plug 6 Verify instrument is ready to be started turn the power switch ON and verify instrument operation A 5 6 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation Power Switch Fuse Re
267. p and seals against the pad on the drum The drum should be down horizontal when performing this sub section 7 5 1 Atthe Prompt type ALIGN TIP EXT and hit Enter This starts the tip extended alignment routine 7 5 2 Following the prompts on the screen adjust the tip position in and out as needed until the tip just meets the end of the drum Press the H key when done to verify the proper position during this alignment Readjust if necessary 7 5 3 Press Enter when done to save the adjustment 7 6 Rotor down The rotor should be perfectly vertical when rotated down 7 6 1 Atthe Prompt type ALIGN ROTOR DOWN and hit Enter This starts the rotor down alignment routine 7 6 2 Following the prompts on the screen adjust the rotor position until it looks perfectly vertical by eye To aid in this adjustment place a minimum of a 6 inch scale or equivalent on the flat part of the side bottom when horizontal of the rotor Let the scale extend down parallel to the vertical guides for the assembly Compare the vertical guides with the scale When they are parallel the rotor should be vertical Caution Use of a straw which may have curvature may lead to an improper alignment Use of a straight edge is recommend Tip It can be helpful to position a cassette with a test tube underneath the pipettor assembly and watch how a tip enters the tube when you press the X key If the bottom and top of a tip
268. peat this alignment starting at the beginning of this section 8 2 6 When alignment is completed disconnect Absolute Pressure Gauge and tubing Be sure to reconnect vacuum chamber tubing to correct transducer fitting E 22 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Appendix E Alignment Procedures 9 Sealer 9 1 Sealer position The sealer wire needs to be positioned so that it will cut the straw off all cards within a distance of Imm 040 to 2 5mm 10 from the card s edge 9 1 1 Place a cassette containing 15 cards without straws in a boat located underneath the vacuum chamber Remove any boats located on the back of the instrument base pan 9 1 2 Atthe Prompt type SEAL INIT SEAL DOWN and hit Enter This will initialize the sealer and lower the sealer wire 9 1 3 Loosen the two screws holding the sealer assembly to the center mount and adjust it in or out as needed so the sealer wire comes within 1 0mm 040 to 2 5 mm 10 in front of all cards in the boat as it is pushed past It is very important that the sealer wire never come in contact with a card The sealer wire must also be parallel to the front edge of all cards in the cassette Tip It is helpful if you remove both end panels to aid in seeing the sealer wire 9 1 4 Tighten the screws holding the sealer assembly when location is adjusted correctly 9 1 5 Atthe Prompt type SEAL UP andhit Enter This will
269. per Motors pin and wiring connections Table 5 4 Stepper Motors Pin and Wiring Connections Red White and Blue are connected Black Yellow and Green are connected STEPPER MOTORS PIN PX244 03AA WIRE COLOR White Common 2 Yellow Common 3 Blue 4 Red 5 Green 6 Black Paddle Pulley Motor Refer to Figure 5 12 for an example of the paddle pulley motor Removal 1 Open or remove the access cover s from the area that exposes the paddle pulley motor you are replacing 2 Tag and disconnect the motor wires attached to the corresponding SPN board 3 Press on the middle of the timing belt and make a mental note of the tension Also turn the pulley and motor shaft and make a mental note of the force required to turn it by hand The belt will need to be adjusted accordingly after the replacement motor is installed 4 Loosen and remove the four mounting screws attaching the motor to the home bracket assembly Note the motor orientation to home bracket 5 Remove the timing belt and motor 6 Measure and note the distance of the drive pulley mounted on the motor drive shaft 7 Loosen the pulley set screws and remove from the motor shaft 8 Discard the motor VITEK 2 amp VITEK 2 XL System Service Manual 5 21 Rev 0100 Chapter Five Component Installation PADDLE PULLEY MOTOR 7 EN TRANSPORT by PULLEY MOTOR Figure 5 12 Paddle amp Transport Pulley Motors Installation ee 5 22
270. perator notified by the flashing load unload LED The operator can then remove the cassette and dispose the processed test tubes The boat will remain in place for the next cassette or it will advance to make room for the next processed boat to come forward to the station Table 4 1 Load Unload Station LED Status Closing the door after removing the cassette causes the LED light to stop blinking LED STATUS LOADING AND UNLOADING STATION STATUS ON The cassette loading door is unlocked Cassettes can be loaded OFF Cassette loading door is locked At this time a boat is traveling through the load unload station BLINKING Boat with a cassette has arrived at the station Cassette loading door can be opened to remove the cassette and dispose of the remaining waste L VITEK 2 amp VITEK 2 XL System Service Manual 4 9 Rev 0100 Chapter Four System Components Figure 4 8 shows the load unload station along with the location of the LED indication light LED INDICATOR al LOADED CASSETTE Figure 4 8 Loading and Unloading Station Transport Assemblies The transport assembly moves the boats by pulling them through each process station within the instrument The transport assembly consists of four independently mounted transports inside the base of the instrument front back left and right Each transport functions the same but is independently controlled Various sensors tell the instrument where each boat is l
271. performed by the instrument after power up two hours after power up and then every 24 hours using the standard as its reference If the verification fails it will auto calibrate up to a specific range It will not perform a automatic calibration if identification cards are processing It waits until cards have completed and have unloaded If identification cards continuously process for 5 days the instrument will generate an error message stating that the fluorescence is approaching calibration limits Figure 4 40 shows a cross section of the FL optical system 3mm Bore Xenon Flashlamp e d Elliptical Reflector coated plastic Detector Board Silicon Photodiodes 445nM Bandpass Filter 365nM Bandpass Filter Lens 5mm l UV Cold Mirror gt UV Cold Mirror A Beamsplitter 365nM Bandpass Filter Sample Well Cover Glass L Optical Shuttle 365nM Reflector Solid Reference Figure 4 40 FL Optical System Cross Section S NOTE Both the TX and FL optical systems should be cleaned periodically using lens paper or an alcohol pad with the excess liquid squeezed out followed by the lens paper 4 38 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Four System Components Waste Collection Station s The waste collection station is located above the cassette load unload station at the front of the instrument The VITEK 2 60 includes one waste collection station and the VITEK 2 120 includes two Acce
272. pipettor tips the firmware believes are available in the instrument the current duty cycle of the exhaust fans located on the back of the instrument the total number of cards read by the instrument and the total number of boats processed See Figure 6 46 VTK2 A gt comp_status Component NVStatus Cycles Vacuum ENABLED 1163 Sealer ENABLED 1360 Pipettor ENABLED 8166 Diluter ENABLED 8169 BarCode ENABLED Version 2 Stacker A ENABLED AL A ENABLED TX1A ENABLED TX2A ENABLED TX3A DISABLED F LRA ENABLED Low Batt Signals 1 Power Fail Signals 1 Diluent level 350 350 100 Tip Count 350 350 1005 Exhaust Fan Duty Cycle 0 Total Cards Cycled 4170 Total Boats Cycled 2923 Failures 3 0 O 2 Figure 6 46 COMP_STATUS 6 52 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Six Troubleshooting COMP STATUS RESET If COMP_STATUS_RESET is entered it will display WARNING Resetting System Status Registers and ask Do you wish to continue Y N If Y is entered the cycles and failures for the Vacuum Sealer Pipettor and Diluter the number of Power Fail and Low Battery signals from the instrument UPS and the total number of cards reads by the instrument will be set to O To zero the total number of boats processed it is necessary to use the BOAT STATUS RESET command COM STATUS COM_STATUS indicates the status of communication between the instrument and the
273. placement Refer to Figure 5 2 for the Power Switch Fuses location Removal 1 Turn the instrument power switch off and unplug power cord from the instrument 2 Note the voltage setting on the fuse block and with a flat blade screwdriver pry open the access over for the fuses Note the position of the fuse block and pull out the fuse block Remove defective fuse Fuse Access Slot Fuse Block insert screwdriver blade into Pull fuse block slot and twist to open the straight out fuses access cover Access cover open Figure 5 2 Main AC Power Switch Fuse Replacement Installation pace Replace fuse in the fuse block The Power Switch should include one MDA 5A 250V fuse for the 1 15V setting and two GDC 5A 250V fuses for the 230V setting Install fuse block into the power switch housing as noted from the removal Close access cover over the fuse block Plug the power cord into the instrument power connection plug Ensure the instrument is ready to be started turn switch ON and verify system operation VITEK 2 amp VITEK 2 XL System Service Manual 5 7 Rev 0100 Chapter Five Component Installation Power Supply Drawer Assembl This replacement procedure will be common to all the components contained inside the Power Supply Drawer Assembly See Figure 5 3 WARNING Power supply is heavy support the cabinet firmly at all times while handling the power supply cabinet Power supply cabinet weighs 14
274. play of the boat between the back rail and the paddle just is removed 3 2 1 Place an empty boat in the front left corner of the base pan Note Raise paddle by hand if necessary to place boat in this position 3 2 20 Atthe Prompt type ALIGN_LTRANS and hit Enter This starts the left transport alignment routine 3 2 3 Following the prompts on the screen position the boat as requested and adjust the left transport so the boat is just barely touching the back rail Do not force the boat into the rail under pressure from the paddle Caution The boat will naturally want to tilt when it is moving towards the back rail This is normal It is important for this alignment that the boat stay tilted and not be squared up against the back rail of the base pan If you accidentally square up the boat during this alignment change the step size to 100 and move out O twice This will allow the boat to tilt as is does normally 3 2 4 Press Enter when done to save the adjustment If the paddle does not look centered in the boat pocket after completion of this alignment then recheck alignment belt tension or transport itself for problem 3 3 Back Transport When the back transport is properly aligned the paddle will cause the boat to just touch the right side rail The free play of the boat between the right side rail and the paddle just is removed 3 3 Place an empty boat in the back right corner of the base pan Not
275. ps Unpacking Procedure The recommended procedure for removing the VITEK ZP from its shipping container is to 1 Cut the fastening straps that are wrapped around the shipping crate Carefully remove and discard the straps VITEK 2 amp VITEK 2 XL System Service Manual 2 1 Rev 0100 Chapter Two System Setu 2 Carefully remove the shipping container top from the bottom mounting skid and set aside Be extremely careful to not damage the instrument or the container top 3 With the container top removed remove the shipping bag and any other shipping material 4 With at least one person on each end carefully lift the VITEK 2 using the hand hold pockets and move away from the bottom skid and end cap Place the instrument in the desired location PROPER HAND HOLD LOCATIONS Both Ends of Instrument Figure 2 1 Proper Hand Hold Locations Installation Procedure After completing the unpacking procedure the VITEK 2 integrated system is ready to be placed in its permanent location The VITEK Z is intended for use on any normal flat bench top commonly found in the microbiology lab The bench top must be capable of supporting the weight and size of the instrument The following should be performed in preparing the VITEK 2 integrated system instrument for use WARNING The WITEK 2 instrument s power source must be properly grounded Cg NOTE See Appendix G for VITEK 2 Installation Checklist 2 2 V
276. pt type CAROUSEL A and hit Enter This will redirect all autoloader alignment commands to Autoloader A You may complete the rest of this section to align Autoloader A then return back to this point 12 1 2 For a 120 after Autoloader A has been aligned type CAROUSEL B and hit Enter to redirect all autoloader alignment commands to Autoloader B You may complete the rest of this section to align Autoloader B 12 2 Autoloader Stroke The Autoloader is properly aligned when it will stop just short of pressing on a test card that 1s setting 1n the carousel slot in front of the carousel load opening 12 2 1 Atthe Prompt type CARO INIT and hit Enter This will initialize the carousel and move it to slot 0 You may skip this step if you have just done this during Cam Stroke alignment 12 2 2 Remove the incubator access cover and install an empty blank 64 well card into the center most carousel slot of the exposed quad You may skip this step if you have just done this during Cam Stroke alignment 12 2 3 Atthe Prompt type CB 52 andhit Enter This will move the card directly in front of the load slot at bottom of incubator 12 2 4 Atthe Prompt type ALIGN AL and hit Enter 12 2 5 Following the prompts on the screen move the Autoloader in or out as needed so it just does touch the card The Autoloader should not apply any pressure to the card at all Note Press the H
