Allinity - DCAU-H00.840.63.03.02

STD/HT

Volume IV - Chapter 33
Alinity ci Interface Module

Document name: 0M00000101.FLX.6
Last revised (ISO 8601): 2019-04-19
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The information contained in this manual is the property of the Manufacturer
Reproduction of text and illustrations is not permitted without prior written approval by the Manufacturer
The Manufacturer reserves the right to alter product specifications at any time without notice or obligation.
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Automation System Alinity ci IM
Table of contents
Reference documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Release notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
33. INTERFACE MODULE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

33.1 - Identification Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
33.2 - Identification Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
33.3 - Technical and Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
33.4 - Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
33.4.1 - Module purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
33.4.2 - Interface Module Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
33.4.3 - Buffer lane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
33.4.3.1 - Path of the Carriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
33.4.3.2 - Process Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
33.4.3.2.1 - Buffer lane - Standard version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
33.4.3.2.2 - Buffer lane - High Throughput version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
33.4.3.3 - Buffer lane pneumatic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
33.4.3.3.1 - Standard version. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
33.4.3.3.2 - High Throughput version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
33.4.4 - Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
33.4.4.1 - Path of the carriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
33.4.4.2 - Process Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
33.4.5 - Sub-assemblies identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
33.4.5.1 - Main assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
33.4.5.2 - Alinity Spur L-Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
33.4.5.3 - Alinity Spur Return. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
33.4.5.4 - Alinity Spur Sampling Bay - Short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
33.4.5.5 - Alinity Spur Sampling Bay - Long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
33.4.5.6 - Alinity Spur End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
33.4.5.7 - Cover assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
33.4.5.8 - Pneumatic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
33.4.5.9 - Electrical Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
33.4.5.9.1 - Electric Panel Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
33.4.5.9.2 - Electric connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
33.4.5.9.3 - CAN-bus layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
33.4.5.10 - CAN-bus net layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
33.4.5.10.1 - Communication System Architecture - Standard version . . . . . . . . . . . . . . . . . . . 44
33.4.5.10.2 - Communication System Architecture - High Throughput version . . . . . . . . . . . . . 45
33.5 - Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
33.5.1 - Assembling Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
33.5.2 - Required tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
33.5.3 - Parts Shipped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
33.5.4 - Preliminary operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
33.5.5 - Main Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
33.5.6 - Electric and pneumatic supplies specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
33.5.7 - Uncrate the Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
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33.5.8 - Installing the Module straight version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

33.5.8.1 - Preparing the Module installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
33.5.8.2 - Positioning and Aligning the Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
33.5.9 - Installing the Module with the L - Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
33.5.9.1 - Preparing the Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
33.5.9.2 - Positioning and aligning the Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
33.5.9.3 - Securing the Interface Module with the L - Turn to the Analyzers . . . . . . . . . . . . . . . 96
33.5.10 - Establishing the main electrical and pneumatic connections . . . . . . . . . . . . . . . . . . . 99
33.5.10.1 - Connecting the Module Straight version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
33.5.10.2 - Connecting the Module with the L - Turn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
33.5.10.3 - Connecting the Spur electric and pneumatic supply . . . . . . . . . . . . . . . . . . . . . . . 108
33.5.11 - Installing the covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
33.5.12 - Resuming the Automation System installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
33.5.13 - Completing the module installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
33.6 - General maintenance rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
33.6.1 - Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
33.6.1.1 - Safety devices, precautionary measures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
33.6.2 - Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
33.6.3 - Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
33.7 - Corrective maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
33.7.1 - External corrective maintenance procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
33.7.2 - Corrective maintenance procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
33.7.2.1 - Alinity Spur L - Turn: motor replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
33.7.2.2 - Alinity Spur L - Turn: Motor Belt assembly replacement . . . . . . . . . . . . . . . . . . . . . 121
33.7.2.3 - Alinity Spur L - Turn: idler pulleys replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
33.7.2.4 - Alinity Spur L - Turn belt: drive assembly replacement . . . . . . . . . . . . . . . . . . . . . . 133
33.7.2.5 - Alinity Spur Return: gate replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
33.7.2.6 - Alinity Spur Return: motor replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
33.7.2.7 - Alinity Spur Return: disk replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
33.7.2.8 - Alinity Spur Return: U-Turn gate replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
33.7.2.9 - Alinity Spur Return: U-Turn gate and diverter replacement. . . . . . . . . . . . . . . . . . . 152
33.7.2.10 - Alinity Spur Sampling Bay: ATR replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
33.7.2.11 - Alinity Spur Sampling Bay: Sampling gate replacement . . . . . . . . . . . . . . . . . . . . 158
33.7.2.12 - Alinity Spur Sampling Bay: gate and diverter replacement . . . . . . . . . . . . . . . . . . 162
33.7.2.13 - Alinity Spur Samplig bay(s): Belt(s) replacement . . . . . . . . . . . . . . . . . . . . . . . . . 166
33.7.2.14 - Alinity Spur L - Turn: belt(s) replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
33.7.2.15 - Alinity Spur End Cap: motor replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
33.7.2.16 - Alinity Spur End Cap: tensioning roller replacement . . . . . . . . . . . . . . . . . . . . . . . 172
33.7.2.17 - Alinity Spur End Cap: idler roller replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
33.7.2.18 - Alinity End Cap: disk replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
33.7.2.19 - Alinity End Cap: tensioning device replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 180
33.7.2.20 - Q7CA Board replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
33.8 - Preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
33.8.1 - External preventive maintenance procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
33.8.2 - Preventive maintenance procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
33.8.2.1 - Gears Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
33.8.2.2 - Module Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
33.9 - Auxiliary procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
33.9.1 - External auxiliary procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
33.9.2 - Auxiliary operations charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
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33.9.3 - Auxiliary procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

33.9.3.1 - Spur belt welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
33.9.3.2 - Spur Belt tensioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
33.9.3.2.1 - Belt tensioning for Spur Sampling bay(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
33.9.3.2.2 - Belt tensioning for Spur L-Turn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
33.9.3.3 - Spur Belt tensioning verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
33.9.3.4 - Spur belts adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
33.9.3.5 - Aspiration gate position adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
33.9.3.6 - Alinity Spur Return Disk adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
33.9.3.7 - Digital pressure switch settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
33.9.3.8 - How to solve the Worklist Incorrect Information warning (S0059) . . . . . . . . . . . . . . 210
33.9.3.9 - Setting the Buffer Lane version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
33.9.3.10 - Alinity ci IM Antennas test procedure (Standard version). . . . . . . . . . . . . . . . . . . 212
33.9.3.10.1 - Antennas reading Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
33.9.3.10.2 - Reading test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
33.9.3.10.3 - Antenna alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
33.9.3.10.4 - Reading range verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
33.9.3.11 - Alinity ci IM Antennas test procedure (HT version). . . . . . . . . . . . . . . . . . . . . . . . 214
33.9.3.11.1 - Antennas reading Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
33.9.3.11.2 - Reading test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
33.9.3.11.3 - Antenna alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
33.9.3.11.4 - Reading range verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
33.9.3.12 - Local energy lockout and tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
33.9.3.12.1 - Local energy lockout / tagout procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
33.9.3.12.2 - Restoring local energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
33.9.3.13 - Test run procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
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Reference documentation
The complete set of the Automation System documentation consists of:
Automation System – Operations Manual

– Service Manual
Data Management – Service Manual
Software (DMS)
The Automation System Service Manual is composed of several chapters; the complete
structure of the Service Manual must be intended as a single manual
Please refer to the “Safety compliance” chapter for detailed informations about
the safety of the Module.
To complete the set of Alinity ci Interface Module documentation also refer to:
Alinity ci Interface Module – Wiring diagram

– Pneumatic diagram
– Automation System layout
Release notes
The table reassumes the changes between the previous and this version of the
document.
Tab. 1 - Release notes
Paragraph Summary
- Minor changes
33.4.5.7 Paragraph updated
33.5.11 Procedure updated
33.7.2.20 Procedure updated
33.9.3.4 Procedure added
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33. Interface Module Assembly

The present Service Manual provides information, procedures and methods for
installation, repair, and servicing of the Alinity ci Interface Module (Alinity ci IM).
33.1 Identification Data

Module name Alinity ci IM
Group Drawing no.: FLX-138-20-0001 (Alinity Spur End Cap Standard and
HT version)
FLX-296-00-0003 (Alinity Spur Return Standard
version)
FLX-296-10-0001 (Alinity Spur Return HT version)
FLX-297-00-0005 (Alinity Spur Sampling Bay - Short
Standard version)
FLX-297-10-0003 (Alinity Spur Sampling Bay - Short HT
version)
FLX-298-00-0005 (Alinity Spur Sampling Bay - Long
Standard version)
FLX-298-10-0002 (Alinity Spur Sampling Bay - Long HT
version)
FLX-299-20-0000 (Optional Alinity Spur L-Turn
Standard and HT version)
33.2 Identification Labels

The Module has three/four identification labels to identify the main elements. The
following figures show where each label is located.
Fig. 1 - Alinity Spur End Cap identification label
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Fig. 2 - Alinity ci Interface Module electrical plate identification label
Fig. 3 - Alinity Spur Sampling Bay - Short and Alinity Spur Sampling Bay -
Long identification labels
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Fig. 4 - Optional Alinity Spur L-Turn identification label
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33.3 Technical and Environmental Specifications

For all technical and environmental information refer to the Operation manual and to the
Technical specifications spreadsheet provided by Inpeco.
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33.4 Description
This chapter contains a general description of the Module and its technical
characteristics. A basic explanation of its principles of operation is also provided.
33.4.1 Module purpose

The Alinity ci IM was designed to send sample tubes to the Alinity ci instruments.
The Alinity ci Interface Module directs carriers to the sample aspiration point using a
Spur with three lanes. The Spur consists of three belts, that are moved by a DC motor.
The Module consists of two major sections, the Main Track Slot and the Instrument
Spur. The Main Track Slot provides the components to divert samples from the Main
Track into the attached Spur, and to receive samples from the Spur and guide them back
on to the Main Track. The Spur manages movement of samples within the Interface
Module, and manages presentation to Alinity ci Instrument modules.
33.4.2 Interface Module Components

The Alinity ci IM components are shown in the following figure.
Fig. 5 - Alinity ci IM main components straight configuration
A - Alinity ci IM with three lanes
B - Aspiration point for CC Analyzer
C - Aspiration point for IA Analyzer
D - Module buffer lane
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Fig. 6 - Alinity ci IM main components Alinity Spur L-Turn
A - Alinity ci IM with three lanes
B - Aspiration point for CC Analyzer
C - Aspiration point for IA Analyzer
D - Alinity Spur L-Turn (if present)
E - Module buffer lane
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33.4.3 Buffer lane

33.4.3.1 Path of the Carriers
The following figures shows the carriers path and the belts spin directions.
Fig. 7 - Buffer lane Carrier Path
A - Main lane
B - Secondary lane
C- Spur exit lane.
Fig. 8 - Buffer lane with STAT Carrier Path
A - Main lane
B - Secondary lane
C- Spur exit lane.
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33.4.3.2 Process Controls

The Carrier identification is performed using Radio Frequency Identification (RFID)
antennas on the Buffer lane as well as on the Interface Module.
A detail of the process is shown below.
33.4.3.2.1 Buffer lane - Standard version

