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hybriSpot12 Service Manual V3.EO_EN (17/12/2015) 1/41 SERVICE MANUAL VITRO S.A Calle Luís Fuentes Bejarano. Edificio Nudo Norte (Local 3) 41020 Sevilla (SPAIN) www.vitro.bio T. +34 902 366 974 F. +34 902 366 977 e-mail: vitro@vitro.bio http://www.vitro.bio/ mailto:vitro@vitro.bio hybriSpot12 Service Manual 2/41 INDEX 1 GENERAL DESCRIPTION ....................................................................................................... 3 1.1 Introduction .......................................................................................................................3 1.2 Aim ......................................................................................................................................3 1.3 Rights and Warranties ......................................................................................................3 1.3.1 Intellectual property ................................................................................................3 1.3.2 Usage ..........................................................................................................................3 1.3.3 Documentation and general information ..........................................................4 1.4 Information and security instructions ............................................................................5 2 TECHNICAL INFORMATION ................................................................................................. 6 2.1 Technical data ..................................................................................................................6 2.2 Minimum requirements for a computer .......................................................................6 2.3 Serial Number ....................................................................................................................7 2.4 Special Tools ......................................................................................................................7 2.5 Recommended Tools.......................................................................................................8 2.6 Content list .........................................................................................................................9 2.7 Troubleshooting .............................................................................................................. 10 3 UNPACKAGING ................................................................................................................. 12 4 INSTALLATION ..................................................................................................................... 13 5 HYBRISOFT INSTALLATION .................................................................................................. 13 6 USB BARCODE READER CONFIGURATION ....................................................................... 13 7 MECHANICAL SYSTEM ....................................................................................................... 13 7.1 Safety Instructions .......................................................................................................... 13 7.2 General Description – Spare Parts .............................................................................. 14 7.2.1 Housing and Covers.............................................................................................. 14 7.2.2 Reaction Chamber ............................................................................................... 17 7.2.3 Hydraulic System ................................................................................................... 18 7.2.4 Electronic System .................................................................................................. 19 7.3 Access to the Hydraulic Circuit................................................................................... 21 7.4 Access into the instrument and electronics circuits ............................................... 21 8 ELECTRONIC SYSTEM .......................................................................................................... 23 8.1 Cables Colour Codes ................................................................................................... 23 8.2 General Description ...................................................................................................... 23 8.2.1 Boards interconnections ...................................................................................... 