277. r 3 Remove two of the carousel quadrants to expose the right side of the right hockey table plate With the instrument turned off it 1s easy to turn the belt drive assembly by hand positioning the quadrants for removal 4 Loosen and remove the 5 screws securing the right hockey table plate Remove the plate 5 Tag and disconnect the motor wires attached to the carousel SPN board 6 Loosen and remove the two mounting screws securing the heat sink motor bracket to the incubator assembly Remove the bracket and motor 7 Loosen and remove the four screws mounting the stepper motor to the heat sink motor bracket Note the motor orientation to bracket 8 Measure and note the distance of the drive pulley mounted on the motor drive shaft 9 Loosen the pulley set screws and remove from the motor shaft 10 Discard the motor INCUBATOR ASSEMBLY INCUBATOR MOTOR Figure 5 17a Incubator Motor VITEK 2Z amp VITEK 2 XL System Service Manual 5 29 Rev 0100 Chapter Five Component Installation Installation 1 Install the motor pulley on the motor shaft to the distance measured during removal of motor After applying threadlocking adhesive place set screws of motor pulley over flat spots of shaft and tighten set screws securely 2 Mount the replacement stepper motor to the heat sink motor bracket in the same orientation as removed 3 Place the motor and bracket in its mounting position on the incubator Inst
278. r zo SPN Pipetter g OPN Carousel Ribbon Cable DB9 Conn Left Trans no SPN 24 Pin Ribbon Cable m UPS I F 16 Pin Ribbon Cables J6 J8 J17 J23 SPN Board Connectors I W11 DB9 Conn DC Power Supply Board Figure 4 46 VITEK 2 System Electronics and BCB Connections VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 4 45 Chapter Four System Components Vitek 2XL System Electronics LCD Assy see HCB A diag User I F DB9 Conn FL Power Supply J1 Ji 2 Wire W8 Harness 40 Pin TP 2 Wire Harness see HCB B diag DB9 Conn FL Power Supply 34 Pin TP 4 Wire 14 Pin TP Ribbon Cable Ribbon Cable Harness Ribbon Cable 14 Pin TP 34 Pin TP 4 Wire a W9 T P6 P1 Ribbon Cable Ribbon Cable Harness 10 Pin TP Ne Ribbon Cable DB25 Conn P5 Diluter Bay Controller Board BCB SCS I F Carousel A 14 Pin TP PIC Ribbon Cable P4 J10 SPN w1 Reader 24 Pin TP Ribbon Cable A SPN We Carousel B 10 SPN Reader B SPN UPS I F J4 J6 J8 J17 J23 SPN Board Connectors W11 DB9 Conn DC Power Supply Board Figure 4 47 VITEK Z XL System Electronics and BCB Connections 4 46 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Four System Components Figures 4 48 and 4 49 show the instrument jumper configurations HEADER Figure 4 48 VITEK Z BCB Jumper Configuration
279. r Cable P N 186075 10 e Terminal or PC capable of VT 100 terminal emulation and the appropriate RS 232 cable to attach terminal or PC to 25 pin female connector labeled diagnostic on Vitek 2 cable e One Pipettor Diluter Accessory Kit P N V1219 e Four Quads 60 Eight Quads 120 P N 533208 1 or 533272 1 e One Boat P N 531106 1 e One Cassette w button memory installed P N 530136 1 e Fifteen 12 x 75 mm plastic test tubes P N 396547 1 e Fifteen 64 well cards at least two of which must be bar coded P N 001021 1 or 001022 1 e One 3mm alignment pin P N 371342 1 e Hand tools including Phillips and slotted blade screwdrivers and set of metric Allen wrenches e Feeler Gage with a 0 002 thick blade E 6 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Appendix E Alignment Procedures 2 Alignment Setup This section will go through the necessary steps to prepare an instrument for alignment In most cases this section will have to be performed prior to performing any of the remaining sections in this procedure 2 1 2 2 2 3 Instrument Configuration The instrument must be properly configured before it can be aligned This sub section may be skipped for instruments which have been configured and aligned once before 2 1 1 Refer to document 530602 to verify that all boards are jumpered correctly Instrument should be off Disposable Installation The instrument must have quads straws a
280. r SPN board N VAC VAC SEAL SPN board N_SEAL VAC SEAL SPN board N_AL Reader SPN board N_CAM Reader SPN board N_STACKER Reader SPN board N_READER Reader SPN board N_CARO Carousel SPN board N_INCU Carousel SPN board N_EJECTOR Carousel SPN board VITEK 2 amp VITEK 2 XL System Service Manual 6 41 Rev 0100 Chapter Six Troubleshootin SPN SENSORS SPN SENSORS can be used to diagnose optical switch sensors For example if it was necessary to verify the instruments right lid sensor was working first the Right Transport SPN Board should addressed as the current node Then after the SPN SENSORS command is executed a table describing the connector location on the SPN Board plus the present state of the sensor will be displayed See Figures 6 34 to 6 40 WS IZ SN x J4 J14 THES J16 Left Transport Motor Left Paddle Motor Front Paddle Motor Boat Sensor Left Lid Pronk Transport MOCOr Front Transport Encoder Home Home clear closed clear Figure 6 34 SPN SENSORS for Node 2 Front Left Transport SPN gis IZ gea J4 up gis JLG Right Transport Motor Right Paddle Motor Back Paddle Motor Cassette Sensor Right Lid Back Transport Motor Back Transport Encoder Home Home clear closed clear Figure 6 35 SPN SENSORS for Node 3 Back Right Transport SPN J3 Js cis os os J4 Jl54 6 42 Tdi Motor Pump Motor Lip Motor Rotor Motor Drum Motor Pump Motor
281. r describes the components of the system and their operation It contains the descriptions of the boards and the major subassemblies Chapter Five Component Installation This chapter describes how to remove install and mechanically align the subassemblies that may be encountered during repair of the VITEK 2 integrated system Chapter Six Troubleshooting This chapter includes accessing and applying dml commands used in troubleshooting and diagnosing instrument failures along with displaying system statuses VITEK 2Z amp VITEK 2 XL System Service Manual 1 1 Rev 0100 Chapter One Organization of the Manual This chapter also represents a General Troubleshooting Table for the VITEK 2 integrated system error detecting and reporting system This Table lists the malfunctions and the actions to be taken Following these chapters are appendices listing procedures for decontamination cleaning board layouts and schematics and alignment calibration procedures You will also find a glossary of terms in the back of the manual After completing this service manual you should be able to do the following Identify the VITEK and the VITEK Z XL integrated system instruments and independent subsystems Determine the instrument flow path and explain each subsystem operation Troubleshoot errors in the VITEK 2 integrated system module Determine and perform alignment calibration procedures for the VITEK 2 integrated
282. r exchange 5 54 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation CARD LEDGE MOUNTING SCREWS a iv N a SPRING LOADED MOUNTING CLIPS 1 a T E CAPTIVE SCREWS Figure 5 35 TX Optics Module Placement Installation l Carefully install the TX optics module s into the reader head assembly Order is important See Figure 5 35 2 Install the mounting screws attaching the optics module s to the frame 3 While supporting each of the optics modules one at a time push the clamp lever on the top of each of the TX optics modules and the FL optics module Gently allow the optics to hinge down 4 Manipulate the belt up and over the optics and reposition the belt around the roller plate assembly 5 Install the reader ledge on to the frame and tighten the three captive screws 6 Carefully close each of the optics modules until the clamp lever locks in place ensuring the drive belt is 1n the proper position on the rollers 7 Position and tighten the motor so the belt tension is the same as noted earlier Open the optics to check the belt tension and rotate the motor shaft and pulley checking the force required 8 Re connect the flat cables to the TX optics and snap the Reader SPN board back onto the standoff posts 9 Re install the Diluter Cover including the saline bag and then re connect the drain tube 10 Close the top access do
283. r to Figure 5 13 for an example of the diluter pulley motor Removal 1 Open the large access door to expose the diluter assembly 2 Tag and disconnect the motor wires attached to the diluter SPN board VITEK 2 amp VITEK 2 XL System Service Manual 5 23 Rev 0100 Chapter Five Component Installation 3 Press on the middle of the timing belt and make a mental note of the tension Also turn the pulley and motor shaft and make a mental note of the force required to turn it by hand The belt will need to be adjusted accordingly after the replacement motor is installed 4 Loosen and remove the two screws securing the diluter pulley motor assembly to the diluter dispenser assembly 5 Remove the timing belt and the diluter pulley motor assembly 6 Loosen and remove the four mounting screws attaching the stepper motor mount to the motor Note the motor orientation to motor mount 7 Measure and note the distance of the drive pulley mounted on the motor drive shaft 8 Loosen the pulley set screws and remove from the motor shaft 9 Discard the motor Figure 5 13 Diluter Pulley Motor Installation 1 Install the motor pulley on the motor shaft to the distance measured during removal of motor After applying threadlocking adhesive place set screws of motor pulley over flat spot of shaft and tighten set screws securely 2 Mount the motor to the stepper motor mount using the four mounting screws in the same orientation as remove
284. raise the sealer wire 9 1 6 Remove the cassette containing the 15 cards 9 2 Sealer current The sealer must conduct 8 5 amps through the sealer wire in order to reach the correct temperature 9 2 1 Atthe Prompt type LOOPK TEST SEALER and hit Enter This will turn on the sealer current and display it to the screen 9 2 2 Adjust R14 on the Vacuum Sealer PCB until the screen displays 8 5 0 1 amps 9 2 3 Pressthe Space Bar toendthe LOOPK TEST SEALER command and get the Prompt back VITEK 2 amp VITEK 2 XL System Service Manual E 23 Rev 0100 Appendix E Alignment Procedures 10 Carousel 10 1 Carousel Selection If aligning a 60 then skip this sub section If aligning a 120 this sub section is required 10 1 1 For a 120 atthe Prompt type CAROUSEL A and hit Enter This will redirect all carousel alignment commands to Carousel A You may complete the rest of this section to align Carousel A then return back to this point 10 1 2 For a 120 after Carousel A has been aligned type CAROUSEL B and hit Enter to redirect all carousel alignment commands to Carousel B You may complete the rest of this section to align Carousel B 10 2 Home Offset The home offset is properly aligned when the first topmost carousel slot of the quad that is still within the housing upper left quad is centered on the reader head drive mechanism and the card ejector Note It is important
285. re discussed in Chapter Four Figure 3 3 and Figure 3 4 illustrates a block diagram of the VITEK Z instrument transport system flow and station locations B VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Three System Overview CARD SEALER STATION VACUUM STATION DISPENSER PIPETTOR STATION CASSETTE SCAN STATION User Interface AUTOLOADER amp READER INCUBATOR STATION WASTE COLLECTION STATION LOAD UNLOAD STATION Figure 3 3 VITEK 2 60 Station Block Diagram CARD SEALER STATION AUTOLOADER amp READER INCUBATOR SECTION A VACUUM STATION DISPENSER PIPETTOR CASSETTE SCAN STATION STATION User Interface WASTE COLLECTION STATION SECTION A LOAD UNLOAD STATION SECTION A AUTOLOADER amp READER INCUBATOR SECTION B WASTE COLLECTION STATION SECTION B LOAD UNLOAD STATION SECTION B Figure 3 4 VITEK 2 120 Station Block Diagram VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 3 3 Chapter Three System Overview User Interface System A keypad and screen shown in Figure 3 5 are located on the front of the VITEK Z The VITEK 2 uses the screen to send you messages about its operation on board disposables and possible problems You use the keypad to respond to VITEK 2 instructions send commands to the VITEKe2 and perform other functions LCD Display Screen Function Buttons