Fig. 9 - Buffer lane devices - STD version
1. As the carrier approaches the Alinity ci Module instrument interface, the Routine
Queue Diverter (D0) allows to divert the sample tube into the secondary lane or
allow the sample tube to continue along the Main lane.
2. The Stop Gate (G0) controls the introduction of sample tube from the Main lane to
the secondary lane. Then the released carriers arrive at the Spur. The TAG
antenna 6A1 and the associated board (4A1) identifies the carrier RFID.
3. At the process end, the carriers released from the Spur to return on the Main Track.
To prevent a collision with the carriers coming along the Spur exit lane processed
sample tube, the carrier on the Main Track is stopped at the G7 gate and checked
by the sensor 7BF2.
4. The sample tube coming along the Spur exit lane is checked by the sensor 7BF1.
When the gate G6 releases a carrier, the gate G7 stops the carriers on the primary
Track main lane to avoid the collisions.
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Fig. 10 - Buffer lane with STAT devices - STD version
1. As the carrier approaches the Alinity ci Module instrument interface, the Routine
Queue Diverter (D0) allows to divert the sample tube into the secondary lane or
allow the sample tube to continue along the Main lane to the STAT Diverter Gate
(D1).
2. The Routine Queue Stop Gate (G2) controls the introduction of sample tube from
the secondary lane into the Spur. Then the released carriers arrive at the Spur. The
TAG antenna 6A1 and the associated board identifies the carrier RFID.
3. The Track Diverter Gate (D1) can divert a sample carrier into the STAT Spur input
or allow the sample tube to continue along the Main lane. If diverted, the carrier will
arrive at the Spur. The Diverter Gate (D1) is the last point on the main track slot at
which a sample can be diverted into the Spur.
4. At the process end, the carriers released from the Spur to return on the Main Track.
To prevent a collision with the carriers coming along the Spur exit lane processed
sample tube, the carrier on the Main Track is stopped at the G7 gate and checked
by the sensor 7BF2. The sample tube coming along the Spur exit lane is checked
by the sensor 7BF1. When the gate G6 releases a carrier, the gate G7 stops the
carriers on the primary Track main lane to avoid the collisions.
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33.4.3.2.2 Buffer lane - High Throughput version

Fig. 11 - Buffer lane devices - HT version
1. As the carrier approaches the Alinity ci Module instrument interface, the NSD (5A1)
allows to divert the sample tube into the secondary lane or allow the sample tube
to continue along the Main lane.
2. The NSD (5A1) controls the introduction of sample tube from the buffer lane into
the Spur. Then the carriers arrive at the Spur.
3. At the process end, the carriers released from the Spur to return on the Main Track
To prevent a collision with the carriers coming along the Main Track, the sensor
7BF1 checks the carrier passage and the ATR device (5A2), actuated by an
electric motor, returns the carrier along the secondary lane exit, avoiding eventual
collisions.
For further details about the standard devices (NSD, ATR), please refer to the
Service Manual chapter “TMA-Track Module Assembly”.
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Fig. 12 - Buffer lane with STAT devices - HT version
1. As the carrier approaches the Alinity ci Module instrument interface, the NSD (5A1)
allows to divert the sample tube into the secondary lane or allow the sample tube
to continue along the Main lane to the STAT NSD (5A2).
2. The Routine Queue Stop Gate (G0) controls the introduction of sample tube from
the secondary lane into the Spur. Then the released carriers arrive at the Spur. The
TAG antenna 6A1 and the associated board identifies the carrier RFID.
3. The STAT NSD (5A2) can divert a sample carrier into the STAT Spur input or allow
the sample tube to continue along the Main lane. If diverted, the carrier will arrive
at the Spur. The STAT NSD (5A2) is the last point on the main track slot at which
a sample can be diverted into the Spur. The STAT Bridge (B0) allows a proper
carrier transfer from the lanes.
4. At the process end, the carriers released from the Spur to return on the Main Track
To prevent a collision with the carriers coming along the Main Track, the sensor
7BF1 checks the carrier passage and the ATR device (5A3), actuated by an
electric motor, returns the carrier along the secondary lane exit, avoiding eventual
collisions.
For further details about the standard devices (NSD, ATR), please refer to the
Service Manual chapter “TMA-Track Module Assembly”.
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33.4.3.3 Buffer lane pneumatic system

Gates are controlled by a Control Board located in the Electric panel near to the
Interface Module. The board controls solenoid valves activating stop gates and
diverters. The EV Group is located near to the Alinity ci IM.
Please always refer to the Automation System pneumatic layout to know where
the EV groups are exactly located.
Remember:
1 MPa = 10 bars
1 MPa = 145 psi
33.4.3.3.1 Standard version

Fig. 13 - Buffer lane pneumatic diagram - STD version
0P00023358.01
Tab. 2 - EV board - STD version (Sheet 1 of 2)
EV Cable Description Device

EV6 7YV1 Stop gate G7 (Fig. 9)
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EV1.1 7YV2 Stop gate G0 (Fig. 9)
EV2.1 7YV3 Diverter D0 (Fig. 9)
Fig. 14 - Buffer lane with STAT pneumatic diagram - STD version
0P00022160.00

EV2.1 8YV2 Diverter D0 (Fig. 10)
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EV2.2 8YV4 Diverter G1 (Fig. 10)
33.4.3.3.2 High Throughput version

Fig. 15 - Buffer lane pneumatic diagram - HT version
0P00027753.00
Tab. 4 - EV board - HT version

NS1 Stop gate NSD 5A1 (Fig. 11)
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Fig. 16 - Buffer lane with STAT pneumatic diagram - HT version
Tab. 5 - EV board - HT version

7YV1 Stop gate G0 (Fig. 12)
7YV2 Bridge B0 ( Fig. 12)
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33.4.4 Interface Module

33.4.4.1 Path of the carriers
The following figures shows the carriers path and the belts spin directions.
Fig. 17 - Path of the carriers on Alinity ci IM straight version
A - Alinity Spur Main lane
B - Alinity Spur Sampling Bay aspiration lane
C - Alinity Spur exit lane.
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Fig. 18 - Path of the carriers on Alinity ci IM with Alinity Spur L-Turn
A - Alinity Spur L-Turn Main lane
B- Alinity Spur Main lane
C- Alinity Spur Sampling Bay aspiration lane
D- Alinity Spur exit lane
E- Alinity Spur L-Turn exit lane
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33.4.4.2 Process Controls

The Carrier identification is performed using Radio Frequency Identification (RFID)
antennas on the Buffer lane as well as on the Interface Module.
A detail of the process is shown below.
Fig. 19 - Interface Module devices
1. The Spur Entry Stop Gate (G3) regulates carriers entry onto the Spur from the Main
Track (or from the Alinity Spur L-Turn), and, if necessary, hold the incoming
samples while carriers from the U-Turn are re-introduced to travel through the Spur
another time. When released form the Spur Entry Stop Gate (G3), the released
carrier arrived at the Module Diverter Gate (G4) of first Sampling Bay. The TAG
antenna (9A2) and the associated board identifies the carrier RFID.
2. Each Alinity ci Module has a queue. Each queue has a Module Divert Gate. The
Spur can divert samples arriving at the Module Divert Gate (G4) into the Module
queue or allow them to continue to the next Sampling Bay Diverter Gate. In the
case of last Module Gate, the next gate will be the U-turn Stop Gate (G6), not
another Sampling Bay Divert Gate. The Sampling Bay Diverter Gate (G4) have a
sample presence sensor (7BF2) in addition to the carrier RFID reader (6A1).
3. The Module Aspiration Gate (G5) holds samples in position at the Alinity ci Module
aspiration point. The Module Aspiration Gate is positioned in one of two locations
on each module slot, depending on whether the module is CC or IA type.
To ensure no movement occurs during Sample presentation, each Module
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Aspiration Stop Gate has a sample carrier presence sensor (7BF1) that provides
continuous motion detection during specimen acquisition.
4. Released from the Module Aspiration Gate (G5), the carrier returns into the Spur
Main Lane through the ATR (8A1).
5. Once a sample has travelled through the Spur it is stopped at the U-Turn Divert
Gate (D6) and the associated Antenna (9A1) determinate whether it should be
released to the main track, or make a U-Turn and travel through the Spur another
time.
6. At the process end, the carriers are released to return on the Main Track.
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33.4.5 Sub-assemblies identification

The Module is composed of several sub-assemblies. In the following paragraph, every
assembly is identified and analyzed.
Fig. 20 - Sub-assemblies identification
Item Description
(A) MAIN ASSEMBLY
(B) ALINITY SPUR L-TURN
(C) ALINITY SPUR RETURN
(D) ALINITY SPUR SAMPLING BAY - SHORT
(E) ALINITY SPUR SAMPLING BAY - LONG
(F) ALINITY SPUR END CAP
(G) COVER ASSEMBLY
(H) ELECTRICAL ASSEMBLY
- PNEUMATIC SYSTEM
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33.4.5.1 Main assembly

The Main assembly is the base structure of the Module, contains also the Electric Panel.
Fig. 21 - Main assembly components
A - Frame
B - Main connection plate
C - Secondary connection plate
D - Solenoid valves
E - Q7 Carrier board
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33.4.5.2 Alinity Spur L-Turn

The Alinity Spur L-Turn allows positioning of the Analyzers parallel to the Main Track
instead of perpendicular.
Fig. 22 - Optional “L spacer” components
A - Belts Motor E - Connection plate

B - Motor driver F - Sections connection system
C - Transmission group G - Idler pulleys groups
D - Motor pulleys
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33.4.5.3 Alinity Spur Return

Alinity Spur Return assembly allows to manage the transfer of carriers and sample tubes
from the main track to the Analyzer sampling points. The Alinity Spur Return also allows
re-routing of carriers back into the Spur.
Fig. 23 - Alinity Spur Return assembly
A - U-Turn system motor
B - U-Turn system diverter gate
C - Idler pulleys
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33.4.5.4 Alinity Spur Sampling Bay - Short

The device is used as configurable sampling point for the Analyzer.
Fig. 24 - Alinity Spur Sampling Bay - Short components
A - Sampling point in IA Analyzer configuration F - Antenna driver

B - Sampling point in CC Analyzer configuration G - ATR driver
C - ATR H - Solenoid valves
D - Sections connection system I - Module diverter gate
E - Connection plate
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33.4.5.5 Alinity Spur Sampling Bay - Long

The device is used as configurable sampling point for the Analyzer. This Sampling Bay
is longer due to the presence of the SCM Module on the Analyzer.
Fig. 25 - Alinity Spur Sampling Bay - Long components
A - Sampling point in IA Analyzer configuration F - Antenna driver

B - Sampling point in CC Analyzer configuration G - ATR driver
C - ATR H - Solenoid valves
D - Sections connection system I - Module diverter gate
E - Connection plate
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33.4.5.6 Alinity Spur End Cap

The Alinity Spur End Cap is the final section of the Alinity ci IM,it moves the carrier from
the Spur Main lane to the Spur exit lane.
Fig. 26 - End Cap components
A - Spur belts Motor
B - Motor driver
C - Transmission group
D - Motor pulleys
E -Tensioning device
F- Sections connection system
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33.4.5.7 Cover assembly

The upper covers protect the Operator from:
– Analyzer mechanical movements
– Biohazard
Fig. 27 - Upper cover assembly straight configuration
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Fig. 28 - Upper cover assembly with Alinity Spur L-Turn
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33.4.5.8 Pneumatic System

