BOND-III™

Preventative Maintenance Checklist

1 Safety Notes
1. Standard laboratory practices MUST be followed when performing the preventative
maintenance. Liquids in the BOND-III™ are hazardous; please wear appropriate safety
clothing, gloves and safety glasses.
2. When working with or around Printed Circuit Boards (PCBs) ensure that the BOND-
III™ is powered off but the power cable remains connected to an earthed outlet. Use
a grounding strap when contact with electronics can occur.
3. Bulk reagent containers should have been regularly cleaned by the customer. If the
customer chose not to do so, encourage them to clean bottles on the next reagent
refill. Offer to help them, should they wish to perform the operation at the time of
the preventative maintenance.
2 Outline
The Preventative Maintenance (PM) routine is designed to prevent malfunctions of the
BOND-III™ instrument as a whole by investigation of parts, modules and/or assemblies that
are likely to affect the instrument reliability after the initial manufacturer warranty period
has expired.
The routine is structured by modules and should be followed in the order listed. Tick the
checkboxes next to each step when completed. If one of the checks identifies a problem
please refer to the relevant section in the latest version of the BOND Service Manual to
determine the appropriate course of action. Please attach the complete PM Checklist to the
Mobile or Technical Service Job.
3 Estimated Time to Complete
The estimated time to complete this PM for one instrument is: 7 hours 30 minutes.
4 Equipment and Information Required:
Safety clothing, safety glasses and gloves
External Hard Drive (minimum 20 GB)
Bond Calibration Jigs S21.2085
Interlock Override Magnets S21.1967
General Toolkit including flashlight
Test Detection Kit and an open container
70% Alcohol (for cleaning)
Latest BOND Service Manual
Replacement Heaters (if required)
5 Parts Required
The BOND-III™ PM kit (S21.4562) is designed to be used in full, please utilise all the parts
included in the kit and mentioned in this checklist.
However 6 x OEM611 Adaptor ⅛ NPT, 6 x OEM606 Barb ¼ -28, 3 x 21.2598 Hare Probe and 1
x OEM3683 Barbed T Fitting ¼ are included in case of damage.

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Review the instruments history and order any TSB kits which need to be performed on the
instrument prior to being onsite. Perform the required TSB(s) at the most logical stage
during the PM process.
Note: All abnormal conditions found during the PM routine must be noted at the end of this
checklist and brought to the customer’s attention.
Note: Instrument must be idle (connected and initialised) for the following steps.

6 Check Communication and Electrical cables

6.1 Check to ensure the Control Kit communication and power connections are free from
unnecessary tension and are secure.

6.2 Check the HUB / Switch is not damaged and clear of any fluid.

7 Check Main Lids and Doors

7.1 Check the Main Lid and ensure that the Main Lid is able to remain open.

7.2 Check the Main Lid and Bulk Reagent doors work correctly by opening and closing
them. Look for damage/wear or for stiffness in the hinges which could indicate they
are rusted.

7.3 Check the Latching / Interlock Magnets. Ensure they are secured to the Main Lid and
are working correctly.

8 Bond Software Functionality

Alarms and Interlocks

Check the Main Lid alarm is active when the Lid is opened.

8.1 Figure 1 - Lid/Door Alarm

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9 SSA’s Flush and Wash block Cleaning

9.1 Use the Interlock Override Magnets to override the interlocks on the Main Lid.

9.2 Open the Service Software and connect to the instrument. Go to Service Component
VerificationFluidics and Vacuum.

• Pour 100 ml of the 70% alcohol into the Wicking Post of

position 1 and 10 on SSA 1 Note: Ignore prompt from Bond
service software “Pour 10-30ml Buffer”.
• Select Verify flush from SSA1 to HAZ Separator Bottle then
click Execute.

• Pour 100 ml of the 70% alcohol into the Wicking Post of

position 1 and 10 on SSA 2 Note: Ignore prompt from Bond
service software “Pour 10-30ml Buffer”.
9.3 SSA Flush • Select Verify flush from SSA2 to HAZ Separator Bottle then
click Execute.

• Pour 100 ml of the 70% alcohol into the Wicking Post of

position 1 and 10 on SSA 3 Note: Ignore prompt from Bond
service software “Pour 10-30ml Buffer”.
• Select Verify flush from SSA3 to HAZ Separator Bottle then
click Execute.
• Then select Verify flush from HAZ Separator Bottle to HAZ
Waste Bulk Bottle and click Execute.

