Preventive Maintenance SOP: GTP™ - Good Titration Practice™

changer
Preventive Maintenance SOP

GTP™ - Good Titration Practice™
Rondo
Rondo sample changer
sample
Contents
1 Visual checks ...............................................3
2 Functional checks .........................................4

2.1 Introduction............................................................. 4
2.2 Required material and tools ...................................... 4
2.3 “Nonstop” functional test (V1.0 & V2.2) ..................... 4
2.4 “Single steps” functional test ..................................... 6
2.5 Endurance tests ....................................................... 9
© 2010 All rights reserved Mettler-Toledo AG, Analytical, Schwerzenbach
No part of this document may be reproduced or transmitted in any form or by any means, electronic
or mechanical, including photocopying and recording, for any purpose without the express written
permission of Mettler-Toledo AG, Analytical, Schwerzenbach
U.S. Government Restricted Rights: This documentation is furnished with Restricted Rights.
METTLER TOLEDO RESERVES THE RIGHT TO MAKE REFINEMENTS OR CHANGES WITHOUT NOTICE.
1 Visual checks
These operations do not require the instrument to be opened. Perform the checks and fill the form
"Preventive Maintenance Checklist" on last page of this SOP.
Component Checks
Rack drive • Check the power cable has no defects and is securely attached to the
power inlet.
• Check the connection cable and plug has no defects and is securely
attached to the titrator.
• Check the On/Off switch for smooth operation.
• Check all screws for a tight fit.
• Check the housing for contamination with chemicals, cracks and
discolorations. Clean it with a clean cloth moistened with water or
alcohol.
Keyboard • Check the keyboard for cracks and damages.

• Clean with a clean cloth moistened with water or alcohol.
Sample rack • Check the proper seating of the clips.

• Check the rack surface for contamination with chemicals, cracks and
discolorations. Clean it with a clean cloth moistened with water or
alcohol.
• Check the transparent cover disk accommodating the magnets at the
bottom of the rack.
• Check if no magnets are missing or if they are not corroded.
Tower/s • Check the tower housing for contamination with chemicals, cracks
and discolorations.
• Wipe off the housing surface with a clean cloth moistened with water
or alcohol.
• Make sure that the holes of the rinsing unit (PowerShower™) are
clear. If they are clogged, clean them with water or compressed air.
• Clean the window of the beaker recognition system with a clean cloth
moistened with water or alcohol.
• Check the connectors and tower connecting cable.
Documentation • Identify the Rondo model depending on the sample rack size (either
60, 30, 20, 15 or 12) and record its serial number, location and date
of performing the Preventive Maintenance.
• Record the results of the visual check in the corresponding tables of
Preventive Maintenance Checklist (a template for making a
photocopy is at the end of this document).
• Sign and put the date at the bottom of the Preventive Maintenance
Checklist.
14.9.2010 METTLER TOLEDO 3 / 10

Version 09/2010 Preventive Maintenance SOP 51710894
2 Functional checks
2.1 Introduction
Functional checks do not require the Rondo to be opened and to be connected to a titrator.
Functional tests check the Rondo in two modes:
• “Nonstop” functional test with the steps taking place automatically.
• Functional test in single steps activated manually.
During these tests all photocell gates and sensors are triggered at least once.
Please allow the instrument a warm-up time of at least 30 minutes before the testing is
carried out.
2.2 Required material and tools
Instrument Rondo sample changer

Titrator (required for endurance test)
Tools TTL I/O test connector ME-51108805

RS232-loopback plug ME-51107288
Labware, cables & RS232 connecting cable Rondo sample changer to titrator
accessories Appropriate titration beakers depending on the sample rack type
2.3 “Nonstop” functional test (V1.0 & V2.2)

This test is used to identify in which step any error occurs. The functional test goes through one
complete cycle. If no error occurs, the cycle is automatically repeated (endless loop). If an error
occurs, however, the Rondo stops after the first cycle and the Status LED flashes.
2.3.1 Preparation
• Insert the male loopback test connectors in the COM1, COM2, COM3 and TTL-I/O interfaces.
• Plug the stirrer, pumps and power cable.
• Place the sample rack with all sample beakers on the rack drive.
• Using one tower: fit the conditioning clip at the last position (before “1”) on the sample rack.
• Using two towers: fit the one conditioning clip at the last position (before “1”) and a second on
diametrically opposite the first.
2.3.2 Starting the test

• Press the “Pump2” key and hold it down.
• Simultaneously switch on the Rondo.
• After 10 seconds release the “Pump2” key.