24 8.2.2 Power Circuit Board .............................................................................................. 25 8.2.3 Main Connections ................................................................................................. 26 8.3 Display Circuit Board ..................................................................................................... 30 8.4 Service Port and Program Port .................................................................................... 31 8.5 DC Power Connector ................................................................................................... 32 8.6 Camera circuit board and Camera Housing .......................................................... 32 9 HYDRAULIC SYSTEM ........................................................................................................... 33 8 CONTROL SOFTWARE ......................................................................................................... 34 8.1 Valves and Pumps Control Area ................................................................................ 34 8.2 Temperature Control .................................................................................................... 35 8.3 Commands Menu ......................................................................................................... 37 8.4 Auto Settings Menu ....................................................................................................... 37 8.5 Flash Memory Programming........................................................................................ 38 hybriSpot12 Service Manual 3/41 1 GENERAL DESCRIPTION 1.1 Introduction HybriSpot 12 is a new semi-automatic analyzer that meets all the requirements to perform PCR amplification and later DNA array reverse hybridization on a nylon membrane, based on the principle of the DNA-FLOW. By means of this technology, hybridization process takes place by passing the reagents through the membrane by means of a hydraulic vacuum system that causes a vertical liquid flow. This assay allows hybridization to occur in a tridimensional environment and improves incubation time from hours to minutes and increases sensitivity and specificity. HybriSpot 12 is used for the design and automation of in vitro molecular tests in the field of infectious disease, cancer as well as genetic diseases among others, where quick sensitive and specific results are required. HybriSpot 12 is manufactured by Vitro, S.A in our industrial plants located in Seville-Spain. 1.2 Aim This manual is a referencing guide for the Technical Service field engineers when these procedures are performed: Unpacking. Hardware installation. Technical checkout. Maintenance. 1.3 Rights and Warranties 1.3.1 Intellectual property All acts that violate the rights of intellectual property inherent to the product as a whole or any of its components or parts are prohibited. 1.3.2 Usage This device has been designed to be used in an in vitro diagnosis laboratory. We disclaim any liability, in the event that the same or any component thereof is subject to misuse and / or use other than for which it was designed. Users are the only responsible for the management,use, testing, processes and outcomes that occur and are obtained with the instrument, or as an auxiliary device. hybriSpot12 Service Manual 4/41 The manufacturer of the product or one of the components could not take responsibility for defects when the product has been sold or misused in a market for which it was not designed for. By means of CE marker, the manufacturer indicates that the device complies with the requirements laid down in European Directives to be applied. 1.3.3 Documentation and general information The manual supplied with the instrument is owned by Vitro, SA and is provided to customers and authorized distributors for its use. Unless prior express written consent of Vitro SA authorization, copying, dissemination and distribution- fully or partially- is forbidden, in any form and/or mean, including all systems and electronic means, the text, images and illustrations contained in the manual. The information contained in the manual (data, figures, drawings, technical details etc.) represent the current state of scientific knowledge and latest technology as we understand it after conducting thorough investigations in this field, and should not be considered as warranted as our products. Note this depends on the commercial contract between the parties. No liability, damages, financial loss or profit is accepted from or relevant to the statements contained