9.4 Cleaning the Wash • Clean the Wash Block and remove DAB build-up using a Q-Tip
Block and 70% alcohol.

9.5 Cleaning the BFR • Clean all the BFR’s Wash Block using a Q-Tip/Cotton bud
Wash Block And 70% alcohol.

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10 Probe, Insulation Block and Syringe Change

Ensure that the Bond User Application Software is running.

In the Bond user GUI, access Maintenance  Instrument Name

“name” Replace Aspirating Probe. This will prepare the
fluidics system for the Probe replacement and drain the fluid
from the Probe and Syringe.
Once the fluid has been removed from the instrument and the
instrument has disconnected from the GUI, TURN-OFF the
instrument and start replacing the Insulator Block, Aspirating
Probe, Syringe & Plunger Screw as per instructions below.

Remove aspirating probe and replace Insulator block following

the procedure in the Service Manual. However, do not turn-
on the instrument and do not conduct the tests as specified in
the replacement procedure. (Test will be conducted later)
Note: Clean the Z-Axis Rod (Probe Holder) with tissue and alcohol
before installing the new insulator block. Be gentle when re-
connecting the gold connectors on the coaxial cable, push in the
connector until it clicks and then stop pushing any further.

Use a multi-meter to check the resistance across the insulator

block as per the figure below. The value should be greater than
13k ohms (13,000 ohms). If it is below or above this value,
10.1 Aspirating Probe & disconnect the gold connectors on the coaxial cable and
reconnect gently.
Insulation Block
Replacement

Figure 2 - Insulator Block Resistance Check

Replace the Aspirating Probe from the instrument following

the procedure in the Service Manual. However, do not turn-on
the instrument and do not conduct the tests as specified in
the replacement procedure. (Test will be conducted later)

Demonstrate the probe replacement to a trained user of the

instrument so that it can be completed by the customer in the
future. (Replace as per User Manual).

Replace the Syringe following the instructions in the Service

10.2 Syringe & Plunger
Screw Replacement
Manual. Replace the screw holding in the Plunger of the
syringe with the one provided in the kit. Be careful not to over
tighten or damage the thread of the syringe pump assembly.
(9 Port Syringe Pumps do not need to be lubricated).
However, do not turn-on the instrument and do not conduct
the tests as specified in the replacement procedure. (Test will
be conducted later)

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11 System Tasks (Database backups)
Note: During Database backups perform Step 12-18

Move any pre-existing database backups from the customer’s

default folder to a network or external HDD. A complete backup
can be several gigabytes; however, backups are incremental, so
11.1 System Operational any one backup will likely add megabytes rather than gigabytes
Tasks to the overall disk usage. Backup the Bond DB (and copy the
.dat files onto the customer’s network or external HDD).

Note: The customer is to store a copy of the

Database in a secure location.

12 Removed Panel

12.1 Remove the back and the left/right side cover of the instrument.

13 SSA Maintenance

Clean the Guide Bars and Cams with 70% alcohol if there is dirt or
residue present.

Clean

13.1 SSA Checks Figure 3 – Dirty Guide Bar Figure 4 - Cam/Bracket Residue

Check the Covertile clamp (Top Plate) springs for tension and free
operation. Clean the BFR long rail with a tissue and alcohol.
Replace the Covertile clamps if worn or out of alignment as per
Service Manual: BOND-III / Part Replacement / Slide Staining
Assemblies / Top Plate Assembly.

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 Check the operation of Top Plate Hinges.

Check the BFR long rail is not loose.

Check the BFR position sensing plate is not loose.

Check the operation of Slide Tray Locking Tab with the Top Plate.
There should be a positive force required to insert and remove
the slide tray.
Figure 5

13.2 Give all SSA’s and the Reagent tray assembly of the instrument a wipe down with a
cloth/tissue and 70% alcohol solution to remove liquids or residue on the instrument.

14 SSA’s Sump Maintenance

14.1 Perform the SSA Sump Maintenance Cleaning on all three SSA’s as per Service Manual.

Give the Sump a wipe with 70% alcohol solution to remove residue

Example of Bad Sump blockages

Figure 6

If you encounter SSA Sumps that look similar to the figure above please remember to take a
photo and attach it to your Mobile Service Electronic Record or Technical Record.