The pneumatic system is functionally divided into two separated sections:
– Track: pneumatic actuators on track (see "Buffer lane - Standard version"
(par. 33.4.3.2.1) for Standard version or "Buffer lane - High Throughput version"
(par. 33.4.3.2.2) for HT version)
– Module: pneumatic actuators on the Alinity ci IM
A diagram showing the Module pneumatic system is shown below.
Fig. 29 - Pneumatic assembly
A - Sampling bays EV manifold
B - Spur Return section EV manifold
C - Pressure switch and indicator
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Fig. 30 - Pneumatic system - General distribution
Remember:
1 MPa = 10 bars
1 MPa = 145 psi
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Fig. 31 - Pneumatic system diagram
0P00026164.00
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33.4.5.9 Electrical Assembly

The electrical system controls both the device functions and the Automation System
interfacing with the device itself.
The electric panel is placed inside the support structure.
Fig. 32 - Main Electrical panel straight configuration
Fig. 33 - Main Electrical panel with L-Turn
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33.4.5.9.1 Electric Panel Components

Fig. 34 - Main Electrical panel components
B A C
D E F G
0Q00001109.03
A - Q7CA board E - Relay

B - Motor driver F - Power supply
C - Antenna driver G - Fuse
D - Circuit breaker
Fig. 35 - Alinity Spur Sampling Bay - Short and Alinity Spur Sampling Bay -
Long Electrical Plate components
A B
0Q00001110.02
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A - Antenna driver B - Motor driver
Fig. 36 - Alinity Spur End Cap Electrical Plate components
A
0Q00001112.01
A - Motor driver
Fig. 37 - Alinity Spur L-Turn Electrical Plate components
A
0Q00001113.01
A - Motor driver
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33.4.5.9.2 Electric connections

Fig. 38 - Electric connections diagram
0S00000755.04
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Fig. 39 - Electric connections diagram with Alinity Spur L-Turn
0S00000761.04
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33.4.5.9.3 CAN-bus layout

33.4.5.10 CAN-bus net layout
0Q00001109.03
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33.4.5.10.1 Communication System Architecture - Standard version

Here below is the diagram showing the Module system communication bus architecture.
Fig. 40 - Alinity ci IM architecture Standard version
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33.4.5.10.2 Communication System Architecture - High Throughput version

Here below is the diagram showing the Module system communication bus architecture.
Fig. 41 - Alinity ci IM architecture HT version
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33.5 Installation Instructions

This section describes the operations required for opening the supplied packing,
removing protections and assembly of parts and guards safely restoring electric and
pneumatic connections.
Follows the conceptual maps representing all the possible Analyzers configurations.
Fig. 42 - Straight configuration layout conceptual map
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Fig. 43 - Alinity Spur L-Turn configuration layout conceptual map
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33.5.1 Assembling Prerequisites

The floor must have characteristics suitable to bear the Module weight, for information
about Module weight, please refer to the "Technical and Environmental Specifications"
(par. 33.3).
33.5.2 Required tools

Prepare the tools needed to execute the installation.
Be sure to have all the tools needed to perform the assembling procedure, see the
“Service Tools chapter”, “Basic installation / maintenance equipment tools” section for
tools reference chart.
If a specific tool is required to execute an operation, the tool code is indicated in the
procedure, and also listed in the module specific section of the “Service Tools chapter”.
33.5.3 Parts Shipped

For any information about the crates identification, dimension and weight refer to the
packing list provided with the shipment.
HEAVY OBJECT
It is necessary to use a lifting system to lift up and move the Module.
33.5.4 Preliminary operations

Operations to do before starting the assembly on the Module:
– Identify the Module installation location. Refer to the Automation System layout.
Clean from any interference and trip hazards the area of installation.
– Clear a 3 m by 3 m (9.84 ft by 9.84 ft) work space around the Module installation
location.
– Place a sign in a clearly visible location on the power connection indicating that
maintenance is in progress and power must remain disconnected.
– Verify clearances around the Alinity ci IM, see "Main Clearances" (par. 33.5.5)).
– Verify the electrical and pneumatic supplies, see "Electric and pneumatic supplies
specifications" (par. 33.5.6).
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33.5.5 Main Clearances

To ensure optimal ventilation and for a safe and efficient operator maintenance, it is
required to leave the free space around the Module as indicated in the following figures
Fig. 44 - Main clearances for straight configuration
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Fig. 45 - Main clearances for Alinity Spur L-Turn configuration
33.5.6 Electric and pneumatic supplies specifications

The electric and pneumatic power supply are supplied by the Automation System.
For detailed information about electrical, pneumatic and earth connections, refer to:
• "Technical and Environmental Specifications" (par. 30.3)
• Wiring Diagrams
• Pneumatic Diagrams.
The connection that grounds the Automation System track also provides ground to the
module.
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33.5.7 Uncrate the Module
Operating procedure
During the installation, personnel MUST NOT wear ties, watches, bracelets, or loose-fitting clothing.
a. Identify the crate containing the Alinity ci IM.
b. Use a forklift with adjustable blades to move

the Module shipping container to the
installation area. Insert the blades as
indicated in the figure.
c. Open the shipping crate or remove the cardboard box (depending on the shipping method).
d. Pull the packing off the pallet.
e. Remove the protective sheets, if any.

Remove the protective sheets with care, do not use cutting tools in order to avoid potential damaging
to cables or mechanical parts.
f. Remove all free parts and place them aside.
g. Remove the belts and or brackets securing the module sub-assemblies to the pallet, if any
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33.5.8 Installing the Module straight version

33.5.8.1 Preparing the Module installation
Operating procedure
Do not power on the Module until the end of the installation procedure.

The following procedure is valid only for a Module straight version installation.
If you are installing an Interface Module with L - Turn, please refer to the "Preparing the Module
Installation" (par. 33.5.9.1) procedure.
a. Check that the installation space on the track has no loose cables or tubings in the open space between
the upper and lower extrusions. Store any excess cables or tubing into the upper cable storage area.
b. Move the Module sub-assemblies from the crate to its approximate position at the main track.
Always refer to the track layout drawing for positioning the Module.

During handling:
• Make sure not to pinch any cables or air tubes while moving the Module sub-assemblies.
• DO NOT lift or hold the Module using the upper cover or the top of the working surface.
c. Approach the Module sub-assemblies close to the track installation point, by referring to the dimensions
shown in the Automation System layout.
d. Remove the top, side and bottom covers on the Spur.

Covers removal enables easier assembly, routing of cables, seeming and tensioning of the belts and
attaching the Spur to the track.
e. Remove the track side panels (A), the top

separator (B) and the side panels (C), if
present.
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Operating procedure (Continues)

Check that the indicated buffer lane
spacer is in the showed position.
If not, place it in the right position.
f. Put a square (A) on the track upper profile (B).
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g. Move the square in contact with the edge of
the profile (B).
h. Keeping the square (A) in contact with the

track profile, assemble the plate provided with
the alignment tool p/n 0A00019362 (C) to the
track side at 3 mm [0.118 in.] from the square.
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i. Locate the Alignment tool (p/n 0A00019362).
j. Insert the four provided nuts inside the track

slots, in order to be ready to assemble the
Alignment tool
k. Screw without tightening the four bolts

securing the Alignment tool (A) to the track
side, close to the plate (C).
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l. Level the Module by acting on the adjustable
feet (A) - see Fig. 46 - and placing the (B)
bubble level tool (p/n PFD0694) with two
Track Leveling Tools (p/n 403600150), as
shown in figure.
m. Loosen the nut (B), screw or unscrew the nut Fig. 46 -Adjustable feet
(A) to raise or lower the Alignment tool. When
the adjustment is done, tighten the nut (B).
n. Install the target plates (A) included in the

Alignment tool to the Analyzer closest to the
Main Track, by using the holes dedicate at the
Interface Module support brackets.
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o. Approach the Analyzer(s) to the Alignment
tool, until the tool spacers (A) are in contact
with the Analyzer surface.
Refer to the Analyzer documentation to
perform a safe and correct alignment.
The tool spacers are adjustable

elements, just release the fixing screw
(A) and move the spacer.
When a proper position is reached, tight
the screw.
p. Align the Analyzer position by following next

steps:
Handle the Instrument with care by
referring to the Instrument service
documentation. The following steps
have to be carried out by the Instrument
service team.
p.1 Adjust the position of the Analyzer until the

two pointers (B) are both centered on the
targets (C).
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p.2 Raise the Analyzer off its wheels and onto its feet.
The instrument should also be level.

p.3 Once the Instrument has been raised and leveled, check again the alignment of the pointers on the targets.
p.4 If not centered, act on the adjustable feet of the Analyzer to adjust it. Ensure also that the Analyzer is
leveled.
p.5 The Instrument position is now correctly set.
q. Act on the indicated fixing screw to remove

carefully the Alignment tool (A).
Do not remove the alignment plate (B),
it must be used for maintenance
procedures.
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r. Remove the targets (A) and install the
support brackets (B) to the Analyzer.
Each Sampling Bay must have 2
support brackets. The last Sampling
Bay will have only one support bracket,
the second support bracket will be
placed under the Alinity Spur End Cap.
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33.5.8.2 Positioning and Aligning the Module
Operating procedure

To avoid injuries and/or damages to the Module handle it in two or more people.

During handling:
shown in the Automation System layout.
d. Move the sections that compose the Module (except the Main assembly) on a suitable working plane.
e. Remove the top, side and bottom covers on the Spur Return, Sampling Bay - Short, Sampling Bay - Long
(if present) and the End Cap.
attaching the spur to the track.
f. Move the Alinity Spur Sampling Bay - Short

close to the Alinity Spur Return and align the
two sections:
• Placed in contact and align the two spur

sections.
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• Insert the dowel pins in position (A) and
align the plates with the four holes
present in the two sections (B).
• Insert and tighten the four fixing plate
screws.
g. Move the Alinity Spur Sampling Bay - Short

close to the Alinity Spur Sampling Bay (Short
or Long), if any:

sections.
If the mentioned sub-assembly is not
present, go to next step.
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screws.
h. Move the Alinity Spur Sampling Bay (Short or

Long) close to the Alinity Spur End Cap:

sections. 
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screws.
• Install and tighten the fixing screws (on

both side) to fix the tensioning device to
the Alinity Spur Sampling Bays (Short or
Long).
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Pay attention not to damage the
tensioning system pins during the
operations.
i. In some cases can be necessary move the

sampling gate(s) into the IA Analyzer
aspiration point (A) or into the CC Analyzer
aspiration point (B):
Please refer to the Automation System
Layout to determinate the spur
configuration.
These steps are valid for both

operations, the following images are for
representative purposes.
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i.1 Unscrew the indicated fixing screws and
remove the sampling gate assembly.
During the operation pay particular
attention not to damage the antenna
and sensor cables.
i.2 Move the two support block (A) to the CC

aspiration point by acting on the indicated
fixing screws.
i.3 Switch the position of the gate upper plate.