286. replacement belt will need to be adjusted accordingly 3 Loosen the four mounting screws attaching the motor to the motor mount bracket Slide the motor to loosen the timing 4 Remove the belt from the motor pulley and discard belt VITEK 2 amp VITEK 2 XL System Service Manual 5 19 Rev 0100 Chapter Five Component Installation MOTOR TIMING BELT BELT TENSION ADJUSTMENT SCREWS ON DRIVE MOTOR Figure 5 11 Example Timing Belt Installation 1 Install the new drive belt on the pulleys 2 Position and tighten the motor so the belt tension is the same as previously noted Rotate the motor shaft and pulley checking the force required to turn Be sure not to over tighten belt 3 Close the access doors or covers that were removed earlier 4 Ensure the instrument is ready to be turned ON and verify the system operation 5 Verify alignments See Appendix E Alignment Procedure Pulley Motors The VITEK 2 60 instrument has fourteen motors that use belts and pulleys and the VITEK 2 120 has sixteen The motor assembly is identical for each of these different tasks Paddle Motor qty 4 Transport Motor qty 4 Diluter Motor Pipettor Vertical Motor Pipettor Pivoting Motor Vacuum Motor Incubator Motor qty 2 for 120 Reader Head Motor qty 2 for 120 99 9 9 9 9 9 5 20 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation The following is a list of the Step
287. ring the following steps Initializing the pipettor See pip init Rotating drum so a pipette tip falls into drum slot Extending taper pin to insert into pipette tip Verifying the presence of pipette tip by performing vacuum check using pressure transducer Engaging solenoid to retract horizontal slide The rotor motor rotating the pipettor snout a pre aligned number of steps counterclockwise so the pipette tip 1s in the down position VITEK 2 amp VITEK 2 XL System Service Manual 6 17 Rev 0100 Chapter Six Troubleshootin A GET failure will occur during the following steps The vertical motor lowering the pipette tip into a pre existing volume of liquid in a test tube The pipettor pump extracting the specified amount of liquid The vertical motor raising the pipette tip from the test tube Verifying presence of liquid in pipette tip by performing pressure check with pipettor pressure transducer A PUT failure will occur during the following steps The vertical motor lowering the pipette tip into a test tube with pre existing liquid The pipettor pump evacuating the liquid from the pipette tip into the test tube and then extracting some of the mixed liquid The vertical motor raising the pipette tip The vertical motor lowering the pipette tip into the mixed liquid completely evacuating the pipette tip and mixing liquid with forced air from the pump The vertical m
288. roblems For practical purposes the VITEK 2 label will be used in this manual when information applies to both the VITEK 2 and VITEK 2 XL If there is additional or different information specifically for the XL it will be denoted as VITEK 2 XL This chapter explains how the manual is organized and how to use the manual The Table of Contents lists all the chapters in this manual Each chapter is subdivided into heading levels corresponding to a procedure or description Organization of the Manual The information in the manual is organized into six chapters They are arranged so that the information you need first is in the beginning of the manual Information required for maintenance after the system 1s operating 1s found in later chapters The following is a brief outline of what you will find Chapter One Organization of the Manual This chapter explains how the manual is organized and how to use the manual Chapter Two System Setup This chapter is a complete guide for the installation and setup of the VITEK 2 integrated system It begins with the unboxing of the instrument and proceeds through its power up and configuration This chapter also contains environmental spatial and electrical requirements Chapter Three System Overview This chapter introduces the VITEK 2 integrated system hardware and describes the basic parts of the software system Chapter Four System Components This chapte
289. rom the readings Total Number of Lamp Flashes Indicates that the lamp has flashed 2744180 times When a lamp is changed this value should be reset to 0 by entering FL TOTAL FLASHES O at the diagnostics prompt Flash sector erase cycles Indicates that 16 erases have been performed on the Bay Controller board memory Each time the fluorescence history is updated with a new Gain solid DAC or Soft offset calibration performed by the automatic internal validation this number is incremented It only tracks the number of erase cycles of the FLASH ROM sector this number should not exceed 100 000 Calibrations Targets Indicates the values used by the calibration routines The calibration routines adjust the parameters below until the values above are reached Target Shuttle Calibration Values shuttle finger print Indicates the value that the shuttle solid standard reads when the system is calibrated These values are used to calibrate the system between liquid calibrations Liquid Calibration Setting Indicates the settings of the last liquid calibration Current Settings Indicates current settings from the fluorescence calibration When the instrument is powered on the calibration is validated Then it validates calibration again after 2 hours and then every 24 thereafter until power is cycled If cards are processing it will wait for them to complete before performing calibration validation Ref Pot Indic
290. rousel To enable this function type SBOAT SIM LOAD 1 and press ENTER Once finished with this tool type SBOAT SIM LOAD 0 and press ENTER to disable this function WARNING It is imperative that BOAT_SIM_LOAD 0 or COLD is performed prior to leaving instrument so cards will be loaded properly TRANS The TRANS command is used in conjunction with keywords These keywords tell the transport to achieve a specific task at a specific location Following are the arguments and keywords with a description of how they are used Arguments Description lt a gt F B L or R Front Back Left amp Right transports lt c gt 1 15 representing the card position on the cassette lt n gt a number of steps lt p gt the pocket location on the corresponding transport See Figure 6 9 VITEK 2 Transport Pocket Locations amp Figure 6 10 VITEK 2 XL Transport Pocket Locations Keywords Description TRANS B lt c gt With the front transport position card lt c gt at the bar code reader TRANS C lt a gt Performs a check home command to the front back left or right transport displaying any lost steps TRANS D lt c gt With the front transport positions card lt c gt at the diluter TRANS H lt a gt lt p gt Hooks the given transport boat pocket See Figure 6 9 VITEKe2 Transport Pocket Locations and Figure 6 10 VITEK 2 XL Transport Pocket Locations TRANS I a Initializes the front back left or right transport TRANS J
291. s 0 Seals EMPEY Paddle Current Spot SPOT 5 0 Total Cycles 42 Retries 0 Failures 0 OLSGLUS Empty Paddle Current Spot SPOT 4 0 Total Cycles 43 Retries 0 Failures 0 Status Empty Paddle Current Spot SPOT_1 0 Total Cycles 41 Retries 6 Failures 0 otaLusti EMPEY Paddle 1 4 Figure 6 5 BOAT_STATUS Current Spot SPOT_1 0 Total Cycles 41 Retries 6 Failures 0 The SPOT is the current boat position There are 6 boat positions on the VITEK 2 and 8 boat positions on the VITEK 2 XL See Figure 6 6a VITEK Z Boat Spots positions and Figure 6 6b VITEK Z XL Boat Spots positions In this case the boat is in spot 1 The 0 following the colon indicates the sub spot There are many sub spots on the front and back transport for card preparation 1 e bar code positions diluter position pipettor position auto loading position etc When the transport system is not processing cards it is in an idle state When the VITEK 2 is in an idle state the proper boat positions are spots 1 4 5 amp 6 When the VITEK 2 XL is in an idle state the proper boat spots are 1 5 5b amp 6 Total cycles indicates how many times the boat has circled the transport A retry is a Jam that has been recovered by the instrument without user intervention A failure 1s a jam that has not been recovered by the instrument without user intervention VITEK 2 amp VITEK 2 XL System Service Manual 6 7 Rev 0100 Chapter Six Troub
292. s Undefined Updating database will appear for a few moments d Type the corresponding internal serial number for the new BCB and press ENTER This can be identified by the Device e Finally type the Number that the VITEK Z should be associated with and press ENTER Refer to your note made in step b Updating database will appear for a few moments f Press q ENTER to exit from Instrument Association and press q ENTER to exit from VITEK 2 Setup VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation 8 From the Diagnostics display of the corresponding VITEK 2 type file request BCB_Firmware mot and press ENTER NOTE This command updates the BCB firmware and is case sensitive Uploading the flash from the Work Station to VITEK 2 will take 35 40 minutes 9 From the Diagnostic prompt type fix spn params and press ENTER This updates the SPN parameters as determined by the BCB firmware 10 From the diagnostic prompt type FILE REQUEST followed by the old BCB serial number noted in step 7b and CFG Press ENTER Example FILE REQUEST 00000388740A CFG This command updates Fluorescence Calibration instrument computations and user interface selections from a 24 hour backup residing on the work station DC Power Supply Board Replacement Refer to Figure 5 7 for the location of the DC Power Supply Board Removal 1 Open the top left door of the instrument to access the DC Power Suppl
293. s Yes Touch Memory Yes Yes Bar Code Yes Yes Inside Temp Yes Yes Host Comm Yes Yes Power Fail Yes Yes Low Batt Yes Yes Figure 2 11 VITEK Z XL with TX1 TX2 amp Fluorescence Installed in Section A and TX1 Installed in Section B 2 14 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Two System Setu 4 Verify proper functioning of the instrument circulation fans at the diagnostic window prompt by typing fan 100 and press ENTER Verify the left fans blows into the instrument and the right fan blows outward In approximately one minute the fan will default back to its appropriate speed based on the ambient temperature of the instrument 5 Type ver at the diagnostic prompt and record the firmware versions of Bay Controller Board BCB SPN amp Boot This can also be found at the instrument by selecting Utilities Diagnostics and Version Information from the main menu of the user interface screen 6 Verify incubator temperature at the diagnostic window prompt by typing pr ave incu temp and press ENTER See specifications described later in the chapter This can also be accomplished at the instrument by selecting Utilities Diagnostics and Temperature from the main menu of the user interface screen When the instrument reaches it s required average incubator temperature the instrument Status will change from WARMING to OK CE NOTE The VITEK 2 is given 30 minutes to reach the proper temperature If th
294. s for incubation and reading Before a test card can be incubated and read the wells and channels inside the card must be sealed off from the outside environment This is accomplished by heat sealing the transfer tube that delivered inoculum to the card from its test tube As the boat and cassette move through this station a heated nichrome wire comes in contact with each transfer tube The plastic tube melts causing the majority of it to separate from the card and drop into the test tube The portion that remains in the card is sealed by the melting plastic The heat sealed stub left from the transfer tube is 1 2 5 mm long Figure 3 19 shows the card sealer station r NICHROME HEATED WIRE TRANSFER TUBE IE CARD SEALER STATION Figure 3 19 Card Sealer Station 3 14 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Three System Overview Autoloader amp Reader Incubator Station s After the cards have been sealed the boat and cassette will move to the Incubator Loading Station The components of this station are the carousel incubator and the optics system See Figure 3 20 The VITEK 2 60 includes one Autoloader amp Reader Incubator Station The VITEK 2 120 consists of two Autoloader amp Reader Incubator Stations Section A amp B AUTO LOADER amp M READER INCUBATOR STATION Loss T jum i tte Figure 3 20 Autoloader amp Reader Incubator Station When a bo
295. s modules push the clamp levers on the top of each of the TX optics modules Gently allow the optics to hinge down Press on the belt where the optics sit and make a mental note of the belt tension Also turn the motor shaft and pulley of the reader head motor and make a mental note of the force required to turn it by hand When re assembling the belt will need to be adjusted accordingly Unscrew the three captive screws from the reader ledge and remove the ledge from the reader frame Close the TX optics modules until the clamp levers lock in place Note the placement of the timing belt on the reader head Loosen the timing belt motor and push it upward adding slack to the belt Disconnect the peak detector ribbon cable from the head controller board Also disconnect the peak detector ground cable from the card reader frame Remove the three mounting screws attaching the peak detector assembly to the card reader frame Carefully slide the peak detector and the peak detector cable from the reader optics frame Set the FL modules aside to return for repairs or exchange VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation pe MAL __ fcaerive SCREWS g re CARD LEDGE MOTOR DRIVE BELT TENSION ADJUST SCREWS Figure 5 38a Fl Optics Component Locations FL AUTO CAL ASSEMBLY Figure 5 38b Peak Detector Location VITEK 2Z amp VITEK 2 XL System Service Manual 5 59