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14.2 Remove and replace all 3x Drain Tubes on the Sumps.

(Tubes are supplied in the PM kit)

Figure 7

15 Bottles Check

15.1 Remove all Bulk Bottles and Drip tray and check for spills and leaks. Clean the trays if they
dirty.

15.2 Check bottles for damage / Check connector area / Check Cap for venting.

16 Load Cell Check

16.1 Check the Load Cell connection cables and check for cleanliness, leaks and corrosion.

16.2 Check around the base of the instrument under the drip trays for signs of leaks into the load
cell areas. (If leaks are found trace to the source and correct the problem)

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17 Reagent Supply Line Replacement

Replace the Reagent Supply Line following the instructions in TSB B21.5084.680 A02

17.1
DI water
Epitope Retrieval 1
Epitope Retrieval 2
Wash Buffer
Alcohol

Figure 8
Replace Reagent Supply lines of the following bulk reagent bottles
(Tubes are supplied in the PM kit)

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18 Diaphragms and Tubing replacement

18.1 Replace Viton Diaphragms on all liquid waste Gem Solenoid Valves (14 valves in total) using a
Phillips head screwdriver (PH1, 80mm blade) to prevent damaging the screws. For instructions
refer to Service Manual / BOND-III / Part Replacement / Waste Extraction Module / Individual
Waste Valves. Label or mark all tubing which is disconnected to ensure they are reconnected
correctly once the diaphragms are replaced.
If any diaphragms are considerably damaged, take a photo and attach it to your Mobile Service
Electronic Record or Technical Service Record.

18.2 Use a pin, pop rivet or thin piece of steel to clean the connector at the bottom of the Fluid Valves
to remove any build up which might cause a blockage, if required.
If any unusual build up or blockages are present, take a photo and attach it to your Mobile Service
Electronic Record or Technical Service Record.

Figure 9 - Fluid Valve Connector Cleaning

18.3 Remove and Replace 3x Tubing fitting assembly. (Supplied in the PM kit)

Figure 10 - Fluidic Tubing & Connector

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18.4 Remove and replace the Hazardous waste tube from the Pressure switch HAZ to HAZ waste bottle.

Figure 11 Figure 12

(Bulk waste tube supplied in the PM kit)

18.5 Check and replace any discoloured fluidics tubing, if required.

Figure 13 - Fluidics Tubing & Connector

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19 Instrument Full Initialisation
During this process perform all Bulk bottle sensor checks.

19.1 Remove all Bulk bottles (ER1, ER2, Dewax, DI, Wash Buffer, Alcohol, Bulk Waste1, Bulk
Waste2, Haz Waste)

19.2 Turn on the instrument

19.3 Check that all bulk bottle sensors are showing that all bottles are not present in the GUI

Figure 14 – GUI with no Bulk Bottles Present

19.4 Insert all Bulk bottles (ER1, ER2, Dewax, DI, Wash Buffer, Alcohol, Bulk Waste1, Bulk
Waste2, Haz Waste)

19.5 Check that all bulk bottle sensors are showing the bottles as present in the GUI

Figure 15 - GUI with all Bulk Bottles Present

19.6 During initialisation watch the syringes priming, looking for air bubbles. If air bubbles
appear towards the end of the prime and at the bottom resting point of the plunger it
could indicate a leak in the reagent line. Also confirm each of the BFR’s successfully
primed. Only continue if the instrument initialises successfully.

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Instrument initialized. Log in as Bond Service on the Control Kit and run the Service
Software.

20 Verification of Fluidics System

• Pour 100 ml of 70% alcohol into the Wicking Post of position

1 and 10 on SSA 1 Note: Ignore prompt from Bond service
software “Pour 10-30ml Buffer”.
• Select Verify flush from SSA1 to HAZ Separator Bottle then
click Execute. Check to make sure fluid is entering the
Hazardous Separator Bottle.

• Pour 100 ml of 70% alcohol into the Wicking Post of position

1 and 10 on SSA 2 Note: Ignore prompt from Bond service
software “Pour 10-30ml Buffer”.
• Select Verify flush from SSA2 to HAZ Separator Bottle then
click Execute. Check to make sure fluid is entering the
20.1 SSA Flush Hazardous Separator Bottle.