During the operation pay attention not
to damage the sensor cable.
The gate upper plate with the sensor

(A) must be mounted above the
Analyzer sampling gate.
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i.4 Place the sampling gate assembly in the
aspiration point.
i.5 During the operation pay attention to:
• Route the 6A2 antenna cable between

the antenna and the gate, as shown
aside.
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• Ensure that the pneumatic tubing, that is
routed inside of the cable holder, does
not kink/crimp after the gate is
reassembled to the new position.
j. Only on HT version:
If not already present, install the spacer (by
using PFD0652) in front of the sampling point
at the indicated value:
• (A) If the Aspiration point is configured
for CC Analyzer.
• (B) If the Aspiration point is configured
for IA Analyzer.
Pay attention to install the spacer in

touch with the upper profile (C).
k. Perform the "Spur belt welding" (par. 33.9.3.1) procedure to install properly the belts.
l. Support the Module by placing the support

leg (p/n 0P00027701.xx) as indicated.
to damage any cable or tubing.
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m. Move the Module until both the Spur Module
external profiles edges (A) and the track
external separator edges (B) are aligned (C).
n. In the meantime, place carefully the Interface

Module on the support brackets (A) present
on the Analyzer(s).
o. Insert the mounting nuts, which are included

with the spur, to the track mounting channels
and screw without tightening the four bolts
securing the Spur to the track slot.
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p. It is very important the gap between the lane belts and the main track profile remains in a 0.5mm
[0.0197in] to 1.0mm [0.0394] range: in fact, if this distance is too small, interferences between the lane
belt and the main track profile may occur. If this distance being too large, the carrier may not be transferred
properly to the interface module lane. It is also important to verify that the upper surface of the 1st lane belt
and the upper surface of the main track secondary track belt are at the same level and in the ±0.3mm
[0.0118] range. If this condition is not verified when the spur is properly leveled, carriers may not pass
correctly from the secondary track lane to the interface module 1st lane.
Fig. 47 - Leveling dimension
If the gap between the lane belts and

the main track profile is out of the
indicated range, release the indicated
fixing screw and adjust the Spur
position, then tighten again the screw.
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q. Check the first lane belt clearance relative to the main track secondary lane by pushing the positioning tool
(p/n 0P00006799) through the space between the track profile and the first lane spur belt. The Spur
Positioning Tool should freely pass through the vertical and horizontal openings.
Fig. 48 - Leveling check
r. Check also that the belts are not in touch with

the main track bottom lip (A).
If adjustment is needed, act sequentially on
the four fixing bolts and rise the spur until the
belts are free to move.
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s. Tighten the four bolts securing the Spur to the
track slot.
t. To attach the brackets to the Alinity ci IM,

follow these steps:
• Insert the fixing nut (A) in the Spur slot.
• Screw without tighten the socket set
screw (B) in the fixing nut (A).
• Hold the socket set screw (B) and move
the fixing nut just over the support
bracket.
• Insert and tight the plastic fixing screw
(C) in the fixing nut (A).
• Repeat the operation for all the support
brackets.
u. Insert the Main assembly under the Alinity

Spur Return as shown aside.
If necessary, slightly tilt the Main
assembly under the Alinity Spur Return
during the operation.
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Use the support foot (A) and the hole in
the spur structure (B) to find the
approximate assembly location.
v. When the Main Assembly is placed, leave at

least the indicated distance between the Main
Assembly and the Alinity Spur Return, as
viewed from the back of the Electrical Panel.
• To adjust the height, loosen the nut (B), Fig. 49 - Adjustable feet
screw or unscrew the nut (A) to raise or
lower the Main Assembly. When the
adjustment is done, tighten the nut (B).
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w. Connect the indicated antennas (A) to the
main electrical plate, referring to the Alinity ci
IM wiring diagrams.
x. Remove the Spur central profile of the Spur

Sampling Bay - Short.
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y. Connect the indicated sensors (A) to the main
electrical plate by passing the cable through
the indicated hole (B), referring to the Alinity
ci IM wiring diagrams.
z. Adjust the Main Assembly height to support

the Alinity ci Module.
aa. Mount the indicated angular cover on the

Track structure and ensure it touches the
Main Assembly.
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ab. Install and align the separator to the strip and
tighten the three screws. Use the oversized
pallet tool (p/n 475110032 for Standard
version or p/n 0P00007823.00 for HT version)
to check the spacing on both sides of the
separator.
ac. Move manually the oversized carrier tool (p/n

475110032 for Standard version or p/n
0P00007823.00 for HT version) from the
track lane to the Spur and vice-versa to check
its sliding: it must be smooth, flat, without
steps and any kind of interference.
ad. Remove all the tools from the Interface

Module.
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33.5.9 Installing the Module with the L - Turn

33.5.9.1 Preparing the Module Installation
Operating procedure

To avoid injuries and/or damages to the Module handle it in two or more people.

During handling:
shown in the Automation System layout.
d. Remove the track side panels (A), the top

separator (B) and the side panels (C), if
present.
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Check that the indicated buffer lane
spacer is in the showed position.
If not, place it in the right position.
e. Move the sections that compose the Module (except the Main assembly) on a suitable working plane.
f. Remove the top, side and bottom covers on the Spur Return, Sampling Bay - Short, Sampling Bay - Long
(if present), the End Cap and the Spur L - Turn.
attaching the spur to the track.
g. Move the two indicated pulleys from the

Alinity Spur Return to the Alinity Spur L-Turn:
• Remove the indicated pulleys by acting

on the fixing screws.
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• Fix the previously removed pulleys on
the Alinity Spur L-Turn using the existing
holes, as showed aside.
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33.5.9.2 Positioning and aligning the Module
Operating procedure
a. Move the Alinity Spur Return close to the
Alinity Spur L-Turn and align the two sections:

sections.
• Insert the dowel pin in position (A) and

align the plate with the four holes
screws.
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• On the other side of the Spur, fasten the
two sections with the fixing plate by
tightening the screws shown in red.
• On the lower part of the Spur, use the

holes left empty from pulleys previously
moved to fix the two Spur sections, as
showed aside.
• On the lower part of the Spur, fix with the

indicated screw the angular bracket (A).
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b. Move the Alinity Spur Sampling Bay - Short
close to the Alinity Spur Return and align the
two sections:

sections.

screws.
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c. Move the Alinity Spur Sampling Bay - Short
close to the Alinity Spur Sampling Bay (Short
or Long), if any:

sections.
If the mentioned sub-assembly is not
present, go to next step.

screws.
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d. Move the Alinity Spur Sampling Bay (Short or
Long) close to the Alinity Spur End Cap:

sections. 

screws.
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• Install and tighten the fixing screws (on
both side) to fix the tensioning device to
the Alinity Spur Sampling Bays (Short or
Long).
Pay attention not to damage the

tensioning system pins during the
operations.
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e. In some cases can be necessary move the
sampling gate(s) into the IA Analyzer
aspiration point (A) or into the CC Analyzer
aspiration point (B):
Please refer to the Automation System
Layout to determinate the spur
configuration.
These steps are valid for both

operations, the following images are for
representative purposes.
e.1 Unscrew the indicated fixing screws and

remove the sampling gate assembly.
attention not to damage the antenna
and sensor cables.
e.2 Move the two support block (A) to the CC

aspiration point by acting on the indicated
fixing screws.
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e.3 Switch the position of the gate upper plate.
The gate upper plate with the sensor

(A) must be mounted above the
Analyzer sampling gate.
e.4 Place the sampling gate assembly in the

aspiration point.
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e.5 During the operation pay attention to:
• Route the 6A2 antenna cable between

the antenna and the gate, as shown
aside.
• Ensure that the pneumatic tubing, that is

routed inside of the cable holder, does
not kink/crimp after the gate is
reassembled to the new position.
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f. Only on HT version:
If not already present, install the spacer (by
using PFD0652) in front of the sampling point
at the indicated value:
• (A) If the Aspiration point is configured
for CC Analyzer.
• (B) If the Aspiration point is configured
for IA Analyzer.
Pay attention to install the spacer in

touch with the upper profile (C).
g. Perform the "Spur belt welding" (par. 33.9.3.1) procedure to install properly the belts.
h. Move the Module until both the Spur Module

i. Insert the mounting nuts, which are included

with the spur, to the track mounting channels
and screw without tightening the four bolts
securing the Spur to the track slot.
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j. Support the Module by placing the Support
Leg tool (p/n 0P00027701.xx) as indicated.
k. It is very important the gap between the 1st lane belt and the main track profile remains in a 0.5mm
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If the gap between the lane belts and
the main track profile is out of the
indicated range, release the indicated
fixing screw and adjust the Spur
position, then tighten again the screw.
l. Check the first lane belt clearance relative to the main track secondary lane by pushing the positioning tool
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m. Check also that the belts are not in touch with
the main track bottom lip (A).
If adjustment is needed, act sequentially on
the four fixing bolts and rise the spur until the
belts are free to move.
n. Tighten the four bolts securing the Spur to the

track slot.
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o. Insert the Main assembly under the Alinity
Spur Return from Analyzer side.
Use the support foot (A) and the hole in

the spur structure (B) to find the
approximate assembly location.
p. When the Main Assembly is placed, leave at

least the indicated distance between the Main
Assembly and the Alinity Spur Return, as
viewed from the back of the Electrical Panel.
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• To adjust the height, loosen the nut (B), Fig. 52 - Adjustable feet
screw or unscrew the nut (A) to raise or
lower the Main Assembly. When the
adjustment is done, tighten the nut (B).
q. Connect the indicated antennas (A) to the

main electrical plate, referring to the Alinity ci
IM wiring diagrams.
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r. Remove the Spur central profile of the Spur
Sampling Bay - Short.
s. Connect the indicated sensors (A) to the main

electrical plate by passing the cable through
the indicated hole (B), referring to the Alinity
ci IM wiring diagrams.
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t. Mount the indicated angular cover on the
Track structure and ensure it touches the
Main Assembly.
u. Also respect the indicated distance.
v. Install the indicate leg as shown aside.

The leg is designed to facilitate the
cable wiring, the leg is not designed to
support the Interface Module
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33.5.9.3 Securing the Interface Module with the L - Turn to the Analyzers
Operating procedure
The Alinity ci IM is designed to interface the Alinity ci instruments. Please refer to the Analyzer
Service Documentation for further information regarding the Analyzer positioning.
Referring to the Analyzer documentation is necessary in order to perform a safe and correct
installation of the Analyzer.
a. Insert the Reference pointer tool (A) (p/n

0A00013794.00) into a carrier (B).
b. Remove the screw (C) from the tool.

The screw (C) help you only during the
pointer tool insertion and removal.
You must not place the carrier on the
Spur with the screw inserted.
c. Place the carrier on the Spur aspiration lane

against the Module Aspiration Gate.
Ensure that the carrier with the tool is
not released back to the Main Track.