296. se any access covers or doors previously removed 4 Ensure the instrument is ready to turn on and verify the sensor is operating properly 5 46 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation Transport Assembly Component Replacement The transport replacement and installation procedures are grouped together due to the consistency of their use in the instrument The specific location of each of the transports will require the user to open or remove panels to access the area they serve All transports for the most part operate identical The only change would be in the physical length or bracket construction of the specific transport All of the transport assemblies have mounting screws and bases along with a drive motor motor drive belt transport paddle drive belts positioning sensor and associated wiring from the motors for connection to the SPN board Refer to Figure 5 28a and Figure 5 28b for location of the transports TRANSPORT HORIZONTAL TRANSPORT ASSEMBLY DRIVE BELT TRANSPORT MOUNTING SCREWS Figure 5 28a Transport Replacement Motor End View 5 adi TRANSPORT ASSEMBLY EXE et BA MOUNTING pA SCREWS Figure 5 28b Transport Replacement Opposite End View VITEK 2Z amp VITEK 2 XL System Service Manual 5 47 Rev 0100 Chapter Five Component Installation Transport Paddle Drive Belt Refer to Figure 5 29 for the location of a transport paddle dri
297. sel hub Align the notch to the spring loaded locking pin as shown in Figure 5 33 REMOVAL CAROUSEL QUADRANT P ALIGNMENT SLOT Figure 5 33 Carousel Quadrant Replacement 5 52 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation 3 Position and push the quadrant section until the quadrant locks into place on the carousel hub spring loaded locking pin Figure 5 34 QUADRANT PROPERLY f IN PLACE 4 Figure 5 34 Carousel Quadrant Properly in Place 4 Install the Incubator Access Cover and close the instrument covers VITEK 2 amp VITEK 2 XL System Service Manual 5 53 Rev 0100 Chapter Five Component Installation Optics System Component Replacement The optics system component replacement procedures are written to allow you to make the required replacements as efficiently as possible Each component of the optics system is not included in these procedures however the main items are covered in a simple and sequential step by step approach for the components that are field replaceable Transmittance TX Optics Replacement Refer to Figure 5 35 for location of the TX optics Removal 1 Open the top covers of the instrument 2 Disconnect the drain tube from the Diluter Cover and then unscrew and move the Diluter Cover including the saline bag to the side 3 Tag and disconnect the ribbon cables that are plugged into both sides of the TX opti
298. sensors operate identical The only change would be in the physical positioning or mounting See Figure 5 26 for an example of the Reflective Sensor Table 5 7 lists the reflective sensor wiring configuration Reflective Sensors Loading Station Cassette Detector p n 530161 1 Left Front Boat Sensor Assy p n 530181 1 Stacker Cover Sensor Vitek 120 p n 530181 1 Table 5 7 Reflective Sensor Pin and Wiring REFLECTIVE SENSOR WIRING 1 5VDC Detector N C 2 Negative Emitter Black 3 Positive Emitter Red 4 Ground detector Green 5 Sense Out Detector White Removal 1 Open the front door s or remove any access cover s of the instrument to access the reflective sensor 2 Tag and disconnect the sensor cable attached to the respective SPN board Note the mounting position 3 Remove the screw and lock washers holding the sensor and remove the sensor from the mounting bracket 5 44 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation BOAT SENSE REFLECTIVE SENSOR Figure 5 26 Example Reflective Sensor Installation l Place the new reflective sensor onto the mounting bracket in the position as noted from the removal Install the mounting screws The loading station cassette detector should be located 2 2 5 mm from edge of Daily Panel If the left front boat sensor assembly is mounted to the boat sensor bracket 1t should mount flush with the
299. sing if currently in a paused condition Cards will begin to be read EJECTOR INIT EJECTOR INIT initializes the ejector to its ejector home sensor If the cycle is completed without errors no message will be displayed EJECTOR CYCLE EJECTOR CYCLE performs an ejector cycle CAM CYCLE CAM CYCLE performs a cam cycle STACKER SIACKER INIT STACKER INIT initializes the push plate to its stacker push plate home sensor If the cycle is completed without errors no message will be displayed STACKER CYCLE STACKER CYCLE performs a stacker cycle 6 38 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Six Troubleshooting FLASH LOG The instrument log 1s located on the Bay Controller Board BCB and is stored in the flash memory It can include up to 128k of data Once the flash log is full the oldest logged information will be overwritten Each line of the flash log is formatted the same way and includes a variety of information such as instrument communication processing alarms doors opening user interface entry interment power up and firmware updates The first entry on each flash log line is either ALM or LOG An ALM line indicates an alarm message that occurred on the instrument A LOG line details instrument activity not generating alarm messages There may be a LOG line before or after the ALM line with detailed information for troubleshooting The time stamp 1s the second entry on each flash l
300. sing DML Using Diagnostic Terminal of the Work Station 1 Atthe bioM rieux bioLIAISON Main Menu select System System Maintenance and Diagnostic Terminal 2 The following menu will appear Connection TTY List Enable logging no List AV gt 2 comii isol 132x40 bist AV 3 Press the List button located across from Connection TTY All the TTY ports configured for diagnostics communication will be displayed in a pop up window 4 Select the associated tty port the VITEK ZP instrument diagnostic cable is plugged into on the Work Station Refer to Table 2 2 for Proper TTY Connections VITEK 2 amp VITEK 2 XL System Service Manual 6 1 Rev 0100 Chapter Six Troubleshootin 5 If you wish to enable logging press the arrow button to change the no to a yes Enable Logging If Yes is chosen the Work Station will keep a captured log of the diagnostics terminal session When the diagnostics terminal is closed a file will be created on the Work Station hard drive This file can be copied to a DOS floppy disk and read by a PC using the following procedure a Atthe dms prompt type cd tmp and press ENTER This will change the present working directory of the Work Station to tmp b Atthe dms gt prompt type 11 and press ENTER A list similar to the following will appear E w cr r X Boot system 10346 25 Dec 10700 Arxtermboq295YHBag drwxrwxrwx 2 root system 52 r5 Dee 2 997 varto drwxrwxrwx 2 root sy
301. slot alignment be such that they appear off center approximately the same amount left and right from the center as the 15 slots move past the reader head top card guide 10 3 5 Press Enter when done to save the adjustment Note You may now replace the carousel access cover rear access panel close all the optics modules release the card latch and replace stacker tray VITEK 2 amp VITEK 2 XL System Service Manual E 25 Rev 0100 Appendix E Alignment Procedures 10 4 Bottom Bias The bottom bias is properly aligned when a carousel slot is centered in the autoloader opening at the bottom of the carousel during a carousel slot load movement 10 4 1 10 4 2 10 4 3 10 4 4 10 4 5 E 26 Atthe Prompt type ALIGN CARO BOTTOM and hit Enter Following the prompts on the screen move the carousel left or right as needed so that the slots are centered with the card load opening in the bottom of the carousel The alignment software will automatically move to the next slot each time you make an adjustment Tip It is helpful to open the cassette load door half way and use a penlight to allow you to visually see how the carousel lines up with the autoloader opening in the carousel After completing alignment press G to check all 60 slots on all four quads Press the Space Bar to stop the slot cycling Note Make sure this 1s done with the carousel moving in a clockwise direction After c
302. sponse exit from kermit and check all connections and settings C NOTE These settings configure the modem to answer at 19 200 baud rate or 10 11 12 13 14 15 lower with software flow control Type at amp w and press ENTER to save the settings The monitor should again display the response OK Exit from kermit by pressing the CTRL and keys simultaneously immediately followed by the letter c Exit from the Command Terminal window Turn the external modem off Place all the modem switches in the up position Turn the external modem on Connect the modem to a dedicated analog phone line and label the modem with the corresponding phone number Verify Remote Diagnostics Connect PC modem to a separate analog phone line Open Hyper Terminal or an equivalent communications software package on the PC 3 Configure the communication package COM port as follows Terminal VT 100 Baud Rate as required Parity None Data Bits 8 Stop Bits 1 9 9 9 9 Dial the VITEK Z system modem phone number and wait for a connection A login prompt will appear if connected successfully 5 When login appears type dms and press ENTER 6 When password appears type dms and press ENTER The dms prompt should appear 7 From the dms prompt connect to the corresponding VITEK ZP diagnostic port This would be accomplished by typing either dml1 dml2 dml3 or dml4 and press ENTER See Table 2 4 2 12 VITEK
303. ss to the station s is gained by pivoting the waste collection door down The waste collection station consists of a waste collection tray a snap action sensor a stacker motor a stacker push plate a push rack home sensor a push plate and a stacker empty sensor Each station houses up to 60 cards which are held upright and tight by the spring loaded pressure plate and tray card stop as the tray fills A snap action sensor switch detects when the waste collection tray has been removed for emptying When the tray is replaced the control system starts a internal counter that monitors the cards ejected into the tray and alerts the operator when the tray approaches full Figure 4 41 shows the waste collection station and tray STACKER PUSH PLATE Figure 4 41 Waste Collection Station Upon completion of the card testing by the VITEK Z the test cards are ejected from the carousel and are transported by the reader system to the waste collection area The stacker push plate fully extends placing the card between the card stop of the tray and a spring loaded pressure plate completing the card ejection cycle VITEK 2 amp VITEK 2 XL System Service Manual 4 39 Rev 0100 Chapter Four System Components Figure 4 42 shows the card ejector area CARD STOP Figure 4 42 Card Ejection Area CE NOTE The waste collection tray should be emptied whenever a new cassette is loaded into the instrument and also should be cleaned periodic
304. stem 512 15 Dec 02 00 gda mon c The filename containing AixtermLog is the captured log file Insert a floppy into the floppy drive of the Work Station From the dms gt prompt type doswrite AixtermLog XXXX log txt and press ENTER XXXX the corresponding extension d The file will be called log txt on the floppy and can be read using a PC and Notepad Wordpad or Word S NOTE To print this file directly from the Work Station it is only necessary to type Lp AixtermLog XXXX and press ENTER 6 Once all the fields are properly selected press the EXECUTE button A Diagnostics Terminal window will appear 8 Press the ESCAPE key twice on the Work Station to display the instrument DML prompt The prompt will be displayed with the given instrument name WARNING Pressing the ENTER key will execute the last command the instrument was given e To disconnect from DML either close the Diagnostic Terminal or press the CTRL and keys simultaneously immediately followed by the letter c WARNING Always disconnect when complete 6 2 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Six Troubleshooting Accessing DML Using Physical Connection From VITEK Z to PC 1 Connect the data diagnostic reader cable to the VITEK ZP instrument Connect the end of the cable marked DIAGNOSTIC to an available PC COM port 2 Open Hyper Terminal or an equivalent communications software package on the PC Configure
305. sure transducer continues to monitor the vacuum chamber pressure sending the voltage signal to the SPN board Ce NOTE Airis forced from inside the test card via the transfer tube and bubbles up through the suspension The channels and wells inside the test card are now in a vacuum 4 26 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Four System Components 7 After five seconds the proportional valve is opened gradually to raise the pressure inside the vacuum chamber The absolute pressure transducer continues to monitor the vacuum chamber pressure sending the voltage signal to the SPN board The continuously changing voltage is sampled by the SPN board at regular intervals and compared to the programmed rate Figure 4 29 to return to atmospheric pressure approx 60 seconds Ifthe rate of change is too fast a lower voltage signal is sent to the proportional valve closing down the valve to slow down the amount of air being drawn into the vacuum chamber to return to atmospheric pressure Ifthe rate of change is too slow a higher voltage signal is sent to the proportional valve which opens wider to speed up the amount of air being drawn into the vacuum chamber to reach atmospheric pressure tm NOTE The increasing air pressure inside the vacuum chamber forces the suspension in each test tube to flow through the transfer tube and into the channels and wells of the card 8 The proportional valve is opened 100