in the manual. The manufacturer reserves the right to change the technical specifications and manufacturing processes without notice. Only in this way it is possible to continuously improve technology and manufacturing techniques used in our products. hybriSpot12 Service Manual 5/41 1.4 Information and security instructions The following safety precautions and regulations must be observed when the instrument is used particularly for medical diagnosis and in vitro. The failure to follow these instructions can lead to reporting false negative results and the incorrect distribution of the samples. I. All notes in the Service Manual should be read carefully, paying particular attention to the following sections: Installation Disinfection procedures II. The installation must follow these reasonable steps to ensure that the location where the instrument is installed meets the environmental and electromagnetic specifications for the analyzer. Any significant movement of the equipment must be performed by qualified personnel. III. The user should be informed and trained to perform daily maintenance and check to ensure the correct operation of the instrument. IV. Carefully, follow the instructions in the Service Manual for the operations to perform to turn on and off the hybriSpot 12. V. All precautions and recommendations, normally used in the laboratory (good laboratory practice standards), must be followed. VI. If the laboratory does not have power sources protected, you may need an uninterruptible power supply (UPS) to protect and nurture the instrument during a power outage. VII. Using hybriSpot 12 do not ensure the absence of contamination by biological risk, so the instrument should be handled as potentially infectious item and the usual precautions for these cases should also be followed. Do not eat, drink or smoke while handling the device. VIII. To reduce the risk of electric shock: Keep away from open circuits. The instrument must be connected to a ground. The instrument must be equipped with a three-pole cable for connection to 230V or 115V. hybriSpot12 Service Manual 6/41 2 TECHNICAL INFORMATION 2.1 Technical data Nominal Voltage: 100 – 240 V Nominal Frequency: 50/60 Hz Secondary Fuses: 2 xPTC Nominal Power 150 VA Dimensions (Length X width x height) (without webcam embedding) 235x230x200mm Gross weight (without packaging material) 5 kg Gross weight (with packaging material) 6.8 kg Operating Temperature Range 15ºC - 32º C Operating ability 12 samples per cycle Standard Cycle Time 50 min – 12 samples Temperature Range 20°C - 60°C (Reaching limit temperature takes longer) Heating Rate 4,5°C/Min. (Measured between 30°- 40°C with ambient temp. of approx. 23°C) Cooling Rate 2°C/Min. (Measured between 30ª- 40°C with ambient temp. of approx. 23°C) Temperature Accuracy ± 2°C(worsened at high temperatures) Temperature Uniformity ± 1,5°C Temperature Range During Storage Suggested between +5°C and + 45°C Samples Configuration Max.12 operating samples Operating Pressure Only tested at atmospheric pressure Operating Humidity Suggested between 30% - 70% non- condensing Humidity During Storage Suggested between 30% - 70% non- condensing 2.2 Minimum requirements for a computer Processor: Intel Core i3 Memory: 4 Gb Hard Drive: 250 Gb Operating System: Windows 7 (32/64 bits) Windows 8.1 (32/64 bits) USB ports free: 1 (as minimum) Network Connection: Ethernet 10/100 Mbps – RJ45 Recommended Display: 16:9 format hybriSpot12 Service Manual 7/41 2.3 Serial Number To get the serial number of manufacture of the product, see the nameplate on the back of the instrument. 2.4 Special Tools These tools are not provided with the instrument. Used for: Firmware updating. Communication with the PC to use the Technical Service Software. Vacuum verification. PC Connector cable Program Port Cable Kit. Vacuometer Vacuum Test Cap VIT-20001 – PC Connector Cable VIT-20002 – Program Port Cable Kit VIT-20003 – Vacuometer VIT-20004 – Vacuum Test Cap hybriSpot12 Service Manual 8/41 2.5 Recommended Tools These tools are recommended in order to the Technical Service can give Support to the instrument. These tools are not supplied as spare parts neither as special tools. Clean Cutter Pliers Socket Wrench Socket Set Set of Allen Wrenches (Metric) Set of Torx Screwdrivers Set of flat Screwdrivers Set of Philips Screwdrivers Set of Tube Wrenches Pliers Tweezers Thread Sealant hybriSpot12 Service Manual 9/41 Thermal Paste Infrared Thermal Detector 2.6 Content list Spares included in the hybriSpot12 are: hybriSpot 12 hybriSpot12 equipment Clean tube Waste