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d. Approach the Analyzer to the Alinity ci IM,
until the distance between the Analyzer left
wall structure and the divert lane edge of the
Main track and the distance of the Analyzer
rear support panel reach the indicated values.
Refer to the Analyzer documentation in
to perform a safe and correct
alignment.
e. To attach the brackets to the Alinity ci IM,

follow these steps:
• Insert the fixing nut (A) in the Spur slot.
• Screw without tighten the socket set
screw (B) in the fixing nut (A).
• Hold the socket set screw (B) and move
the fixing nut just over the support
bracket.
• Insert and tight the plastic fixing screw
(C) in the fixing nut (A).
• Repeat the operation for all the support
brackets.
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f. Check the Alinity ci IM is bubble-leveled by
placing the level tool (p/n PFD0694) on two
Track leveling tools (p/n 0P00006796.00) on
the Spur Return section, as shown in figure.
If the Spur is not level, re-level it by adjusting
the screws attaching it to the track, the height
of the Main assembly and the support leg.
After the Spur is level, level the Analyzer to
the Spur.
g. Tight the screws of the support brackets and

remove the support leg.
h. Install and align the separator to the strip and

tighten the three screws. Use the oversized
pallet tool (p/n 475110032 for Standard
version or p/n 0P00007823.00 for HT version)
to check the spacing on both sides of the
separator.
i. Move manually the oversized carrier tool (p/n

0P00007823.00 for HT version) from the
track lane to the Spur and vice-versa to check
its sliding: it must be smooth, flat, without
steps and any kind of interference.
j. Remove all the tools from the Interface

Module.
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33.5.10 Establishing the main electrical and pneumatic

connections
33.5.10.1 Connecting the Module Straight version
Operating procedure
a. To Connect cables and tubings from the
Interface Module to the Main track section:
• Pass the cables and tubings from the

main connector plate (A) through the
cable entry frame (B).
Pay attention to pass properly the
cables and tubings through the cable
entry frame, following the Module wiring
diagrams.
For further information, refer to the
"Electrical Assembly" (par. 33.4.5.9), to
the "Pneumatic System"
(par. 33.4.5.8), to the Fig. 55 - Standard
Sampling connection map or to the Fig.
56 - HT Sampling connection map, to
the Fig. 54 - External Connections -
Track Side Block Diagram, to the
Module wiring diagrams and also to the
following connectors maps.
Fig. 53 - Cables and tubings connection map
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At the Main assembly exit, use cable
ties to organize cables (A) and tubings
(B) and route them to the Main track.
Fig. 54 - External Connections - Track Side Block Diagram
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Fig. 55 - Standard Sampling connection map
• Connect the 0C00007462 and 0C00007463 cables to the 5A1 Antenna board (please refer to the
wiring diagrams)
• Connect the 0C00007461 cable to the Main track line (please refer to the wiring diagrams and to the
Automation System Layout).
• Connect the air tubing to the Main track air supply (please refer to the wiring diagrams and to the
• Connect the Ethernet cable to the Main track Ethernet line (please refer to the wiring diagrams and to
the Automation System Layout).
• Connect the Main power supply to the Main Track Main power supply line (please refer to the wiring
diagrams and to the Automation System Layout).
Fig. 56 - HT Sampling connection map
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• Connect the 0C00007462 cable to the 4A1 Antenna board (please refer to the wiring diagrams).
• Connect the 0C00007463 cable to the 5A1 NSD (please refer to the wiring diagrams).
diagrams and to the Automation System Layout).
b. Connect the Automation System Ethernet line to the connectors plate (please refer to Fig. 53 on page 99).
c. If not already done, remember to plug the

LAS cable of the Alinity ci Interface Module:
• plug the LAS Ethernet cable to the

connectors plate (A) and route it inside
the Spur cable duct (B).
• reach the command center and plug the
Ethernet LAS cable into the Ethernet
port located above the LIS cable
connection. (C).
d. Plug also the LIS cable to the command

center (D) and route it inside the Spur cable
duct (B).
For further information about the LIS
connection, please refer to the
Automation System Layout to
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33.5.10.2 Connecting the Module with the L - Turn
Operating procedure
a. Connect cables and tubings from the
connectors plate (A) to the Alinity Spur L-Turn
connectors plate (C), by passing the cables
inside the electrical panel up to the Alinity
Spur L-Turn cable duct (B).
b. Now connect the cables from the Alinity Spur

L-Turn connectors plate (A) to the Main
Track, by passing the cables through the leg
(B).
For further information, refer to the
"Electrical Assembly" (par. 33.4.5.9), to
the "Pneumatic System"
(par. 33.4.5.8), to the Fig. 59 - Standard
Sampling connection map or to the Fig.
60 - HT Sampling connection map, to
the Fig. 58 - External Connections -
Track Side Block Diagram, to the
Module wiring diagrams and also to the
following connectors map.
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Fig. 57 - Module Connectors plate map
Fig. 58 - External Connections - Track Side Block Diagram
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Fig. 59 - Standard Sampling connection map
• Connect the 0C00007462 and 0C00007463 cables to the 5A1 Antenna board (please refer to the
wiring diagrams)
diagrams and to the Automation System Layout).
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Fig. 60 - HT Sampling connection map
• Connect the 0C00007462 cable to the 4A1 Antenna board (please refer to the wiring diagrams).
• Connect the 0C00007463 cable to the 5A1 NSD (please refer to the wiring diagrams).
diagrams and to the Automation System Layout).
c. Close the cable entry frame hole in the lower part of the Main assembly by using the plastic blank plate.
d. Connect the Automation System Ethernet line to the connectors plate (please refer to Fig. 61 on page 110).
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e. If not already done, remember to plug the
LAS cable of the Alinity ci Interface Module:
• plug the LAS Ethernet cable to the

connectors plate (A) and route it inside
the Spur cable duct (B).
• reach the command center and plug the
Ethernet LAS cable into the Ethernet
port located above the LIS cable
connection. (C).
f. Plug also the LIS cable to the command

center (D) and route it inside the Spur cable
duct (B).
For further information about the LIS
connection, please refer to the
Automation System Layout.
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33.5.10.3 Connecting the Spur electric and pneumatic supply
Operating procedure
a. Connect all the pneumatic tubings coming
from the Spur Return to the indicated
manifold (A).
For further information please refer to
the Interface Module pneumatic
diagram.
b. Connect the Spur sections by using the

dedicated connection plates:
• Connected the cables to the Spur first

connectors plate (A) and route them
inside the first Spur cable duct, as
shown aside.
Remember to plug the air supply to the
dedicated plug (B).
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• If present the Spur sampling bay - Long,
connect the second Spur section cables
and tubings to the first Spur section
connectors plate and rout them inside
the main cable duct, as shown aside.
• If present the Spur sampling bay - Long,

route the cables from the main cable
duct to the second Spur cable duct, as
shown aside.
Remember to plug the air supply to the
dedicated plug (A)
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• Connect the Spur End cap cables to the
last connectors plate (A).
Remember to close the air supply
connector with a dedicated plug.
For further information please refer to
the "Electrical Assembly"
(par. 33.4.5.9), to the Module wiring
diagrams, to the "Pneumatic System"
(par. 33.4.5.8), to the Fig. 62 - Cables
and tubings routing conceptual map
and also to the following connectors
map.
Fig. 61 - Connectors plate map
Fig. 62 - Cables and tubings routing conceptual map
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A - SPUR FIRST CONNECTORS PLATE

B - FIRST SPUR CABLE DUCT
C - FIRST SPUR SECTION CONNECTORS PLATE
D - MAIN CABLE DUCT
E - SECOND SPUR CABLE DUCT
F - END CAP CONNECTORS PLATE.
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33.5.11 Installing the covers
Operating procedure
a. Only for the IA configuration remove the
indicated plate from the Analyzer.
Refer to the Analyzer documentation to
remove correctly the plate.
b. Place the indicated spacers (A).
c. Install the cover replacing the previous one

present on the Analyzer.
d. Only for the IA configuration, restore the plate

position.
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e. Install the indicated cover on the Analyzer.
Use the High-Strength Threadlocker
(PFD0258) to fix properly the screws.
f. Install all the covers on the Interface Module and the removed covers from the Track. Restore also the Spur
Sampling Bay - Short central profile.
g. On the first spur (Spur Sampling Bay - Short)

unscrew the indicated fixing screws and
remove the indicated cover.
This operation must be performed only

on the Alinity Spur Sampling Bay -
Short to be installed just after the Alinity
Spur Return.
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33.5.12 Resuming the Automation System installation

Operating procedure
a. Continue the Automation System installation by following the “TMA - Track Module Assembly” chapter,
“Installation Instructions” section, starting from the operations listed in “Setting up modules bus bar plug”
paragraph.
33.5.13 Completing the module installation
Operating procedure
The following steps require the controlled power up of the Automation System has been already carried out.
a. Set the Module off-line (see the “Module off-line procedure”, chapter “Common Maintenance Operations”,
Common procedures section).
b. Set the Analyzer(s) type as follow:
b.1 From the GUI, press the “Overview” button and select “Alinity ci”.
b.2 From the Diagnostics options press “Settings” and select “Analyzer X”.
b.3 Set the proper Analyzer(s) type present on the Automation System.
For information about Analyzer configuration, please refer to the Automation System Layout.
c. Execute in sequence:
• "Setting the Buffer Lane version" (par. 33.9.3.9).

• "Spur belts adjustment" (par. 33.9.3.4)
• "Aspiration gate position adjustment" (par. 33.9.3.5)
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33.6 General maintenance rules

33.6.1 Safety
Service Personnel must maintain safety awareness while working in the lab or near
mechanical components.
Please refer to the “Safety compliance” chapter for detailed informations about
the safety of the Module.
33.6.1.1 Safety devices, precautionary measures

Only qualified authorized personnel can execute replacement and procedures. Before
starting a replacement procedure, Service Personnel:
– Shall refer to Module documentation, such as mechanical or installation
schematics and or electric drawings.
– Shall read and understand completely all safety and work accident prevention rules
presented in this Service Manual.
– Shall provide readable labels that the system is being serviced.
• Attach specific labels “EQUIPMENT IN MAINTENANCE STATE - DO NOT
SWITCH ON THE POWER SUPPLY” next to general switches.
• If the replacement procedure requires the safety cover or safety devices
removing, signal this condition with signs: “DANGER: SAFETY DEVICE
REMOVED FOR MAINTENANCE”. Use caution and reset all safety shields
and devices as soon as possible.
– Shall disconnect main power and shut off the main input air supply. The
maintenance operations on the Module are only to be carried out with the system
power cut-out (electrical power and compressed air); it is therefore important to
make sure that any interconnected voltages are deactivated, and where
necessary, to wait for sufficient time to allow the discharge of the capacitors in
some of the system circuits.
– Shall discharge the air pressure in the Automation System circuits to avoid
windings of the tubes when disconnected or unexpected movements of actuators.
– Shall always make sure that the ground connections are active and legal. The lack
of a ground connection to any equipment can cause injuries to Service Personnel,
operators, or other service personnel.
– Shall always use tools in good condition. Use them for their design purpose only.
Inappropriate use of tools or the use of tools in poor condition could cause serious
damage or injury.
After replacement procedures have been completed and before restarting the Module,
always make sure that:
– All covers, guards, and/or safety devices removed during replacement procedures
are functioning and have been correctly reinstalled.
– Maintenance and other personnel are at a safe distance.
– Make sure that tools or other materials are not placed next to the equipment.
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33.6.2 Equipment
The component securing systems (screws, nuts) have been standardized, using as few
variations as possible. See the “Service Tools chapter”, “Basic installation /
maintenance equipment tools” section as reference about the minimum equipment
needed for maintenance operations.
If a specific tool is required to execute an operation, the tool code is indicated in the
procedure, and also listed in the module specific section of the “Service Tools chapter”.
33.6.3 Disposal
The disposal of waste oils, greases and other used components is to be carried out in
accordance with the laws in force in the country where the module is installed. Also in
case of partial or complete disposal of the system, the disposal of these parts must be
carried out in accordance with the laws in force in the country where the Automation
System is installed.
Contact Inpeco for information about the Automation System disposal.
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33.7 Corrective maintenance