The TOWER B LED then flashes to indicate that the “nonstop” functional test is active.
Note: In order to localize an error, the Rondo has to be switched off as soon an error occurred. After
that the “single steps” test should be activated.
•
Localize the error by going through the individual steps.
2.3.3 “Nonstop” functional test sequence

Test Sample Rack
Steps Inquiry Status OK / failed
1 Loopback test at COM1
[1]
4 Loopback test at TTL-I/O
5 Tower A present? Read SW Ver/Rev
6 Tower B present? Read SW Ver/Rev
[2]
7 Lift moving down 400 steps
[2]
8 Lift moving to Zero position
9 Tower A Lift Zero position request Zero Pos?
10 Tower B Lift Zero position request Zero Pos?
11 Rack Present request Rack present OK?
12 Rack moving to 0-position
13 Rack 0-position request 0-position OK?
14 Rack ID read ID OK? ID OK?
15 Rack moving to next position
16 Resolver request Position OK?
17 Tower A present? Read SW Ver/Rev OK: next 20 / No: next 18
18 Tower A female connector Read SW Ver/Rev OK: next 20 / No: next 19
[3] OK: next 1 / failed: Rondo
19 After 1 complete cycle audible signal
stops, Status LED blinking
Test Tower (Tower A or Tower B or both)
Steps Inquiry Subsequent steps
20 P1 ON for 5"
21 P2 ON for 5"
22 Stirrer ON (50%)
23 Stirrer OFF
24 Beaker recognition green LED ON
25 Lift moving down 400 steps
26 Lift moving to Zero position
27 Lift Zero position request
28 Lift moving slow to titration position
29 Clip detection read Clip present?
30 Lift moving to Rotate position

31 Read beaker recognition Beaker present?
32 Request Rotate position Rotate position OK? Go to 18 (Tower B is
present)
or to 19 (if Tower B is not
present)
[1] All three RS232 (COM1 - COM3) as well as TTL-I/O inputs and outputs are tested separately. If one (or more) inputs or
outputs are defective, the system waits for 5 seconds with the LED flashing before proceeding with the next test step.
[2] If two Towers are installed, both lifts are activated simultaneously.
[3] Audible signal is generated after completing all tests. If a Tower is tested, the beep comes after completing the Tower test.
2.4 “Single steps” functional test

2.4.1 Preparation
• Insert the male loopback test connectors in the COM1, COM2, COM3 and TTL-I/O interfaces.
• Plug the stirrer, pumps and power cable.
2.4.2 Procedure
• Press the “Pump1” key and hold it down.
• Simultaneously switch on the Rondo. The following status should appear:
LED Status
1 POWER on
2 STATUS off
3 TOWER A on
4 TOWER B off
• After 10 seconds release the “Pump1” key. The following LEDs on the keypad light up:
LED Status
1 POWER on
2 STATUS off
3 TOWER A flashes
4 TOWER B off
The “Single steps” functional test is now active. The “STOP/CONT” key is then used to initiate one
step at a time.
Note: Even if there is an error in a tested step, the examination continues. If the “Error” status
appears in a step, the functional component concerned must be examined.
If an error condition arises, this is indicated by the STATUS LED flashing for 5 seconds, but
not until the next time the “STOP/CONT” key is pressed.
If no error has occurred in the particular test step, this confirmed by blinking of green Tower B
LED and the test can be continued with the next step.

2.4.3 “Single steps” functional test sequence (V1.0 and V2.2)
Test Sample Rack
Steps Inquiry Status: OK Status: failed

1 Loopback test at COM1 next 2 Status LED blinking 5"
➔ go to 2
[1]
➔ go to 3
[1]
➔ go to 4
[2]
4 Loopback test at TTL-I/O next 5 Status LED blinking 5"
➔ go to 5
5 Tower A present? Read SW Ver/Rev next 6 Status LED blinking 5"
➔ go to 6
6 Tower B present? Read SW Ver/Rev next 7 Status LED blinking 5"
➔ go to 7
[3]
7 Lift moving down 400 steps next 8 Status LED blinking 5"
➔ go to 8
[3]
8 Lift moving to Zero position next 9 Status LED blinking 5"
➔ go to 9
9 Tower A Lift Zero position request Zero Pos? next 10 Status LED blinking 5"
(or 11) ➔ go to 10 (11)
10 Tower B Lift Zero position request Zero Pos? next 11 Status LED blinking 5"
➔ go to 11
11 Rack Present request Rack present OK? next 12 Status LED blinking 5"
➔ go to 12
12 Rack moving to 0-position next 13 Status LED blinking 5"
➔ go to 13
13 Rack 0-position request 0-position OK? next 14 Status LED blinking 5"
➔ go to 14
14 Rack read next 15 Status LED blinking 5"
OK?
➔ go to 15
15 Rack moving to next position next 16 Status LED blinking 5"
➔ go to 16
16 Resolver request Position OK? next 15 Status LED blinking 5".
until rack Rack goes to 0-position
again in 0- ➔ go to 17
position
17 Tower A present? Read SW Ver/Rev next 20 No: next 18
18 Tower A female connector Read SW Ver/Rev next 20 No: next 19
19 After 1 complete cycle audible next 1 Rondo stops, Status
signal [4]
red LED blinking