tube Clean bottle Waste bottle USB cable Power supply Power cord Orings set Grids set hybriSpot12 Service Manual 10/41 2.7 Troubleshooting INCIDENCE COMMENTS CHECKS POSSIBLE CAUSE OF FAILURE (In case failure persists after checking) RESOLUTION The instrument does not start When the instrument is on (and the rear switch is pressed) the display lights should turn on immediately showing the firmware version installed. The side fan should also turn on. Verify that the power supply is functioning properly. Green LED lighting should be on. Otherwise, check that the outlet has power supply and cable A / C is properly connected Power supply failure Replace power supply Check that the power is properly connected to the instrument PCB or wiring error Replace the instrument The display does not work properly It is possible that the instrument is properly powered, but due to a failure in the wiring of the display, it is not turned on or simply it does not show text.In any case, the side fan should be on Check that the side fan is on If the fan works properly, it means that the equipment is properly powered. The failure should be the display board. Replace the instrument. The instrument does not create a vacuum There can be several causes. Is the failure is coming from the presence of a residue in one of the wells of a row that fails, the final user can try to solve it. Other causes such as failure of peristaltic pumps, valves, fittings, etc., can only be solved by field engineers Check that there is no waste in the area of the o-ring. If the fault persists, it is recommended to remove the grids and o- ring and placing them back Possible leakage in the hydraulic system. Replace the instrument. Follow the instructions for check and review the Hydraulic System. The instrument loses fluid (reactive / wash) Both in normal operation and during a wash cycle, some leaking can be detected by checking the bottom of the instrument. More likely, one connector of the peristaltic pumps is leaking. Leaking at hose pump connector. If the user has a 2.5mm allen key, he can open the maintenance plate and check this. In any case, the instrument should be replaced. Replace the instrument The instrument takes too long to reach the target temperature Typically, for HPV or zoonoses, the highest temperature ramps should not take more than 10 minutes to complete. This depends, also, on the room temperature. Check that the instrument is properly used and that the side fan is on. You should also check that the computer display changes the temperature of the reaction chamber. Possible failures: Fan breakdown, temperature sensors, PCB… Replace the instrument hybriSpot12 Service Manual 11/41 INCIDENCE COMMENTS CHECKS POSSIBLE CAUSE OF FAILURE (In case failure persists after checking) RESOLUTION The instrument does not indicate when it reaches target time / temperature When the target temperature/time is reached, the instrument buzzes with built- in speaker included in the display board in order to alert the user and continue the cycle. In case of temperature, the buzz should coincide with the green led lighting of the display Failure in the display board Replace the instrument The LED lighting system of the image capture system are not turned on With the image capture system connected to the PC USB and the switch ON, both diffuser LEDs lighting and the red LED signal should be ON Check that the USB cable connections on PC and capture system are correct Failure on the image capture system electronic board Replace the image capture system hybriSoft does not get images from webcam If the LEDs work correctly, hybriSoft should receive the image from the webcam Make sure MS Windows recognizes the webcam. If MS Windows recognizes the camera, the failure is in the software. Otherwise, there is a failure either in the camera or in any other electronic connections. Replace the image capture system hybriSpot12 Service Manual 12/41 3 UNPACKAGING Remove the documentation included. Remove packaging waste. Remove the plastic protection of the reaction chamber cover and image capture system and pick up both items. Remove protection foam. Remove the power supply, cables and auxiliary tubes, bottle and hybriSpot hybriSpot12 Service Manual 13/41 4 INSTALLATION Connect hybriSpot 12 to power supply Connect waste and cleaning tubes to the side connectors Connect waste tank to the corresponding tubes. 