Corrective maintenance can be defined as the maintenance which is required when an
item has failed or worn out, to bring it back to working order.
This part of the Service Manual describes repair and replacement procedures required
to keep the Module working efficiently.
33.7.1 External corrective maintenance procedures

For all the common maintenance procedures to be performed on the Module devices,
please refer to the Service Manual chapter “Common Maintenance Operations”.
For all the common maintenance procedures to be performed on the Buffer lane
devices, please refer to the Service Manual chapter “TMA - Track Module Assembly”.
33.7.2 Corrective maintenance procedures

The maintenance charts that follow define the maintenance procedures to be performed
on the Module. Each chart contains the following information:
Text Description of the information

State Highlights the conditions in which the Alinity ci IM is to be
set before starting the maintenance operation.
Material Material required for the operation. This refers to spare
parts and consumable material.
Equipment Equipment required for the maintenance.
Preliminary procedures/ Indicates the activities to be carried out before the
note operating procedure. It also contains notes to give more
in-depth information on the intervention.
Operating procedure Describes the operating procedure step by step, with
explanatory pictures where necessary.
Verification procedure Indicates activities that are to be carried out after the
operating procedure. Usually it indicates the activity in
reverse to that described in the preliminary procedure.
In the following part of the Service Manual, it is possible to find the corrective
maintenance procedures of the Alinity ci IM module.
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33.7.2.1 Alinity Spur L - Turn: motor replacement

State: – Power off
Material: – See chapter “Spare parts catalogue”
Equipment: – See "Equipment" (par. 33.6.2)
Preliminary procedures / notes

– None.
Operating procedure
a. Perform the “Cutting off energy supplies” procedure - see chapter “Common maintenance operations”,
Common procedures section.
Place a sign in a clearly visible location on the power connection indicating that maintenance is in
progress and power must remain disconnected.
b. Perform the "Local energy lockout / tagout procedure" (par. 33.9.3.12.1) procedure.
c. Remove the indicated covers, by unscrewing

all fixing screws where necessary.
d. Disconnect the motor cable from the driver board.
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e. Unscrew the two screws that fasten the motor
bracket and remove the motor.
f. Replace the motor with a new one.
g. If necessary, replace also the cogged belt following the "Alinity Spur L - Turn: Motor Belt assembly
replacement" (par. 33.7.2.2) procedure.
h. Fasten the motor bracket to the Module using the two fixing screws.
i. To obtain the right belt tensioning, move

down the motor and tighten the two fixing
screws.
j. Restore electrical connection and covers.
k. Perform the "Restoring local energy" (par. 33.9.3.12.2) procedure.
l. Power up of the Automation System - see “Restoring Power after a shutdown” procedure, chapter
“Common maintenance operations”, Common procedures section.
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Verification procedure
a. Login as FSE - see the “Login and Logout” procedure, chapter “Common Maintenance Operations”,
Common procedures section”.
b. Set the Module on-line.
c. Press the “Start” button to start the Automation System and verify the correct execution of the process.
d. Search the screen for error messages.

If no error code was reported the procedure is successfully completed.
e. Before return the Automation System to the Operators, execute the logout.
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33.7.2.2 Alinity Spur L - Turn: Motor Belt assembly replacement

– Grease (p/n PFD0243)

– None.
Operating procedure
a. Perform the “Cutting off energy supplies” procedure (see chapter “Common Maintenance Operations” -

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d. Remove the central separator with the
triangle shaped cover by acting on the
screws, as shown in the figure.
e. Loosen the two screws that fasten the motor

bracket to the driver group and relax the
motor belt.
f. Slightly lift up on the two carrier belts to access the two motor belt group screws.
g. Remove the two screws.
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h. Slide the belt off of the motor shaft for remove
it.
i. Remove the motor belt group by pulling it

straight up.
j. Now, it is possible to replace the complete

group or only the cogged belt.
k. To replace the cogged belt:
k.1 Remove the retaining ring (A). Remove the

two shims/washers and shaft spacer.
k.2 Press on the shaft to remove. It will slide out

as shown.
k.3 Remove the old belt and discard it.
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l. Place the new belt into the belt group
housing.
m. Slide the shaft back into position and rotate

shaft while inserting. This allows for proper
meshing of the belt and shaft gear.
n. Install remaining components in the reverse

order of removal.
o. As a final check pull on the belt and it should

move smoothly at the same time rotating the
outer shaft gear.
p. Install the motor belt group taking care to align the conical gears.
q. Verify that the gears group has a sufficient

amount of grease. If not, clean the gears with
a cleaning cloth to remove the old grease,
and spread one milliliter of PFD0243 grease
over the gears.
Take care not to dirty the belts or the covers.
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r. In order to obtain the right belt tensioning,
move down the motor and tighten the two
screws.
s. Reassemble all the parts reversing the steps used for disassembly.
t. Perform the "Restoring local energy" (par. 33.9.3.12.2) procedure.
u. Power up of the Automation System - see “Restoring Power after a shutdown” procedure, chapter

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33.7.2.3 Alinity Spur L - Turn: idler pulleys replacement


– None
Operating procedure
b. Perform the "Local energy lockout / tagout procedure" (par. 33.9.3.12.1) procedure.
c. Remove all the upper and lateral covers from the Interface Module.
d. Detach all the support brackets from the

Interface Module by unscrewing the indicated
screws (one for each racket).
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e. Support the Module by placing the support
To avoid injuries and/or damages to the
Module handle it in two or more people.
a. Disconnect and put aside cables and tubings

from the connectors plate (A) to the Alinity
Spur L-Turn connectors plate (C).
b. Disconnect and put aside also the cables

routed in the leg (B) from the Alinity Spur
Track.
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c. Remove the separator by unscrewing the
indicated fixing screws.
d. Remove also the indicated profile.
e. Remove also the indicated fixing screw from

the angular bracket (A).
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f. To separate the L - Turn Spur and the Spur
Return:
• Unscrew the fixing screws shown in red
and remove the angular fixing plate.
• Unscrew the indicated screws that fix

the two Spur sections, as showed aside.
• move away the straight part of the

Interface Module from the L - Turn Spur.
Module handle it in two or more people
attention to support properly the L -
Turn Spur.
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g. Unscrew the four indicated bolts securing the
Spur to the track slot.
Before removing the Spur, take note
about the fixing plate position.
h. Put the L - Turn Spur on a suitable working

plane.
i. Remove the indicated screws and replace the

damaged pulley group(s).
Before removing the belt drive
assembly relax the belts.
j. Reassemble all the removed parts and the spurs reversing the steps used for disassembly.
k. Move the Module until both the Spur Module

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l. Tighten the four bolts securing the Spur to the
track slot.
m. It is very important the gap between the 1st lane belt and the main track profile remains in a 0.5mm
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n. Check the first lane belt clearance relative to the main track secondary lane by pushing the positioning tool
o. Perform the following procedures:

• "Securing the Interface Module with the L - Turn to the Analyzers" (par. 33.5.9.3).
• "Connecting the Module with the L - Turn" (par. 33.5.10.2) to restore electrical and pneumatic
connections.
• "Installing the covers" (par. 33.5.11).
• "Restoring local energy" (par. 33.9.3.12.2)
p. Power up of the Automation System - see “Restoring Power after a shutdown” procedure, chapter
q. Perform the "Resuming the Automation System installation" (par. 33.5.12) procedure from step •

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33.7.2.4 Alinity Spur L - Turn belt: drive assembly replacement


– None
Operating procedure
c. Remove all the upper and lateral covers from the Interface Module.
d. Detach all the support brackets from the

Interface Module by unscrewing the indicated
screws (one for each racket).
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e. Support the Module by placing the support
Module handle it in two or more people.
a. Disconnect and put aside cables and tubings

from the connectors plate (A) to the Alinity
Spur L-Turn connectors plate (C).
b. Disconnect and put aside also the cables

routed in the leg (B) from the Alinity Spur
Track.
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c. Remove the central separator with the
triangle shaped cover by acting on the
screws, as shown in the figure.
d. Remove also the indicated profile.
e. Remove also the indicated fixing screws from

the angular bracket (A).
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f. To separate the L - Turn Spur and the Spur
Return:
• Unscrew the fixing screws shown in red
and remove the angular fixing plate.
• Unscrew the indicated screws that fix

the two Spur sections, as showed aside.
• move away the straight part of the

Interface Module from the L - Turn Spur.
Module handle it in two or more people
attention to support properly the L -
Turn Spur.
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g. Unscrew the four indicated bolts securing the
Spur to the track slot.
Before removing the Spur, take note
about the fixing plate position.
h. Put the L - Turn Spur on a suitable working

plane.
i. Loosen the two screws that fasten the motor

bracket to the driver group and relax the
motor belt.
j. Remove the two screws.
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k. Slide the belt off of the motor shaft for remove
it.
l. Remove the indicated screws and replace the

damaged belt drive assembly.
Before removing the belt drive
assembly, relax the belts by acting on
the L-Turn Spur tensioning system
m. Reassemble all the removed parts and the spurs reversing the steps used for disassembly.
n. Move the Module until both the Spur Module

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o. Tighten the four bolts securing the Spur to the
track slot.
p. It is very important the gap between the 1st lane belt and the main track profile remains in a 0.5mm
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q. Check the first lane belt clearance relative to the main track secondary lane by pushing the positioning tool
r. Perform the following procedures:

• "Securing the Interface Module with the L - Turn to the Analyzers" (par. 33.5.9.3).
• "Connecting the Module with the L - Turn" (par. 33.5.10.2) to restore electrical and pneumatic
connections.
• "Installing the covers" (par. 33.5.11).
• "Restoring local energy" (par. 33.9.3.12.2).
s. Power up of the Automation System - see “Restoring Power after a shutdown” procedure, chapter
t. Perform the "Resuming the Automation System installation" (par. 33.5.12) procedure from step •
a. Login as FSE (see the “Login and Logout” procedure, chapter “Common Maintenance Operations”,
b. Set the Module on-line

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33.7.2.5 Alinity Spur Return: gate replacement


– None.
Operating procedure
c. Remove the covers by unscrewing all fixing screws.
d. Remove the separator profile.
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e. Disconnect the pneumatic tubings.
f. Remove the damaged gate, by unscrewing

the indicated screws, and replace it with a
new one.
Place the new gate in contact with the

profile, as shown aside.
g. Reassemble all the removed parts reversing the steps used for disassembly.
h. Restore the removed tubings and covers.
i. Perform the "Restoring local energy" (par. 33.9.3.12.2) procedure.
j. Power up of the Automation System - see “Restoring Power after a shutdown” procedure, chapter
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b. Set the Module on-line

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33.7.2.6 Alinity Spur Return: motor replacement


– None.
Operating procedure
c. Remove the indicated cover.
d. Disconnect the motor cable from the driver board.
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e. Unscrew the indicated screw to release the
motor shaft.
f. Unscrew the four screws that fasten the

motor bracket and remove the motor
assembly.
While removing the motor turn it

through the arrow direction to extract
properly the motor shaft
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g. Unscrew the indicated fixing screws and
Replace the motor with a new one.
h. Reassemble all the removed parts reversing the steps used for disassembly.
Check that the disk is completely in

contact with the belts on both sides. If
not, follow the "Alinity Spur Return Disk
adjustment" (par. 33.9.3.6) procedure.
i. Restore electrical connection and covers.
j. Perform the "Restoring local energy" (par. 33.9.3.12.2) procedure.
k. Power up of the Automation System - see “Restoring Power after a shutdown” procedure, chapter

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33.7.2.7 Alinity Spur Return: disk replacement


– None.
Operating procedure
b. Remove the covers by unscrewing all fixing screws.
c. Perform the "Local energy lockout / tagout procedure" (par. 33.9.3.12.1) procedure.
d. Unscrew the indicated screw to release the

disk.
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e. Replace carefully the damaged disk with a
new one.
Please pay attention to replace the disk
in the right verse: the rough surface
must be up while the smooth surface
must be down. Also be careful not to
damage (bend) the new disk during the
positioning phase.
f. Reassemble all the removed parts reversing the steps used for disassembly
Check that the disk is completely in

contact with the belts on both sides. If
not, follow the "Alinity Spur Return Disk
adjustment" (par. 33.9.3.6) procedure.
g. Restore the removed covers.
h. Perform the "Restoring local energy" (par. 33.9.3.12.2) procedure.
i. Power up of the Automation System - see “Restoring Power after a shutdown” procedure, chapter

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33.7.2.8 Alinity Spur Return: U-Turn gate replacement


– None.
Operating procedure
c. Remove the covers by unscrewing all fixing

screws.
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d. Unscrew the two fixing screw and remove the
indicated plate.
e. Disconnect the sensor cables from the two

sensors (A)
f. Unscrew the indicated fixing screws and

remove the cylinder support plate.
g. Remove the dowel pin indicated by red.
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h. Remove carefully the assembly toward the
arrow direction.
During the operation pay attention to
remove the pneumatic fittings (A). 
i. Reassemble all the removed parts reversing the steps used for disassembly.
j. Restore pneumatic fittings and covers.