Test Tower (Tower A or Tower B or both)
Steps Inquiry Status OK Status: failed
20 P1 ON for 5" next 21 Status LED blinking 5" ➔
go to 22
21 P2 ON for 5" next 22 Status LED blinking 5" ➔
go to 23
22 Stirrer ON (50%) next 23 Status LED blinking 5" ➔
go to 24
23 Stirrer OFF next 24 Status LED blinking 5" ➔
go to 25
24 Beaker recognition green LED ON next 25 Status LED blinking 5" ➔
go to 26
25 Lift moving down 400 steps next 26 Status LED blinking 5" ➔
go to 27
26 Lift moving to Zero position next 27 Status LED blinking 5" ➔
go to 28
27 Lift Zero position request next 28 Status LED blinking 5" ➔
go to 29
28 Lift moving slow to titration position next 29 Status LED blinking 5" ➔
go to 30
29 Clip detection read Clip present? Wait 5”, Status LED blinking 5" ➔
next 30 go to 31
30 Lift moving to Rotate position next 31 Status LED blinking 5" ➔
go to 32
31 Read beaker recognition Beaker present? Wait 5”, Status LED blinking 5" ➔
next 32 go to 33
32 Request Rotate position Rotate position next 18 Status LED blinking 5" ➔
OK? [5]
(or 19) go to 18 (or 19)
Explanation
[1] Loopback test at COM2 and COM3 fail with firmware version 2.0 and 2.1.
Recommendation
In case of failures during the “single steps” examination, it is highly recommended to update the
Rondo sample changer from V2.0 or 2.1 to V2.2
[2] All three RS232 (COM1 - COM3) as well as TTL-I/O inputs and outputs are tested separately. If
one (or more) inputs or outputs are defective, the system waits for 5 seconds with the LED
flashing before proceeding with the next test step.
[3] If two Towers are installed, both lifts are activated simultaneously.
[4] Blinking of the red Status LED after the test is completed, indicates that one of the tests during
the "single step" examination failed.
[5] If Tower B is not present, the examination is finished what is confirmed with the audible signal (as
described at step 19).

2.5 Endurance tests
2.5.1 Endurance test (V1.0 and V2.2)
This endurance test is controlled from the DL5x or DL7x titrator. Detailed instructions for initiating the
endurance test are given in the Service Manual for the particular titrator in section B “Serial
interfaces”.
Preparing the Rondo

• Insert the male loopback test connectors in the COM1, COM3 and TTL I/O interfaces.
• Connect the titrator to the COM2 interface on the Rondo.
• Plug in the stirrer, pumps and power cable.
• Switch the Rondo on.
Preparing the titrator

• Select the Service mode.
• Select SERIAL INTERFACE MENU.
• In the menu make the following selections:
o 0: select device (2 ST20/ST20A)
o 6: select ST20 device (1 for DL5x or 2 for DL7x. Select using the keypad).
o 7: ST20 test Æ enter 2 for endurance test
Test sequence
• The sample rack rotates twice.
• The entire sample rack is processed and at every beaker the green beaker recognition LED in the
tower must light up.
• Pump 1 is switched on for 5 seconds.
• The stirrer is switched on for 5 seconds.
• The lift moves from the “Zero” position to the “Titrate” position and then to the “Rotate” position.
• The lift waits 5 seconds, then moves back to the “Zero” position again.
• The test sequence restarts automatically.