306. surface and clean Check solid state relay operation for vacuum pump replace as necessary Check voltage available to vacuum pump replace AC power board as necessary Check vacuum pump operation replace pump Verify vacuum chamber cycles up and down drive screws with no obstructions Check drive motor belt pulleys and motor operation Replace belt and or motor ensure proper sync of lead screw position Replace piping components tubing amp fittings Replace SPN board control 17 Sealer Alarms or Failures Check cutting wire integrity replace assembly if necessary Check Vac Seal SPN board integrity replace 1f necessary 18 Door latch problems Verify door sensor flag is not bent Check alignment of sensor flag to optical sensor Verify proper voltage to door interlock sensors solenoid while it is energized Check alignment to the load unload solenoid door lock plunger to the locking mechanism Verify proper voltage to load unload door solenoid while it is energized For door open message problems check the wiring of the door interlock sensors Verify power supply voltages Replace SPN board control 19 UPS Failure Check AC supply voltage to the UPS Check and verify communication cables and power cables properly installed VITEK 2 amp VITEK 2 XL System Service Manual 6 63 Rev 0100 pe MOTOR NUMBER Chapter Six Troubleshooting Motor Number and Name Listing MOTOR
307. system After completing the various chapters in this manual you should be able to complete the items listed under each chapter Chapter One You will be able to recognize the various typographic conventions used throughout the manual Chapter Two You will be able to describe how to unpack the VITEK 2 integrated system and prepare it for use You will be able to identify on sight all of the VITEK 2 integrated system specifications Chapter Three You will be able to state the general operating theory of the VITEK 2 integrated system module You will be able to describe the purpose of each of the following VITEK 2 subsystem stations User Interface System Load Unload Station Cassette Scan Station Dispenser Pipettor Station Vacuum Station Card Sealer Station Auto Loader amp Reader Incubator Station s Waste Collection Station s c S od oM oM od oco 1 2 VITEK 2Z amp VITEK 2 XL System Service Manual Rev 0100 Chapter One Organization of the Manual Chapter Four You will be able to identify the various internal components that make up the subsystems of the VITEK 2 integrated system Chapter Five You will be able to remove and install various components and subsystems of the VITEK 2 integrated system Chapter Six You will be able to access dml and apply commands to determine instrument statuses and troubleshoot problems You will be able to identify a malfuncti
308. t Front Boat Sensor MT3 Left Transport Home Switch SWA J19 J8 J4 if Front Motor B2 J18 J11 J7 J12 Blank E Left Transport Transport SPN Board Home Switch 530 04 SW1 vds J9 Blank TO E Al J13 Cabinet Fan Vacuum Sealer SPN Bd B6 amp DC Power Supply Bd Cabinet Fan B5 J6 J5 J2 J16 J3 J14 Front Left Paddle Paddle Left Lid Encoder Home Home Sensor Switch Switch Switch MT1 MT2 SW2 SW3 Figure B 8 Left Transport SPN Board B 14 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Appendix B Schematics and Diagrams Right Transport SPN Board Loading Right Station Right Transport Cassette Transport Motor Home Switch Sensor BTE MT6 SW8 J8 J11 J4 J1 Rear Transport Motor B8 Blank Blank J19 J18 e Right Transport Mero Transport SPN Board Switch 530 04 SW5 Right J9 Lid Sensor TO MTS Carousel SPN Bd run 600ny A2 J13 Blank pore HRS DC Pwr Supply Bd i 08120 a J6 J3 Blank Encoder Sensor MT4 Figure B 9 Right Transport SPN Board VITEK 2 amp VITEK 2 XL System Service Manual B 15 Rev 0100 Appendix B Schematics and Diagrams Diluter SPN Board Diluter
309. t as needed to center the pipettor tip over a test tube in position 15 of the cassette Tighten the two Phillips screws securely 7 8 6 Rotate drum back down to its horizontal position 7 8 7 Move the boat and cassette of tubes to the right so that the tube in position 4 1s now centered underneath the pipettor tip 7 8 8 Pressthe Space Bar toendthe PIP POINT command and get the Prompt back VITEK 2 amp VITEK 2 XL System Service Manual E 19 Rev 0100 Appendix E Alignment Procedures 7 8 9 Atthe Prompt type DIL DOWN PIP POINT and hit Enter This will rotate the diluter to the down position and lower the pipettor again 7 8 10 Slide the cassette to the right and center the test tube in position 4 under the pipettor point 7 8 11 Follow instructions for your Rifle type identified in a previous step Original Machined Rifle Loosen the Allen head set screw which clamps the support post located behind the diluter mounting plate and rifle just enough to allow for in and out adjustment without sag Using the center Phillips head screw on the front of the plate adjust the assembly in or out as needed to center the diluter shot tube over the test tube in position 9 of the cassette Verify the diluter plate did not rotate or sag then tighten the allen head set screw securely Newer Cast Rifle Loosen the Allen head set screw located directly above the center Philips head screw on the front of the diluter plate
310. t be performed prior to performing the Tilt down position sub section Note Associated tubing is not required on the diluent tube shot tube for this 6 1 6 2 6 3 E 14 alignment Tilt home position The shot tube must be centered in the sensor that senses the fluid level 6 1 1 Atthe Prompt type ALIGN DIL FLUID and hit Enter This will step the tube in and out of the sensor to find the center point This is an automatic adjustment Tilt down position When dispensing diluent the shot tube needs to be perfectly vertical to dispense fluid into a test tube 6 2 1 Atthe Prompt type ALIGN DIL DOWN andhit Enter This will tilt the shot tube down so that you can adjust how vertical it iS 6 2 2 Following the prompts on the screen adjust the shot tube position until the tube looks perfectly vertical by eye O will move the tube clockwise I counterclockwise Note This must be done after the tilt home position has been set in the previous sub section 6 2 3 Press Enter when done to save the adjustment Shot tube will move to approximately the two o clock position Pump home position The diluter pump must have enough free travel to properly dispense the fluid from the shot tube 6 3 1 Atthe Prompt type ALIGN DIL PUMP andhit Enter This adjustment is made automatically by the software If the terminal does not display successful on the screen then you h
311. t housing 4 Install the mounting screws 5 Move the Diluter Cover including the saline bag back into place and secure 6 Reconnect the drain tube 7 Close the access panels 8 Ensure the instrument is ready to turn ON and verify proper operation Refer to Table 5 1 for any voltage readings and test point information 5 18 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation Card Handling System The replacement card handling system component parts which we will cover in these procedures are very similar in physical steps for the specific area that they serve or control however they may be positioned or located throughout the instrument All the transporting motors are identical in manufacturer but the biggest difference is what they are driving Some motors are driving belts the others are gear or directly coupled to a device or component they are driving These components will include the following 9 9 9 9 9 Timing Belts Pulley Motors Gear Motors Direct Drive Drum Motor Positioning Sensors Transports Timing Belts Refer to Figure 5 11 for an example of a timing belt Removal Open or remove the access cover s from the area that exposes the timing belt you are replacing 2 Press on the middle of the timing belt and make a mental note of the tension Also turn the pulley and motor shaft and make a mental note of the force required to turn it by hand The
312. tate DIL FILL DIL FILL fills the dispensing tube with saline If the cycle is completed without errors no message will be displayed Dil fill includes The diluter motor rotating the dispensing tube counterclockwise to its home position The home position is determined when the diluter home sensor detects the flag on the diluter block Verifying the air read of the dispensing tube using the diluter sensor assembly Engaging the diluter solenoid allowing the saline to begin filling the dispensing tube Detecting the saline at the tip of the tube using the diluter sensor assembly Disengaging the solenoid stopping the flow of saline DIL EMPTY DIL_EMPTY empties the diluter dispensing tube If the cycle is completed without errors no message will be displayed Dil_empty includes The diluter motor rotating the dispensing tube a pre aligned number steps clockwise so the dispensing tube is in the down position Activating the diluter pump so it forces air out of the dispensing tube at a controlled rate Initializing the diluter DIL CYCLE Performs both the dil fill and dil empty commands If the cycle is completed without errors no message will be displayed 6 16 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Six Troubleshooting Dil_cycle includes The diluter motor rotating the dispensing tube counterclockwise to its home position The home position is determined whe
313. tational path of the dispenser tube assembly Verify dispenser tube full sensor is functioning replace if necessary Verify motor supply voltages on DC power supply board Verify and replace diluter pulley motor if required Verify wiring to the dispenser solenoid is intact Verify operating of the dispenser solenoid replace dispenser solenoid Verify diluter pump and check valve operation Replace SPN board control Check the drum for proper amount of tips and fill as necessary Check straw sensor pad in place and not loose Verify rotating fingers are functioning properly and delivering tips Replace rotating finger drive motor if necessary Verify hollow pipette tip not clogged bellofram pump and linear actuator functioning Verify pipettor pivoting home positioning sensor is functioning replace if necessary Verify vertical home positioning sensor 1s functioning replace if necessary Verify motor supply voltages on DC power supply board Verify no obstructions to the vertical column assembly Verify vertical column motor belt is installed pulley set screws tight Replace belt and or tighten pulley set screws VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Six Troubleshooting Table 6 2 General Instrument Troubleshooting Information con t MALFUNCTION GENERAL TROUBLESHOOTING ACTIONS 16 Vacuum System Alarms Check seal on the top vacuum chamber and clean Check boat or Failures
314. te The dispenser system consists of a 1000ml bag of sterile saline solution in the top center compartment of the instrument and a rotating dispenser assembly at the dispenser pipettor station The 1000ml bag of saline is connected to a disposable dispensing tube assembly The bag of saline holds enough solution to process about 330 susceptibility cards Volume tracking software will determine when the saline bag needs replacing and alert the user to this A drain in the compartment is furnished in the event the saline bag leaks solution A plastic tube allows the leaking solution to drain into the spill drawer of the base pan VITEK 2 amp VITEK 2 XL System Service Manual 4 17 Rev 0100 Chapter Four System Components Figure 4 19 shows the 1000 ml bag of sterile saline solution mounted in the top of the instrument STERILE SALINE BAG SOLUTION SALINE BAG COMPARTMENT Figure 4 19 1000 ml Sterile Saline Solution The dispenser assembly consists of a rotating dispenser mounting block assembly a diluter solenoid assembly a diluter pump assembly a diluter motor assembly an optical sensor board for detecting the dispensing tube saline level an optical sensor for the rotational fill position of the dispensing tube a sample prep node SPN board and a disposable dispensing tube assembly The disposable dispensing tube assembly includes a dispensing tube chamber two plastic tubes and a filter to prevent any particulate co
315. tempting this alignment This means the drive nuts should compress the foam washers equally when applying pressure to the vacuum chamber against a boat Place a boat with a cassette into left rear corner of the base pan underneath the vacuum chamber Note If necessary type VAC INIT and hit Enter This will raise the chamber if needed Atthe Prompt type ALIGN VAC DOWN and hit Enter This starts the chamber down alignment routine Following the prompts on the screen adjust the chamber position up and down as needed until the O ring gasket just meets the top of the boat placed underneath I is up and O is down Look at the heads of the three shoulder screws where they touch the drive nut they fasten Slowly move the chamber down until you see the drive nut just starts to compress its foam washer and it just pulls away from the head of the shoulder screw This occurs when the O ring gasket just touches the boat Press Enter when done to save the adjustment The chamber will now return to home and then perform a quick test of the full down position Verify that when the chamber moves down against the boat that the foam washer under each drive nut is compressed about 50 from its normal state Press the Space Bar to end the ALIGN VAC DOWN command and get the Prompt back amp XL System Service Manual E 21 Appendix E Alignment Procedures 8 2 Vacuum Transducer Calibration The vacuum level