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33.7.2.9 Alinity Spur Return: U-Turn gate and diverter replacement

– Oversized Carrier Tool (p/n
475110032 for Standard version)
0P00007823.00 for HT version)
– Magnet tool (p/n 525739000)

– None
Operating procedure

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d. Disconnect the pneumatic tubings from the
fittings (A) and mark the support plate
position (B).
Ensure tubing is marked to enable
correct reconnection.
e. Replace the damaged gate / diverter

assembly by unscrewing the indicated fixing
screws.
Ensure to place the new assembly at
the previously marked position.
f. Reassemble all the removed parts, reversing

the steps used for disassembling.
g. Perform the "Restoring local energy" (par. 33.9.3.12.2) procedure.
h. Power up of the Automation System - see “Restoring Power after a shutdown” procedure, chapter
b. Set the Module off-line (see the “Module off-line procedure”, chapter “Common Maintenance Operations”,
Common procedures section).
c. Adjust the position of the group by following

these steps:
c.1 Insert the Oversized carrier tool (p/n

0P00007823.00 for HT version) on the main
lane of the Interface Module.
c.2 Activate the diverter assembly by placing the

magnet tool (p/n 525739000) on the related
solenoid valve (please refer to the
"Pneumatic System" (par. 33.4.5.8)).
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Verification procedure (Continues)

c.3 To adjust the position of the group, stops the
belt and place a carrier between the main
lane and the sampling lane close to the
central upper profile (A).
c.4 Loosen the screws (B) and move the group

until the diverter until reaches the carrier.
c.5 Tighten the screws (B).
c.6 Start the belts and verify that the Oversized

carrier tool moves smoothly from the return
lane to the main lane, as shown in figure.
c.7 Remove the magnet tool from the solenoid

valve.
d. Perform the "Alinity ci IM Antennas test procedure (Standard version)" (par. 33.9.3.10) procedure.
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33.7.2.10 Alinity Spur Sampling Bay: ATR replacement


– None
Operating procedure
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c. Open the Analyzer back cover.
d. Remove the indicated covers, by unscrewing

e. Remove the indicated cover and the plate (A),

if any.
f. Disconnect the ATR motor cable from the driver board.
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g. Remove the two indicated fixing screws and
remove the ATR assembly.
h. Replace the damaged ATR assembly with a new one.
i. Reassemble all the removed parts, reversing the steps used for disassembling.
“Common maintenance operations”, Common procedures section.

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33.7.2.11 Alinity Spur Sampling Bay: Sampling gate replacement


– None
Operating procedure
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c. Open the Analyzer back cover.
d. Remove the indicated covers, by unscrewing

e. Remove the indicated cover and the plate (A),

if any.
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f. Disconnect cables from the sensors (A) and
from the antenna (B). Disconnect also
pneumatic tubings from the gate cylinder (C).
g. Act on the fixing screws in red to remove the

sensor (A) and the gate upper profile (B).
h. Remove the fixing screws shown in red and

slightly remove the entire sampling gate
assembly.
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i. Replace the damaged sampling gate assembly with a new one.
j. Reassemble all the removed parts, reversing the steps used for disassembling.

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33.7.2.12 Alinity Spur Sampling Bay: gate and diverter replacement

475110032 for Standard version)
0P00007823.00 for HT version)
– Magnet tool (p/n 525739000)

– None
Operating procedure

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d. Unscrew the indicated fixing screws and
remove the central separator.
e. Also unscrew and remove the indicated

screws and plate.
During the operations pay attention not

f. Disconnect the pneumatic tubings from the

fittings and remove the indicated group by
unscrew the fixing screw.
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g. Replace the damaged gate (A) and/or the
diverter (B) by removing the fixing screws.
h. Reassemble all the removed parts, reversing the steps used for disassembling.
i. Adjust the gate and diverter support plate

against the profile edge as showed.
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Verification procedure (Continues)

c. Adjust the position of the group by following
these steps:
c.1 Insert the Oversized carrier tool (p/n

0P00007823.00 for HT version) on the Spur
Main lane.
c.2 Activate the diverter assembly by placing the

magnet tool (p/n 525739000) on the related
solenoid valve (please refer to the
"Pneumatic System" (par. 33.4.5.8)).
c.3 To adjust the position of the group, stops the

belt and place a carrier between the main
lane and the sampling lane close to the
central upper profile (A).
c.4 Loosen the screws (B) and move the group

until the diverter until reaches the carrier.
c.5 Tighten the screws (B).
c.6 Start the belts and verify that the Oversized

carrier tool moves smoothly from the main
lane to the sampling lane, as shown in figure.
c.7 Remove the magnet tool from the solenoid

valve.
d. Perform the "Alinity ci IM Antennas test procedure (Standard version)" (par. 33.9.3.10) procedure.
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33.7.2.13 Alinity Spur Samplig bay(s): Belt(s) replacement


– None.
Operating procedure
progress and power must remain disconnected.
c. Remove the Spur upper covers by acting on the fixing screws.
d. Remove the indicated lateral covers.
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e. Remove also the indicated lower covers.
f. Loosen the indicated pins to relax the belt.

Pay attention not to remove the pins. If
a pin is removed, the nut will fall out of
position.
g. Remove the damaged belt(s).
h. Perform the "Spur belt welding" (par. 33.9.3.1) procedure to weld properly the belt(s).
a. Not necessary.
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33.7.2.14 Alinity Spur L - Turn: belt(s) replacement


– None.
Operating procedure

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d. To Relax completely the belt acting, on both
side, on the indicated fixing screws and pull
back the tension pulley
e. Remove the damaged belt(s).
f. Perform the "Spur belt welding" (par. 33.9.3.1) procedure to weld properly the belt(s).
a. Not necessary.
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33.7.2.15 Alinity Spur End Cap: motor replacement


– None
Operating procedure
c. Remove the covers by unscrewing all fixing screws.
d. Disconnect the motor cable from the driver.
e. Unscrew the fixing four screws that fasten the

motor bracket and remove the motor.
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f. Replace the motor with a new one.
g. If necessary, replace also the cogged belt.
h. Fasten the motor bracket to the Module using the four fixing screws.
i. To obtain the right belt tensioning, move

down the motor and tighten the four fixing
screws.
j. Restore electrical connection and covers.

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33.7.2.16 Alinity Spur End Cap: tensioning roller replacement


– None
Operating procedure
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d. Loosen the indicated pins to relax the belt.
position.
e. Remove the belts.
f. Remove the indicated screws and remove the

tensioning group.
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g. Remove the indicated screws and remove the
lower rollers group.
h. Remove the locking nuts (A) and the pins (B).

Then replace the damaged roller.
Repeat the operation for all the damaged
rollers.
i. Reassemble all the removed parts reversing the steps used for disassembly.
j. Perform the "Spur belt welding" (par. 33.9.3.1) procedure to install properly the belts.
a. Not necessary.
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33.7.2.17 Alinity Spur End Cap: idler roller replacement


– None
Operating procedure
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d. Loosen the indicated pins to relax the belt.
Mark the roller shafts working position
(A).
e. Unscrew the indicated fixing screws and

remove the roller group.
rollers.

f. Remove the indicated screws and replace the

damaged roller.
rollers.
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g. Reassemble all the removed parts reversing the steps used for disassembly.
h. Tension the belts by acting on the tensioning

pins.
Restore the roller shafts in the
previously marked position (A).
i. Restore the removed covers.
j. Perform the "Local energy lockout / tagout procedure" (par. 33.9.3.12.1) procedure.

a. Before return the Automation System to the Operators, execute the logout.
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33.7.2.18 Alinity End Cap: disk replacement


– None.
Operating procedure
d. Unscrew the lock nut (A) to remove the

insulating spacers (B) and the spring (C).
e. Replace carefully the damaged disk with a

new one.
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f. Replace carefully the damaged disk with a
new one.
Please pay attention to replace the disk
in the right verse: the rough surface
must be upward while the smooth
surface must be downward. Also be
careful not to damage (bend) the new
disk during the positioning phase.
g. Reassemble all the removed parts reversing the steps used for disassembly
Please pay attention to reassemble the

disk correctly. The disk must be flat,
completely in contact with the belts on
both sides (A).
If the disk assumes a “V” form, is
necessary to adjust the lock nut (B).
h. Restore the removed covers.
i. Perform the "Local energy lockout / tagout procedure" (par. 33.9.3.12.1) procedure.