2.5.2 Endurance test (V2.0 only)
As there is no programmed test available, a new method has to be created on a T50/T70/T90 titrator.
With two towers, the test should be repeated, using the second tower.
Preparing the Rondo

• Connect the titrator to the COM1 interface on the Rondo.
• Plug in the stirrer, pumps and power cable.
• Fit the conditioning clip at the position 9 on the sample rack
• Switch the Rondo on.
Preparing the titrator

Note: If on the titrator under "Setup > Global settings > Analysis and Resource Behaviour >
"Resources Information when recognizing PnP resources" is activated, a pop-up "Titration
stand detected" must appear.
• On the titrator add the pump 1 to the Rondo Tower 1 and assign an auxiliary reagent to it.
• Create a new method as following:
o Title
o Sample
o Titration stand: Rondo
o Pump: 5 seconds
o Stir: 5 seconds
o Conditioning: flexible, 5 seconds
o End sample
Test sequence
• Start the methods with e. g. 120 samples.
• The entire sample rack is processed and at every beaker the green beaker recognition LED in the
tower must light up.
• Pump 1 is switched on for 5 seconds.
• The stirrer is switched on for 5 seconds.
• At beaker 10 a conditioning takes place.
• The test sequence restarts automatically.

Maintenance
Preventive Maintenance Checklist
for Rondo sample changer
Checklist
Instrument Rondo sample changer Date

Serial number Location
Visual checks and cleaning

Preventive Maintenance
Components Check Clean Replace n/a OK

Rack drive
Power cable • {
Rondo power inlet •
Preventive
Power switch •
Keyboard • •
Blue plugs •
Housing (no cracks and damages) • • {
COM1 interface male connector •
TTL-I/O female connector •
Tower A female connector •
Tower B female connector •
Sample rack
Seating of clips •
Surface • •
Transparent cover disk for magnets • • {
Magnets • {
Tower A
Connecting tubing • • {
Stirrer • • {
Splash guard • •
Rinsing unit (PowerShower™) • •
PUMP 1 female connector •
STIRRER female connector •
Connecting cable to rack drive •
METTLER TOLEDO 1/2 Rondo Preventive Maintenance

Visual checks and cleaning (continued)
Components Check Clean Replace n/a OK
Tower B
Preventive Maintenance Checklist

Connecting tubing • • {
Stirrer • • {
Splash guard • •
Rinsing unit (PowerShower™) • •
STIRRER female connector •
Connecting cable to rack drive •
Maintenance on opened instrument

Components Check Adjust Clean Lubricate n/a OK
Rack drive
Internal gear • • • •
Magnetic sensor •
Start/Stop sensor •
Count sensor •
Tower A
Carriage guide • { • •
Carriage play • •
Beaker recognition optics •
Boards •
Toothed belt •
Tension of the toothed belt • •
Tower B
Carriage guide • { • •
Carriage play • •
Beaker recognition optics •
Boards •
Toothed belt •
Tension of the toothed belt • •
• Standard (mandatory)
{ Optional (if necessary)
The preventive maintenance activities listed above were performed by the METTLER TOLEDO authorized
service specialist, what is confirmed with the signature below:
Name Signature
METTLER TOLEDO 2/2 Rondo Preventive Maintenance

Preventive Maintenance SOP: GTP™ - Good Titration Practice™

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changer

Preventive Maintenance SOP

2 Functional checks .........................................4

Keyboard • Check the keyboard for cracks and damages.

Sample rack • Check the proper seating of the clips.

14.9.2010 METTLER TOLEDO 3 / 10

2.2 Required material and tools

Instrument Rondo sample changer

Tools TTL I/O test connector ME-51108805

2.3 “Nonstop” functional test (V1.0 & V2.2)

2.3.2 Starting the test

14.9.2010 METTLER TOLEDO 4 / 10

Localize the error by going through the individual steps.

2.3.3 “Nonstop” functional test sequence

14.9.2010 METTLER TOLEDO 5 / 10

2.4 “Single steps” functional test

14.9.2010 METTLER TOLEDO 6 / 10

Steps Inquiry Status: OK Status: failed

14.9.2010 METTLER TOLEDO 7 / 10

14.9.2010 METTLER TOLEDO 8 / 10

Preparing the Rondo

Preparing the titrator

14.9.2010 METTLER TOLEDO 9 / 10

Preparing the Rondo

Preparing the titrator

14.9.2010 METTLER TOLEDO 10 / 10

Instrument Rondo sample changer Date

Visual checks and cleaning

Components Check Clean Replace n/a OK

METTLER TOLEDO 1/2 Rondo Preventive Maintenance

Housing (no cracks and damages) • • {

Maintenance on opened instrument

METTLER TOLEDO 2/2 Rondo Preventive Maintenance

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