316. test cards 1n specially fitted slots The front portion of the cassette has 15 wells for the card s inoculum test tubes The cassette 1s placed into a boat for transport through the instrument The special shape of the cassette matches the shape of the boat well which ensures that the cassette 1s properly loaded Each cassette can be fitted with a button memory chip The memory chip stores each card s test information from the Smart Carrier System SCS and is read by the instrument Each memory chip 1s easily installed and removed by the pressure latch lever holding the chip in its carrier The button memory chip and carrier are removed before cassette cleaning and are reusable after being read by the button memory reader The button memory reader is discussed later in this chapter The boat carries the cassettes throughout the various processing stations inside the instrument The instrument can carry up to four boats which normally remain in the system but are removable for cleaning The top surface of the boat forms a specially shaped cavity allowing one way positioning of the cassette into the boat The top surface also forms the bottom of the vacuum chamber discussed later in this chapter The boat cavity design will catch any spill from the loaded cassette The boat rests on four low friction feet to allow for easy movement in the instrument The base around each boat 1s notched in several places for the transport paddles to catch and move t
317. th each transfer tube causing the plastic to melt therefore cutting the transfer tube The majority of the transfer tube then falls into its associated test tube Remaining in the test card 1s the sealed stub 1 mm 2 5 mm from the cards edge Once the entire cassette of cards has been sealed the hot wire retracts back into a wire shield housing where it cools In the event of a halted transport the sealer wire will also retract and stop heating until the problem is corrected The card sealer station consists of a nicrome wire sealer hot wire a hot wire motor assembly to raise and lower the hot wire and an optical sensor to monitor the hot wire up down position The hot wire is controlled by the vacuum sealer SPN Board Figure 4 30 shows the hot wire which melts and seals the transfer tube of the test cards F NICHROME HEATED WIRE i TRANSFER TUBE P CARD Lf SEALER STATION B u z e m amp E S Figure 4 30 Card Sealer Station Hot Wire 4 28 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Four System Components Figure 4 31 shows the hot wire optical sensor assembly MOTOR ASSEMBLY Figure 4 31 Hot Wire Optical Sensor Assembly Top View VITEK 2 amp VITEK 2 XL System Service Manual 4 29 Rev 0100 Chapter Four System Components Reader Incubator Processing System s The VITEK 2 60 system is made up of one set of the follo
318. the Reader SPN board as previously noted Install or close any access doors or covers previously removed Ensure the instrument is ready to turn ON Verify the motor is operating properly and verify alignment See Appendix E Alignment Procedure 8 See Table 5 4 for wiring information UJ pL ae Card Ejector Motor Replacement Refer to Figure 5 20 for the location of the card ejector motor Removal 1 Remove the right rear panel to expose the motor you are replacing 2 Tag and disconnect the motor wires attached to the Incubator SPN Board 3 Move the ejector blade by hand to expose the four pan head screws securing the motor 4 Loosen and remove the four mounting screws attaching the motor to the back of the ejector rack Note the motor orientation to the ejector rack 5 Measure and note the distance of the tray drive gear mounted on the motor drive shaft Loosen the hex screw and remove the gear from the motor shaft 7 Discard the motor e TRAY DRIVE GEAR CARD EJECTOR CARD EJECTOR MOTOR Figure 5 20 Card Ejector Motor Back View 5 34 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation Installation 1 Position the tray drive gear on the motor shaft to the distance measured during removal and tighten hex screw securely 2 Mount the replacement motor onto the ejector rack in the same orientation as removed 3 When tightening the motor mounting s
319. the dispensing tube within 330 cycles or 30 days The firmware will prompt the operator when the bag is approaching the empty level or approaching the expiration date See Figure 3 14 for the location of the Sterile Saline Bag STERILE SALINE BAG FILTER Figure 3 14 Sterile Saline Bag 3 10 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Three System Overview Pipettor System The Pipettor System transfers a volume of fluid bacterial suspension which is predetermined from the bar code from the sample tube to the adjacent susceptibility tube The system includes a drum for disposable pipette tips disposable pipette tips and a pipettor pump assembly to deliver the disposable pipette tips to the tubes See Figure 3 15 for the location and picture of the disposable pipette tips and drum Figure 3 15 Disposable Pipette Tips and Drum Within the Pipettor System the drum internally rotates until a disposable pipette tip is in position for the displacement pump The pipettor pump assembly extends a hollow tapered pin into the drum inserting the tapered pin into the disposable pipette tip A vacuum transducer senses vacuum to verify that a tip is properly attached and then withdraws the pipette tip from the drum Figure 3 16 shows the Pipettor Pump Assembly AE boig DISPLACEMENT PUMP ASSEMBLY Figure 3 16 Pipettor Pump Assembly VITEK 2 amp VITEK 2 XL System Service Manual 3 11 Rev 0100 Ch
320. the number of reads remaining for the card in that position If a determination is made on this card before the maximum number of reads 1s obtained the remaining cycles will change to 0 Current Cycle Indicates the number of reads already performed on the card in that position Status There are 4 status Q Sequencing indicates the card is still processing This is the normal state Completed indicates that the card has finished reading and is waiting to be ejected from the carousel VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Six Troubleshooting Empty indicates that there is not a card in that position however it is the current position aligned with the reader Terminated indicates that an error has occurred while processing this card and it will no longer be read It will remain in the carousel until it can be removed by other means See UNLOAD CARD ZEROSLOT or VITEK 2 Users Manual Cleaning the Carousel Remaining Cycles will indicate at which cycle processing was terminated Card Info Indicates the number for the card type in that position the test type I for ID S for susceptibility the gram stain N for negative P for positive blank for others like Yeast and the card name Bar Code Indicates the bar code number for the card in that position CARA CARA will rotate the carousel to the reader position as indicated in the command referencing the incubator top sensor
321. this command for each finger in the drum total of three times Rotor home The rotor should be perfectly horizontal when home Caution Verify the rotor home optical sensor does not rub against the pipettor tip motor housing when the rotor is turned vertical 90deg From home Adjust sensor back as necessary to prevent rubbing 7 3 1 Atthe Prompt type ALIGN ROTOR HOME and hit Enter This starts the rotor home alignment routine amp VITEK 2 XL System Service Manual E 15 Appendix E Alignment Procedures 7 3 2 Following the prompts on the screen adjust the rotor position until it looks horizontal by eye relative to bottom of the drum Tip To aid in this adjustment place a 6 inch scale minimum or equivalent on the flat part of the bottom of the rotor Let the scale extend underneath the drum assembly Compare the flat on the bottom of the drum with the scale top When the two are parallel the rotor should be horizontal Alternatively you may move the vertical drive belt by hand to lower the pipettor assembly enough so that you can visually compare the bottom of the scale with the middle horizontal cross member of the front cover 7 3 3 Press Enter when done to save the adjustment 7 4 Vertical home The vertical position should be such that when the rotor is home and the tip is extended it enters the center of a straw sitting on the drum plate Note It may be necessary to add one or more pipettor mo
322. those specified herein may result in hazardous light exposure All access doors and covers must remain closed when processing cards to avoid exposure to laser light When making adjustments do not stare into the laser beam Service Information Follow all procedures cautions and warnings in this manual to avoid exposure to laser light The bar code scanner requires no maintenance or service If it fails it must be replaced Do not attempt to repair the bar code scanner All protective housings must be left in place when operating the bar code scanner unless otherwise specified in this manual Avoid exposure by not staring into the beam Do not insert reflective items into the beam 5 2 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation Repair Notes Ee NOTE NOTE Ee NOTE CE NOTE Before removing any circuit cards or internal components place the main AC power switch and the UPS switches in the OFF position and disconnect the AC power cable from its power source The circuit boards for the instrument are sensitive to static electricity Wear a static wrist strap when handling circuit boards or electronic components After removal of any circuit board wrap it in anti static material for storage or shipment Before installing any new circuit board into the VITEK ZP instrument check the switches and jumpers for correct settings by referring to
323. tion new design Installation 1 Carefully install the dispenser assembly into the instrument and install the mounting screws to secure the assembly to the frame If the air pump was removed install the air pump and secure it with the mounting screws Connect the plastic tubing wiring cables and connectors as noted from the removal Install the saline bag compartment and saline bag as noted during removal Install the dispensing tube into the dispenser assembly Close the top and front access doors Ensure the instrument is ready to be turned ON and verify the system operation After turning the VITEK 2 instrument ON perform Alignments See Appendix E Alignment Procedure n2 Po E d 5 70 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation Pipettor Assembly Replacement The design of the instrument permits the user to remove and install the complete pipettor assembly if problems are noted This design makes for efficient change outs Refer to Figure 5 45 for the pipettor assembly when performing the replacement procedure Ee NOTE Take care not to contaminate disposable Removal l Open the top covers of the instrument Disconnect the drain tube from the Diluter Cover and then unscrew and move the Diluter Cover including the saline bag to the side 2 Tag and disconnect the flat ribbon network cable for the pipettor assembly where attached to the pipettor SPN bo
324. tion of the proximity sensor Table 5 6 lists the proximity sensor wiring configuration Table 5 6 Proximity Sensor Pin and Wiring PROXIMITY SENSOR WIRING p n 530156 1 PIN SIGNAL WIRE COLOR 1 5VDC Detector Red 2 Negative Emitter N C 3 Positive Emitter N C 4 Ground detector Black 5 Sense Out Detector White 5 42 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation Removal Open the front left access door to access the pipettor drum Lift the top cover over the pipettor drum Tag and disconnect the sensor cable from the SPN circuit board Remove the screw and lock washers holding the sensor and remove the sensor from the drum PROXIMITY SENSOR Figure 5 25 Pipettor Hall Effect Sensor Installation oom Place the new hall effect sensor into position and install the mounting screws Reconnect the cable to the SPN circuit board connector as noted from removal Install or close any access doors or covers previously removed Ensure the instrument is ready to turn ON and verify the sensor operates properly See Table 5 6 for wiring information See Appendix E Alignment Procedure VITEK 2Z amp VITEK 2 XL System Service Manual 5 43 Rev 0100 Chapter Five Component Installation Reflective Sensor Replacement The VITEK Z 60 has two reflective sensors and the VITEK 2 120 has three All three reflective
325. tomatically ask the Work Station to send information on how to process that card The cassette must be removed and then reinserted into the instrument If the Work Station knows how to process that card and sends it to the instrument the cards will be processed If the Work Station does not know how to process the card the cassette will back to the load unload station again and the information will need to be entered using the Work Station flex panel entry VTK2 A WELLMAPS Card L SPORp Type Cycle Vol Class Group Flex We Map Definition Name Ove 101 101 Ox O F zii 111 11111111 11111111 DML 1 il hOB O O Ejs DML 2 2 103 103 OX O F 11111111 11111111 11111111 11111111 11111111 11111111 11111111 1111111 DML 3 Su eg vius I4 O F 888888