• Pour 100 ml of 70% alcohol into the Wicking Post of position

1 and 10 on SSA 3 Note: Ignore prompt from Bond service
software “Pour 10-30ml Buffer”.
• Select Verify flush from SSA3 to HAZ Separator Bottle then
click Execute. Check to make sure fluid is entering the
Hazardous Separator Bottle.
• Select Verify flush from HAZ Separator Bottle to HAZ Waste
Bulk Bottle and click Execute.
Check to make sure fluid is flushed from the Haz Separator
Bottle.

21 Calibration Part 1

21.1 Before commencing calibration & Verification, retrieve the alignment settings & persistent
settings and save them to C:\program files\VisionBioSystems\Service\Reports\Calibration
Settings. Change the name of the files to reflect whether they are alignment and persistent
settings.

21.2 Calibrate Wash Block Position using Bond Service Software.

21.3 Calibrate DAB Mixing Vial positions using Bond Service Software.

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22 Heaters Test
Note: During the Heater test perform Step 23 Reagent Container Calibration

22.1 Use a flashlight to check for leaks around the Heater Block Housing.

22.2 Visually check the Wicking posts for damage (clean if required).

22.3 Visually check the Heaters for damage and corrosion (clean if required), check the Heaters
are not loose. Any Heaters found to be damaged or corroded should be replaced as per
Service Manual. Note: (Heaters are not supplied in the PM kit).

Figure 16 – Heaters and Wicking Posts

22.4 Check that all Heaters are functional by running the Heater Test in the Service Software in
Service Component Verification Button Heaters. Select “Heater test for all SSA’s” and
click Execute. This test will take approximately 10 minutes. During this test perform Step
23
Note: Replace any heaters showing as suspect or failed or which were found to be faulty.

23 Reagent Container Calibration

23.1 Calibrate Reagent Container as per TSB B21.5093.680

24 Calibration Part 2

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24.1 Calibrate SSA1 and BFR1 using Bond Service Software.

24.2 Calibrate SSA2 and BFR2 using Bond Service Software.

24.3 Calibrate SSA3 and BFR3 using Bond Service Software.

24.4 Calibrate OCR Scanner using Bond Service Software.

24.5 Save the alignment and persistent settings once the calibration has been successfully
completed.

25 LLS Verification Test

25.1 Using the Service Software, select Service component  Robot  Robots LLS Test to verify
LLS sensing operation and the test has passed. If the test fails follow the troubleshooting
guide in the Service Software / BOND-III / Troubleshooting / FSE Troubleshooting Checklist
& Charts / Liquid Level Sensing Faults.
During the test check the Aspirating Probe Fluidic Line and fitting for leaks, blockages or
damage. If damaged replace as per Service Manual / Part Replacement /Main Robot /
Aspirating Probe Tube Assembly.

26 Checks and Tasks

26.1 Save the alignment values, LLS report and Heater test report to an external hard disk or
memory stick.
Note: Reports and alignment settings are required to be attached to your service job or in
mobile service.

27 Final Checks

27.1 Reassemble all Covers on the instrument.

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27.2 Clean all surfaces. Give all external faces of the instrument a wipe down with 70% alcohol
solution and cloth/tissue to remove liquids or residue on the instrument.

27.3 Customer’s & Engineer’s signature on the Service Report for confirmation of PM
completion and instrument operational.

27.4 Attach any additional documentation (eg. Run Events / Pictures / Service Report / PM
Checklist etc.) and to your service job.
Note: The PM checklist is required to be attached to your service job or in mobile service.

27.5 Customer Control Kit and Instrument should be left restarted / re-initialised. NOTE: The
Control Kit should NOT be left in Service Mode. You must “log out” as Service and log back
in as Bond User.

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28 Please use the space provided below to note any abnormal conditions
found during this PM.

Date Please provide month name not number (i.e. 11-May-2011)

Instrument Serial
Number
Firmware Version
Found

Engineer’s Name

Engineer’s
Signature

By signing here, customer accepts that this record is a true reflection of findings and work
carried-out by the engineer and they will undertake staining verification prior to the
instruments use.

Facility Name

Customer
Representative’s
Name
Customer
Representative’s
Signature

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