5 HYBRISOFT INSTALLATION Please refer to the hybriSoft_ Installation guide located at Vitro ftp site. 6 USB BARCODE READER CONFIGURATION An external USB barcode reader could be used. In this case you must assure that the barcode reader has the correct USB PC keyboard configuration. It is necessary add a CR suffix, Carriage Return, for a properly operation. Please refer to the specific manufacturer barcode reader documentation for more information about how to configure it. 7 MECHANICAL SYSTEM 7.1 Safety Instructions Before carrying out any work on the instrument (or on the device), it should be disconnected from the power supply. After repairing, all parts must be connected as originally connected by the manufacturer. No power cord should be clamped between the housing and any other part. Do not disconnect the LCD panel while the instrument is on. Follow the rules to work with components at risk of electrostatic discharge. hybriSpot12 Service Manual 14/41 7.2 General Description – Spare Parts 7.2.1 Housing and Covers 7.2.1.1 Top Panel VIT-120036 – Top Panel VIT-120044 – Housing Cap Set (Top Caps) VIT-120025 – Reaction Chamber VIT-120059 – Reaction Chamber Cover hybriSpot12 Service Manual 15/41 VIT-120030 – O-ring Set VIT-120057 – Grids Set VIT-120032 – Caps Set VIT-120026 – Reaction Chamber Cover Gasket hybriSpot12 Service Manual 16/41 7.2.1.2 Display Panel VIT-120040 – Display Panel VIT-120041 – Front Panel 7.2.1.3 Connections & Maintenance rear panel hybriSpot12 Service Manual 17/41 VIT-120006 – I/O Switch VIT-120007 – DC Power Connector VIT-120011 – Service Port Cable VIT-120021 – Panel Tube Connection Kit VIT-120042 – Connection Rear Panel VIT-120043 – Maintenance Rear Panel 7.2.2 Reaction Chamber VIT-120012 – Thermoelectric Cold Plate Cooler VIT-120012 Thermoelectric Cold Plate Cooler VIT-120023 Bar Straight Set hybriSpot12 Service Manual 18/41 VIT-120029 Quarter turn fastener receptacle VIT-120026 – Reaction Chamber Gasket 7.2.3 Hydraulic System VIT-120003 – Miniature Solenoid Valve VIT-120018 – Tygon Tube ID1/8” – OD1/4” hybriSpot12 Service Manual 19/41 VIT-120019 – Tygon Tube ID1/16” – OD3/16” VIT-120020 – Tygon Tube ID3/32” – OD7/32” VIT-120024 – Manifold Set VIT-120037 – Bottom Panel VIT-120045 – Hydraulic Plate VIT-120046 – Hydraulic Base Plate VIT-120055 – Peristaltic Pump 1.5x1.0mm VIT-120056 – Peristaltic Pump Head 1.5x1.0mm 7.2.4 Electronic System hybriSpot12 Service Manual 20/41 VIT-120004 – Housing Fan VIT-120005 – Temperature Sensor VIT-120008 – Peltier Fan Cable VIT-120009 – Peltier Cable VIT-120010 – Display Ribbon Cable VIT-120013 – Power Circuit Board VIT-120014 – Display Circuit Board VIT-120060 – Web Camera Circuit Board hybriSpot12 Service Manual 21/41 VIT-120033 – Image Capture System Webcam VIT-120058 – Image Capture System V2 7.3 Access to the Hydraulic Circuit To access the hydraulic circuit, remove the five (5) screws of the Maintenance Rear Panel and remove it. 7.4 Access into the instrument and electronics circuits Remove carefully the top panel 4 Housing Caps with the help of two screwdrivers. Insert a screwdriver Phillips nº 2 into the hole of each Housing Caps after the snap fit unblock the lid and pull up it. hybriSpot12 Service Manual 22/41 Lift the lid carefully to avoid damaging the connecting pipes between pumps, valves and Incubation block: hybriSpot12 Service Manual 23/41 8 ELECTRONIC SYSTEM 8.1 Cables Colour Codes As convention all the cables used in the HS12’s components have a specific colour in order to help in a faster identification of each component. Type of Component Colour Picture Fans Green-Black Peltier Purple-Black Valves Yellow-Black Pumps Orange-Black Temperature Sensor Red-White-Black DC Power Red-Black 8.2 General Description hybriSpot12 ServiceManual 24/41 8.2.1 Boards interconnections hybriSpot12 Service Manual 25/41 8.2.2 Power Circuit Board hybriSpot12 Service Manual 26/41 8.2.3 Main Connections hybriSpot12 Service Manual 27/41 Close-up of the connections of Power Supply & Switch, Peltiers and Temperature Sensors: hybriSpot12 Service Manual 28/41 Close-up of the connections of the pumps, valves and fans: hybriSpot12 Service Manual 29/41 Close-up of the location of resettable fuses and control LEDS: Close-up of the location of LEDs control valves and pumps: hybriSpot12 Service Manual 30/41 8.3 Display Circuit Board hybriSpot12 Service Manual 31/41 8.4 Service Port and Program Port VIT-20001 - Service Port Cable (Technical Service Tool) VIT-20002 – Program Port Cable Kit (Technical Service Tool) hybriSpot12 Service Manual 32/41 8.5 DC Power Connector 8.6 Camera circuit board and Camera Housing hybriSpot12 Service Manual 33/41 9 HYDRAULIC SYSTEM General Description 2 1 2 1 2 1 REACTION CHAMBER VALVE 3 VALVE 2 VALVE 1 