326. tor If sequence task is 97 Processing Errors unable to prepare to load this error is generated SCS and Bar Code Reader 90 Processing Errors Process Jam SEQ Sequence failed to process card for multiple reasons Top level function 9 Processing Errors Unload Failure multiple reasons Top level function 92 Processing Errors Carousel Jam SEQ Sequence failed to index carousel for multiple reasons Top level function 93 Hardware Errors Serial Number Failure number device 94 Processing Errors Additional cards were found with A cassette was loaded with FLR Cal cards and calibration qc cards other types of cards were found in the cassette 905 Processing Diluent has been in use longer Warnings than the recommended time 96 Processing Tips have been in use longer than SYS TASK The Tips has expired Warnings the recommended time rmo D A conflict at Slot Get Cassette Info The SCS BarCode string and card type did not match the Bar Code Reader continued VITEK Z amp VITEK 2 XL System Service Manual Rev 0100 Appendix D Error Code Text MESSAGE MAJOR 98 Processing Error 100 Processing Errors 101 102 Optical Error 105 Processing Errors l l 108 108 Hardware Errors l 1 10 Optical Error 111 Processing Warnings Processing Warnings Processing Warnings
327. tor as the cassette is transported through the station The cards push against the card separator s spring loaded lobe shaped plunger causing the card to lay back in the card slot of the cassette The lobed design and the card movement pushes the plunger into the path of the card separator sensor The blocked condition of the sensor tells the instrument that a card is in that particular cassette slot The separator holds the card at an angle for the scanner to read the bar code information on the test card The location of each card in the cassette 1s determined by the card separator in conjunction with the bar code reader Figure 4 13 shows the card separator with the test card in position to be scanned CARD IN SCAN POSITION BiganaBBeaEEEnunes Figure 4 13 Card Separator Holding Card In Scan Position VITEK 2 amp VITEK 2 XL System Service Manual 4 13 Rev 0100 Chapter Four System Components Laser Bar Code Scanner The laser bar code scanner projects a horizontal beam of laser light across the bar code label on the test card and reads the encoded information on the bar code label The laser will read bar code information such as card type lot number expiration date and a unique sequence number From this information the proper dilution volume and optics method will be determined for that card If the instrument is set up in SCS mode the scanned information is also compared to the button memory reader information T
328. transport so the boat 1s just barely touching the back rail Do not force the boat into the rail under pressure from the paddle Press Enter when done to save the adjustment If the paddle does not look centered in the boat pocket after completion of this alignment then recheck alignment belt tension or transport itself for problem VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Appendix E Alignment Procedures 4 Bar Code Reader Alignment mode must be enabled for this alignment to work correctly 4 1 Card Separator Position Bar Code Base The bar code base position is correct when the bar code separator is centered between two cards in a cassette at a bar code reading position The separator bracket should be positioned to be perpendicular to the cassette and adjusted as far back from the cassette as possible but still maintain enough card pressure to separate the two cards completely 4 1 1 Place fifteen 15 64 well cards and fifteen 15 test tubes into positions through 15 of a cassette and place the cassette into a boat positioned at the front left position of the basepan Atthe Prompt type ALIGN BARCODE and hit Enter This will start the bar code alignment routine Following the prompts on the screen hit the Spacebar when the boat and cassette are positioned as requested The boat will then be moved to the Card Separator Note Open the load door for greater visibilit
329. troller Board Then it is uploaded to the computer Work Station If 1t does not match the cassette will back up to the load unload station and a warning message will occur describing the mismatch After this data 1s transferred the instrument marks the cassette button memory as read in preparation for the next batch of cards to be setup on the cassette using the SCS The software will link the card results from the instrument to patient demographic data and any previous test results Cg NOTE The button memory chip can be removed from the cassette so that the cassette can be cleaned VITEK 2 amp VITEK 2 XL System Service Manual 4 15 Rev 0100 Chapter Four System Components Figure 4 16 and Figure 4 17 shows the button memory chip and contacts on the cassette BUTTON MEMORY CHIP Figure 4 16 Button Memory Chip under the cassette Figure 4 17 Button Memory Chip Contacts 4 16 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Four System Components Dispenser Pipettor Station The dispenser pipettor station automatically prepares the organism dilution used for AST Antimicrobial Susceptibility Testing Figure 4 18 shows the location of the dispenser pipettor station PIPETTOR Se DISPENSER STATION c MELLO Figure 4 18 Dispenser Pipettor Station Dispenser System The dispenser delivers 2 33 ml 2 63 ml of sterile saline solution into the test tube of each susceptibility card in a casset
330. tte tip into the test tube and then extracting some of the mixed liquid The vertical motor raising the pipette tip The vertical motor lowering the pipette tip into the mixed liquid completely evacuating the pipette tip and mixing liquid with forced air from the pump The vertical motor raising the fully evacuated pipette tip The vacuum pump homing The vertical motor lowering and forcing air through pipette tip to complete mixing cycle The taper pin retracting into the snout therefore pushing the pipette tip off of the pin and dropping into the test tube of mixed liquid Pipettor initializing VITEK 2 amp VITEK 2 XL System Service Manual 6 19 Rev 0100 Chapter Six Troubleshootin DRUM CYCLE DRUM_CYCLE rotates the pipettor drum This command will cause a pipette tip to fall into the drum slot resting on the horizontal slide If the cycle 1s completed without errors no message will be displayed PIPETTER EN PIPETTER_EN enables disables the pipettor component This is a variable that is stored in non volatile memory To determine its value it is necessary to enter PR before the command If a 1 is displayed the pipettor is enabled Typing SPIPETTER EN O and pressing ENTER will disable the pipettor so it will not operate when cards are processing For proper instrument operation it is imperative that the pipettor is enabled prior to exiting DML To accomplish this use the command PIPETTER_EN 1 or INST DEF
331. ually turn the belt until the vacuum chamber barely touches the boat s sealing surface 8 Loosen the idler pulley bracket to add slack to the belt NOTE Before loosening anything secure belt to the lead drive screw pulleys so phasing is not lost during motor replacement This will save time and effort trying to re phase belt to lead screws 9 While supporting the stepper motor located beneath the upper bearing mount loosen and remove the four mounting screws securing the motor 10 Remove the motor Note the motor orientation to bearing mount 11 Measure and note the distance of the drive pulley mounted on the motor drive shaft 12 Loosen the pulley set screws and remove from the motor shaft 13 Discard the motor VITEK 2 amp VITEK 2 XL System Service Manual 5 27 Rev 0100 Chapter Five Component Installation ty m 4 VACUUM SEALER VACUUM ASSEMBLY VERTICAL MOTOR VACUUM J CHAMBER o es p Figure 5 16 Vacuum Assembly Vertical Motor plate removed Installation 5 28 8 9 Install the motor pulley on the motor shaft to the distance measured during removal of motor After applying threadlocking adhesive place set screws of motor pulley over flat spots of shaft and tighten set screws securely Mount the stepper motor to the upper bearing mount in the same orientation as removed Place the timing belt around the motor pulley and pull belt taught using the idler pulley bracket
332. uce boats into the instrument Another way to do this is by performing a boat cleaning from the User Interface by selecting UTILITIES MAINTENANCE CLEANING and BOAT CLEANING NOTE Reading the variable using a PR command is not a good representation of what 1s really installed BOAT STATUS should be used instead The following are boat count commands and the corresponding boat placement position It is essential that the boats are placed in the proper corner against both boat rails If SBOAT COUNT 1 is entered it is necessary to place a boat in position 1 If SBOAT COUNT 2 is entered place the boats in positions 1 amp 6 If SBOAT COUNT 3 is entered place the boats in positions 1 4 amp 6 If SBOAT COUNT Z4 is entered place the boats in spots 1 3 4 amp 6 6 10 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Six Troubleshooting When the boat count command is entered the instrument will respond with the following message Please COLD BOOT for changes to take effect Place boats in outside corners Position the boats as described above and then type COLD and press ENTER The transport will then place the boats in the idle positions awaiting new cassettes to be loaded Note that the above procedure can be used after a fatal boat jam BOAT SIM LOAD BOAT SIM LOAD can be used for troubleshooting purposes when it is only necessary for cards to process around the transport and not load into the ca
333. uld be blowing out of the instrument 2 Install the mounting bolts for the fan s 3 Connect all wiring cables disconnected from the removal 4 Install the finger guards on the fan s and tighten the mounting nuts 5 Close the top access doors that were opened earlier 6 Ensure the instrument is ready to be turned ON and verify the system operation VITEK 2 amp VITEK 2 XL System Service Manual 5 77 Rev 0100 Chapter Five Component Installation Laser Bar Code Scanner Replacement Refer to Figure 5 50 for the Laser Bar Code Scanner location Removal 1 Open the front covers of the instrument 2 Scribe a line around the scanner mounting bracket then remove the mounting screws from the scanner mounting bracket Tag and disconnect the flat cable from the laser bar code scanner 4 Note the position of the scanner on the bracket and then remove the cover and scanner 5 Set the scanner aside for return repair or replacement A U UJ LASER SCANNER AND COVER MOUNTING BRACKET Screws Underneath Bracket 2 p yu Sd a 4 i i f a P Figure 5 50 Laser Bar Code Scanner Replacement Installation 1 Install the scanner and cover onto the mounting bracket as noted from the removal Tighten the mounting screws Reconnect the scanner flat cable Install the mounting bracket to the scribe mark made during the removal Snug the mounting screws for the scanner mounting bracket Ensure the instrument is rea
334. um Station uses a vacuum chamber and pump The rate of change of the vacuum is regulated by a pneumatic servo feedback system under microprocessor control V ML y VACUUM E CHAMBER k n i Figure 3 17 Vacuum Chamber and Seal 3 12 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Three System Overview Figure 3 18 Vacuum Chamber Vacuum Pump When the boat carrying a cassette reaches the vacuum station the top of the vacuum chamber is lowered onto the boat surface The seal on the vacuum chamber top presses against the boat surface sealing the vacuum chamber The vacuum pump Figure 3 18 starts drawing or evacuating the air from the vacuum chamber The air escapes from the card channels and wells via the transfer tubes and bubble up through the suspension The channels and wells inside of each card are now in a vacuum After a short period the vacuum is slowly released in the vacuum chamber The increasing air pressure inside the chamber forces the suspension in each test tube through the transfer tube and into the channels and wells of the card Once the cards are filled the vacuum chamber raises and the Transport System moves the boat cassette carrier to the next station VITEK 2Z amp VITEK 2 XL System Service Manual 3 13 Rev 0100 Chapter Three System Overview Card Sealer Station The Card Sealer Station completes the functions inside the VITEK 2 that prepare the test card