PUMP 3 PUMP 2 PUMP 1 WASTE TANK WASTE CONNECTION CLEAN/AIR CONNECTION SUCTION MANIFOLD WASTE MANIFOLD CLEAN/AIR TANK CLEAN/AIR CONNECTION 3xTYGON R3630 TUBING (1/16" ID x 3/32" OD) CHAMBER TEMPERATURE SENSOR HOLE TYGON R3603 TUBING (1/8" ID x 1/4" OD) TYGON R3603 TUBING (1/8" ID x 1/4" OD) TYGON R3603 TUBING (1/8" ID x 1/4" OD) TYGON R3603 TUBING (1/8" ID x 1/4" OD) 3xTYGON R3630 TUBING (3/32" ID x 7/32" OD) 3xTYGON R3630 TUBING (3/32" ID x 7/32" OD) A1A2B2 B1 C3 C2 C1 D3 D2 D1 C6 C5 C4 D6 D5 D4 Instrument hybriSpot 12 Plan HYDRAULIC DIAGRAM Author DJ Versión: V01 Fecha: 04/02/14 hybriSpot12 Service Manual 34/41 8 CONTROL SOFTWARE The control software, HS12 Monitor, detects automatically the USB port connection of hybriSpot 12. In case it not automatically detected, you can select the connection port using the drop menu HS12 Port: 8.1 Valves and Pumps Control Area You can make an independent or full set of control for the valves and pumps. To do this, open the Valves / Pump section. ON button turns the valve or pump on and OFF button turns it off. There is a color code to the right of each valve indicating the status of each component: •Valves: Green: Turned off Red: Turned on Blue: Low consumption hybriSpot12 Service Manual 35/41 •Pumps: Green: Turned off Red: Turned on When the valve remains on for long, Duty Cycle Time is activated and low consumption mode is powered on to safeguard the integrity of the valve and save energy. Note that there are two different fans connected to the Valve 4 and Pump 4 positions. The chassis fan is connected to the Pump 4 position and it is always working (This position is always in red color). The peltier fan is connected to the Valve 4 position and is controlled directly by software. The ON and OFF buttons don’t work in this position. 8.2 Temperature Control The temperature control can be monitored through the Temperature Control section. Target Temperature: Target temperature to be reached P, I, D, I Lim Values, Delta Shutdown: Target Parameters (internal use and no documentary evidence) Fan Stop Temp (º C): Temperature at which the fan stops working. Fan Stop Time (Seg): Time when the fan stop working when reaching “Fan Stop Temp”. Temp Gain, Temp OffSet: Target Parameters (internal use and no documentary evidence) hybriSpot12 Service Manual 36/41 There is a visual control to manage if the temperature target value has been reached and the control of the fans. To perform the temperature control, press the Run Control button and to stop control, press the Stop Control button. Temp. Control: Green: Turned off Red: Turned on Blue: Low consumption Target Reach: Green: Target temperature unreached Red: Target temperature reached Fan On: Green: Peltier Fan is not working. Red: Fan Peltier Fan is working. hybriSpot12 Service Manual 37/41 8.3 Commands Menu Read Config: read the configuration of the current RAM memory of the system. Send Config: Send the current configuration to the RAM memory of the system. Write Config in Flash: Write the current configuration from the RAM memory to the Flash memory of the system. Reload Flash Config: Refresh the current configuration in the RAM memory with the one stored in the Flash Memory of the system. Factory Settings: Set the default parameters. System Reset Stop System: 8.4 Auto Settings Menu hybriSpot12 Service Manual 38/41 TEC Profile: Tool used for temporary temperature control settings on the instrument. It is used as a worksheet in which different steps are added, such us objectives temperatures and how long you have to maintain that temperature. 8.5 Flash Memory Programming The procedure for programming the Flash memory is as follows: Connect the Cable Port Kit Program (VIT-20002) to your computer using the USB cable and the program port of the Power Circuit Board. Start the STM ST-LINK utility and connect to the device. The Connect to the target icon is used. hybriSpot12 Service Manual 39/41 Before programming the instrument, delete the content stored in the Flash, pressing the Full Chip Erase button. • A message will indicate the complete deletion of the memory. hybriSpot12 Service Manual 40/41 Once the deletion process is finished, check that the memory content is FFFFFFFF in all entries. To program the new firmware version click on the Program Verify- icon and a new dialog box will appear. hybriSpot12 Service Manual 41/41 Press the Browse button to select the file with the new program to install and press the Start button to begin programming. Once the process is completed, verify that the memory has been successfully programmed.