335. unt shims in order to adequately set the pipettor tip front to back centering with respect to the straw opening If shims are added or removed repeat this sub section completely until all requirements are met 7 4 1 Verify the drum contains straws and is tilted down into its normal position 7 4 2 Atthe Prompt type ALIGN VERT and hit Enter This starts the vertical home alignment routine 7 4 3 Following the prompts on the screen adjust the tip position up and down until it looks centered in the straw that 1s laying on the drum plate Tip It may be helpful to tilt up the drum to get a better view of the straw on the drum plate Be careful when tilting the drum back down over the straw not to pinch it 7 4 4 Press the X key to extend the tip into the straw and check how well centered you are If the straw moves up when you hit X then you are too high If the straw moves down then you are too low 7 4 5 Adjust the vertical position up or down as needed until the straw does not move when you hit X 7 4 06 Press Enter when done to save the adjustment 7 4 7 Manually press the plunger in the center of the solenoid directly below the slide plate underneath the drum to allow you to remove the straw E 16 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Appendix E Alignment Procedures 7 5 Tip extended The tip should extend enough to guarantee the straw is wedged firmly onto the ti
336. unting screws securing the stepper motor to the reader motor bracket Remove the motor Note the motor orientation of motor bracket 6 Measure and note the distance of the drive pulley mounted on the motor drive shaft 7 Loosen the pulley set screws and remove from the motor shaft 8 Discard the motor READER HEAD MOTOR Figure 5 18 Reader Head Motor VITEK 2Z amp VITEK 2 XL System Service Manual 5 3 Rev 0100 Chapter Five Component Installation Installation a A Install the motor pulley on the motor shaft to the distance measured during removal of motor After applying threadlocking adhesive place set screws of motor pulley over flat spots of shaft and tighten set screws securely Install the stepper motor in the same orientation to bracket as removed Place belt around the motor pulley Position and tighten the motor so the belt tension is the same as noted earlier Open the optics to check the belt tension and rotate the motor shaft and pulley checking the force required Reconnect the wires to the reader SPN board as tagged Reinstall side cover and close the top panel door Ensure the instrument is ready to be turned ON and verify the system operation After turning ON verify alignments See Appendix E VITEK Z Alignment Procedure VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation Gear Motor Replacement The VITEK 2 instrument has four motors
337. ution When the vacuum pump is turned on it begins drawing free air through the filter muffler attached to the 4 way solenoid valve To fill the test card the following sequence occurs 1 The vacuum chamber lowers over the boat and cassette 2 The proportional valve is opened 100 3 The 4 way direct acting solenoid is energized and air is evacuated or pumped out of the vacuum chamber through the air filter and the 4 way solenoid valve 4 The absolute pressure transducer monitors the vacuum chamber pressure decreasing and sends a proportional continuously changing voltage output to the SPN board 5 The continuously changing voltage signal 1s sampled by the SPN board at regular intervals and the rate of change is compared to the programmed rate Figure 4 29 to pump down the vacuum chamber approx 25 seconds Ifthe rate of change is too fast a higher voltage signal is sent to the proportional valve which opens wider to slow down the amount of air being drawn from the vacuum chamber by the vacuum pump Ifthe rate of change is too slow a lower voltage signal 1s sent to the proportional valve closing down the valve to speed up the amount of air being drawn from the vacuum chamber by the vacuum pump 6 When the vacuum chamber is pumped down to the vacuum target pressure 0 89 0 04 psia the vacuum pump turns off the 4 way solenoid valve closes and the proportional valve is closed for a total of five seconds The absolute pres
338. ve belt Removal l Open or remove the access cover s from the area that exposes the transport paddle drive belt you are replacing 2 Removing the transport belt clamp by loosening the two screws securing the clamp to the hold and base carriage 3 Count and note the number of teeth on the belt that are exposed past the hold and base carriage brackets Normally three on each exposed end 4 Remove and discard the drive belt TRANSPORT PADDLE HOLD CARRIAGE DRIVE BELT PADDLE BELT MOUNTING SCREWS HOLD CARRIAGE Figure 5 29 Paddle Belt Replacement Installation 1 Thread the belt around the transport pulleys as noted during the removal Ensure the belt teeth are positioned into the pulley grooves 2 Place the ends over the hold carriage mounting The number of exposed teeth should be the same as noted from the removal Rule of thumb Each exposed end of the belt should have 3 belt teeth exposed If belt too tight decrease one tooth at a time 3 Install and tighten the transport belt clamp 4 Install access doors or covers removed earlier 5 Ensure the instrument is ready to be turned ON and verify the system operation 6 Verify alignment See Appendix E Alignment Procedure 5 48 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Five Component Installation Incubator Assembly The replacement procedure for the incubator assembly component parts are covered in this section Removable and repl
339. view Cassette Scan Station Patient identification test data entry may be made prior to placing the cassette into the instrument using an external Smart Carrier Station SCS A button memory device within the cassette will be used to carry this information from the SCS to the VITEK 2 instrument For installations without a SCS a Cassette Only Mode will allow the user to load cassettes that do not have cassette memory Information required to run the test is included in a bar code on the card The user will then be required to manually link the test card bar code to the patient at the computer workstation prior to processing the data from the cards Refer to Figure 3 7 for the location of the Cassette Scan Station a LASER BARCODE SCANNER if e s CASSETTE SCAN STATION Figure 3 7 Cassette Scan Station Laser Bar Code Scanner Each card will have a bar code that includes information such as test type lot number expiration date and a unique sequence number A laser bar code scanner at the Cassette Scan Station is provided to read the card type to determine the proper dilution volume and optics scan method This scanner provides an additional level of security by verifying cards are loaded as indicated by the user in the cassette button memory if a SCS is used 3 6 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Three System Overview CARD SEPARATOR BAR CODES ah E LASER
340. wer Supply Distribution Board SPN Board Left Transport Diluter SPN Board SPN Board Vacumn amp Sealer Custom SPN Board Pipettor Pipettor Snout Board SPN Board Figure B 1a PC Board Top Level Block Diagram 60 VITEK 2 amp VITEK 2 XL System Service Manual B 1 Rev 0100 Appendix B Schematics and Diagrams Vitek 2 PC Board Top Level 120 Unit Workstation Bay Controller Board BCB Carousel A Carousel B Right Transport Head is Board SPN Board SPN Board SPN Board Reader A Reader B Power Supply Distribution Board SPN Board SPN Board Left Transport Diluter SPN Board SPN Board Vacumn amp Sealer Custom SPN Board Pipettor Pipettor Snout SPN Board Board Figure B 1b PC Board Top Level Block Diagram 120 B 2 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Appendix B Schematics and Diagrams BCB Board A Bay Controller Board BCB controls the optics the communications to the workstations the user interface and serves as the master controller for the Sample Prep integrated Network SPN boards USER I F Z P6 TELE cerned c e wd MTEK 2 BAY CONTROLLER 530702 NE ANN C ASM 702 025 01 00 REV nU Jeno an IE us ry G HOR 16 HEAD CTRL A HEAD CTRL B 2 pL POM icm F P1 P5 ce gt RP Cs te gut RDR21 35i em pem il U6 Lu a 6 HOR20 1 S 1 O d d d cies
341. wer up No indicates that the Fluorescence optical interrupt was not detected on power up Functional Yes indicates that no automated validation failures have been detected by the firmware of the instrument No indicates that there has been a validation failure detected by the firmware of the instrument Version Rev Indicates the version of the fluorescence peak detector board FSTEPS Steps into well Indicates the optimum position for reading the well It is set during the Fluorescence calibration while using the black alignment card Typical values range from 7 to 15 Liquid calibrations Indicates the number of successful calibrations performed using calibration liquid Solid calibrations Indicates the number of automatic internal digi POT calibrations performed using the solid reference standard on the shuttle DAC offset calibrations Indicates the number of automatic internal DAC calibrations performed using the solid reference standard The DAC offset 1s an electronic offset adjustment to compensate for electronics variations 6 28 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Six Troubleshooting Software offset calibrations Indicates the number of automatic internal soft offset calibrations performed The software offset is an offset that is used to compensate for electronic noise and physical impurities on the optical system It is subtracted by the firmware f
342. wing primary internal components The VITEK 2 120 Reader Incubator processing system is made up of two sets of the following primary internal components labeled section A amp section B Auto Loader Station Carousel Card Ejector Carousel Incubator Reader System Waste Collection Station 9 9 9 9 Auto Loader Station Test cards transported and processed from the card sealer station are transferred into the slots of the carousel at the incubator auto loader station This station consists of a motor driven rack gear attached to an auto loader pusher and an auto loader home sensor When a boat and cassette reach the card loading station each card will be pushed by the auto loader from the cassette into a slot of the 60 position carousel Then the auto loader will retract back to the auto loader home sensor Figure 4 32 shows the test cards ready to be pushed into the carousel at the incubator auto loader station AUTO LOADER OPEN CAROUSEL SLOT E p m m Figure 4 32 Incubator Auto Loader Station 4 30 VITEK 2 amp VITEK 2 XL System Service Manual Rev 0100 Chapter Four System Components Carousel Card Ejector After the cards have been loaded into the carousel they must complete their first read Identification cards are immediately read by the reader followed by susceptibility cards Then the cards are read every fifteen minutes from its first read Initially this time may vary if more that
343. y Board 2 Disconnect and tag all cables from the DC Power Supply Board 3 Using a flat tip screwdriver gently pry the board off of the standoffs holding the board in place and remove the board from the instrument Be sure not to damage the board Wl DC PC R j SUPPLY BOARD 4 STANDOFFS SAME ON OTHER END AND IN CENTER lali Figure 5 7 DC Power Supply Board Replacement Installation 1 Compare the replacement board with the old board 2 Place the new DC Power Supply Board into position and install on to the standoffs Reconnect the cables to the DC Power Supply Board 4 Ensure the instrument is ready to turn ON and verify board is working See Table 5 1 for voltage test point information UJ VITEK 2Z amp VITEK 2 XL System Service Manual 5 13 Rev 0100 Chapter Five Component Installation Head Control Board HCB Replacement Refer to Figure 5 8 for the location of the HCB circuit board Removal l Open the instrument top covers Disconnect the drain tube from the Diluter Cover and then unscrew and move the Diluter Cover including the saline bag to access the HCB board 2 Tag and disconnect the cables attached to the HCB board 3 Note the mounting position of the board and with a flat tip screwdriver gently pry the board from the standoffs holding the HCB board into place Be sure not to damage the board 4 Remove the HCB Board la STANDOFFS F Figure 5 8 HCB Board R
344. y of the cassette Press the R key seven times to move the cassette so the Card Separator is to the left of card 8 Position will be reported on the diagnostic terminal Following the prompts on the screen press the I or O keys until the card separator is centered between the two cards and applies approximately equal pressure to the back of each one The I key will increase pressure on the right card and the O key will increase pressure on the left card Note The pressure can be checked by gently trying to move the cards side to side left to right with your finger The cards must be fully seated down into the cassette when you try this Push the card down if necessary to seat it into the cassette It is necessary to use the R and L keys to check the other card positions in the cassette Adjust the card separator position so that it best meets the criteria above for all card positions It will not be exactly the same for all positions VITEK 2 amp VITEK 2 XL System Service Manual E 11 Rev 0100 Appendix E Alignment Procedures 4 1 6 Usethe L key as required to move the cassette so the Card Separator is to the left of card 1 4 1 7 Remove the cassette from the boat Open the load door if necessary 4 1 8 Press the R key three times to move the boat so the Card Separator is at card position 4 Verify correct position by looking at reported position on the diagnostic terminal 4

VITEK•2® & VITEK•2® XL INTEGRATED SYSTEM SERVICE MANUAL

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VITEK&bull;2&reg; &amp; VITEK&bull;2&reg; XL INTEGRATED SYSTEM SERVICE MANUAL

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VITEK•2® & VITEK•2® XL INTEGRATED SYSTEM SERVICE MANUAL