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33.7.2.19 Alinity End Cap: tensioning device replacement


– None.
Operating procedure
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d. Loosen the indicated hex nuts to relax the
belt.
position.
e. Remove the belts.
f. Remove the indicated screws and remove the

tensioning group.
g. Reassemble all the removed parts reversing the steps used for disassembly.
h. Perform the "Spur belt welding" (par. 33.9.3.1) procedure to weld properly the belts.
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a. Note necessary.
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33.7.2.20 Q7CA Board replacement

State: – Module off-line
– Locally sourced monitor, keyboard
and mouse

– This procedure lists the operations necessary to replace the Q7 Carrier Board, with Windows Embedded
8.1 Professional 64 Operating System.
Before starting, the Customer must complete all processing and stop the Automation System.
Operating procedure
a. Obtain the IP settings of the Q7CA board to be replaced.
If necessary, refer to the Automation System electrical layout (p/n 0Lxxxxxxxx.xx) for STD systems,
or to the spreadsheet “FLX.xxxx - LISTA NODI.xlsx” for HT systems, provided with the automation
system.
b. If possible, back up the locations - see “Locations Backup and Restore” procedure, chapter “Common
maintenance operations”, GUI/IUI procedures section.
c. Perform the “Cutting off energy supplies” procedure (see chapter “Common Maintenance Operations” -
d. Carry out the "Local energy lockout / tagout procedure" (par. 33.9.3.12.1).
e. Carry out the procedure “Replacing Q7CA board - common steps”, “Common maintenance operations”,
“Q7CA control board” section.
Before executing the controlled power up of the Automation System, perform the "Restoring local
energy" (par. 33.9.3.12.2) procedure and then check that any local energy lockouts along the
Automation system have been removed.
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f. If a location backup is available, perform the data restoration (see “Locations Backup and Restore”
procedure, chapter “Common Maintenance Operations”, GUI/IUI procedures section).
g. Set the Buffer lane version (STD or HT), by referring to "Setting the Buffer Lane version" (par. 33.9.3.9).
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33.8 Preventive maintenance

The Preventive Maintenance is the care and servicing by personnel for the purpose of
maintaining equipment and facilities in satisfactory operating condition by providing for
systematic inspection, detection, and correction of incipient failures either before they
occur or before they develop into major defects.
33.8.1 External preventive maintenance procedures

For all the common preventive maintenance procedures to be performed on the Module
devices, please refer to the Service Manual chapter “Common Maintenance
Operations”.
For all the common preventive procedures to be performed on the Buffer lane devices,
please refer to the Service Manual chapter “TMA - Track Module Assembly”.
33.8.2 Preventive maintenance procedures

The suitable preventive maintenance operations for a Module lifetime long efficiency
holding are listed in the following paragraph.
For detailed information about frequency and time required for the operation,
refer to the “Preventive Maintenance Plan” chapter.
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33.8.2.1 Gears Lubrication

Material: – Not necessary
Equipment: – Grease (p/n PFD0243, foam tip is
advised)
– Flashlight

– None.
Operating procedure
a. Perform the “Cutting off energy supplies” procedure (see chapter “Common Maintenance Operations” -
c. Remove the track upper cover.
d. Remove the triangle-shaped guide.
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e. Remove the block.
f. clean the gears with a cleaning cloth to

remove the old grease, and spread one
milliliter of PFD0243 grease over the gears.
Take care not to dirty the belts or the covers.
g. Reassemble the covers.
c. Start the Module belts.

If no error code was reported the procedure has successfully completed.
e. Before return the Automation System to the Operators, execute the log out.
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33.8.2.2 Module Cleaning

State: – Automation System paused
Material: – Bleach solution (please refer to the
“Safety compliance” chapter, for
detailed about the mixing formula).
Equipment: – Normal equipment

You may be exposed to hazardous chemicals when handling bleach.
Operating procedure
b. Remove the upper covers from the IM.
c. Remove any debris. Using the bleach solution, clean any fluid from the exposed surface.
d. Inspect the belts. If fluid is noted, remove connection cover and clean any fluid using the bleach solution.
Do not use bleach on electrical part or connectors. If debris is noted, clean carefully
e. Spin the belts until the other side is reached.
f. Repeat the previous steps to remove any debris or any fluid, then reassemble the covers.
g. Put the module on-line.
h. Search the screen for error messages. If no error was reported the procedure is successfully completed.
i. Before return the Automation System to the Operators, execute the logout.
a. Not necessary.
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33.9 Auxiliary procedures

This chapter describes the auxiliary procedures useful to execute the maintenance
procedures. The Auxiliary procedures include adjustment procedures, programming
and parametrizing procedures, verification procedures and safety access procedures.
33.9.1 External auxiliary procedures

For all the common auxiliary procedures to be performed on the Module devices, please
refer to the Service Manual chapter “Common Maintenance Operations”.
For all the common auxiliary procedures to be performed on the Buffer lane devices,
please refer to the Service Manual chapter “TMA - Track Module Assembly”.
33.9.2 Auxiliary operations charts

The auxiliary charts that follow define the auxiliary procedures to be performed on the
Module.
Each chart contains the following information:
Text Description of the information

State Highlights the conditions in which the Alinity ci IM is to be
set before starting the maintenance operation.
Material Material required for the operation. This refers to spare
parts and consumable material.
Equipment Equipment required for the maintenance.
Preliminary procedures/ Indicates the activities to be carried out before the
note operating procedure. It also contains notes to give more
in-depth information on the intervention.
Operating procedure Describes the operating procedure step by step, with
explanatory pictures where necessary.
Verification procedure Indicates activities that are to be carried out after the
operating procedure. Usually it indicates the activity in
reverse to that described in the preliminary procedure.
33.9.3 Auxiliary procedures

In the following part of the Service Manual, it is possible to find the Auxiliary
procedures.e
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33.9.3.1 Spur belt welding

– Habasit Belt Join Clamp Tool (p/n 475200000)
– 34mm belt adapter plates Tool (p/n 0A00014235)
– Carrier Belt thermal join Tongs Pq-59/58 Tool (p/n PFD1209)
– Carrier Belt Cutter flex proof Aq-40 Tool (p/n PFD0205)
– Carrier Belt thermal Dissipation tongs Cd-60 Tool (p/n PFD0206)

– The welding operations must be executed in the middle of the Spur section, far from the Spur Return
section and the Spur End Cap section.
– Executive modalities (notes about the welding device use):
• With the welding device power disconnected, clean the tool heat plates.
• Do not connect the device to the power supply until it has totally dried.
• Check the temperature value, it has to be the right one for the welding (temperature can be regulated).
– Welding tool guidelines:
• Place the tool only on an heat resistance surface.
• Avoid dropping the welding tool.
• Do not hang by using its cable.
• The tool welding plates are hot. Do not touch the plates during use.
• Keep the device far from meltable materials.
• Keep the tool away from water.
• After use, pack the device only after it has totally cooled.
Operating procedure
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c. Turn on he Carrier Belt thermal join Tongs
Pq-59/58 Tool (p/n PFD1209). Locate the
LED on the handle with the power cord. This
LED will pass from red to green. A green LED
indicates that the temperature has been
reached and the welding can start.
The Carrier Belt thermal join Tongs
Pq-59/58 Tool (p/n PFD1209) is
already preset to the correct
temperature.
d. Block the two ends of the new belt in the

Carrier Belt Cutter flex proof Aq-40 (p/n
PFD0205), as showed aside.
e. Cut the belt using the scissors, paying

attention to hold the scissors against the tool.
f. If present, adjust imperfect cut with a cutter.
g. Follow the "Alinity Spur Return: disk replacement" (par. 33.7.2.7) and the "Alinity End Cap: disk
replacement" (par. 33.7.2.18) procedures to remove the two disks present on the Spur.
Pay attention not to damage the disks, are very fragile components.
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h. Insert the new belt(s) starting from the lower
part of the Spur.
The upper side (A) of the belt(s) must
be facing the bottom of carriers, the
lower side (B) must be facing the
Interface Module.
i. Pass properly the belt(s) through the

tensioning device group.
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j. Approach each other the two belt ends on the
upper part of the Spur.
k. Insert the lower heat block of the 34mm belt

adapter plates (p/n 0A00014235) inside the
Habasit Belt Join Clamp Tool (p/n
475200000).
l. Position the two belt ends near to the clamp

center and tighten the two clamp screws. The
belt ends should be merged together without
any gaps.
m. The belt waved ends should interlock

merging together in a fairly smooth surface.
n. Cover the belt seam with the top heat block of

the 34mm belt adapter plates Tool (p/n
0A00014235).
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o. Place the Carrier Belt thermal join Tongs
Pq-59/58 Tool (p/n PFD1209) centered over
the plates and seam. For a proper welding
wait 5 minutes.
The seam quality will be compromised

if the time is either too long or too
short.
p. After 5 minutes remove the Carrier Belt

thermal join Tongs Pq-59/58 Tool (p/n PFD
1209).
q. Use the Carrier Belt thermal Dissipation tongs

Cd-60 Tool (p/n PFD0206) for at least 20
minutes to cool the belt and complete the
seaming process.
r. Now the new belt welding is finished. Repeat

the above mentioned operations for each of
the belts to be replaced.
Remove any glue or loose belt material
from the belt edges.
s. Follow the "Alinity Spur Return: disk replacement" (par. 33.7.2.7) and the "Alinity End Cap: disk
replacement" (par. 33.7.2.18) procedures to restore the position of the two disks present on the Spur.
Pay attention not to damage the disks, are very fragile components.
t. Perform the "Spur Belt tensioning" (par. 33.9.3.2) procedure to tension the belt(s).
a. Not necessary.
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33.9.3.2 Spur Belt tensioning

Equipment: – Normal equipment

– The following procedure is intended to provide the guidelines to adjust the belt tensioning after the belt(s)
replacement.
The belts must be completely untensioned before perform any tensioning operation.

– For the Belt tensioning of the Spur Sampling bay(s), follow the "Belt tensioning for Spur Sampling bay(s)"
(par. 33.9.3.2.1) procedure.
– For the Belt tensioning of the Spur L-Turn, follow the "Belt tensioning for Spur L-Turn" (par. 33.9.3.2.2)
procedure.
33.9.3.2.1 Belt tensioning for Spur Sampling bay(s)
Operating procedure
c. Place two measuring marks on a distance of

1,000 mm on each side of the untensioned
belt(s).
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d. If necessary, remove the indicated diverter
and ATR upper plates.
e. Tension the belts by acting on the indicated

pins on the tensioning group.
To have a proper belt tension, act
equally on the two pins of each pulley.
f. Tension the belt with the tensioning device to

the required initial elongation.
The elongation must be 0.3%.
g. With a 0.3% initial elongation, the correct

tension is achieved, if the distance of the
marks has increased to 1003 mm
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h. Reassemble lateral and upper covers.
i. Perform the "Restoring local energy" (par. 33.9.3.12.2) procedure.
d. Once the belt has completed at least one circuit of the installation, the distance between the marks is to be
measured again and then corrected where necessary.
e. Search the screen for error messages.

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33.9.3.2.2 Belt tensioning for Spur L-Turn
Operating procedure
Put a visible sign on the power connection indicating that maintenance is in progress and power must
remain disconnected.
c. Place two measuring marks on a distance of

1,000 mm on each side of the untensioned
belt(s).
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d. To obtain the correct tension, pull the tension
pulley and tighten the screws shown in the
figure.
e. Tension the belt with the tensioning device to

the required initial elongation.
The elongation must be 0.3%.
f. With a 0.3% initial elongation, the correct

tension is achieved, if the distance of the
marks has increased to 1003 mm
g. Reassemble lateral and upper covers.
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d. Once the belt has completed at least one circuit of the installation, the distance between the marks is to be
measured again and then corrected where necessary.
e. Search the screen for error messages.

f. Before return the Automation System to the Operators, execute the logout.
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33.9.3.3 Spur Belt tensioning verification

– Weight Tool (p/n 0P00023688)

– None
Operating procedure
c. Remove the Spur upper covers by acting on the fixing screws.
d. Place the Weight (p/n 0P00023688) on the

belt to be tested.
e. Hold the Weight Tool with one hand and start

the belts.
• If the belt moves properly, the belt is

correctly tensioned.
• If the belt does not move, is necessary to
perform the "Spur Belt tensioning"
(par. 33.9.3.2) procedure.
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f. Search the screen for error messages.
g. Before return the Automation System to the Operators, execute the logout.
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33.9.3.4 Spur belts adjustment


– The following procedure is intended to collect the guidelines to proper adjust the spur belts.
Operating procedure
b. Press the “Overview” button.
c. Press the “Alinity c” button.
d. From the Diagnostics options select “Diagnostics”.
e. Press the “Belt motor” button and select “On” to start the belts.
f. Check the proper belt rotation. If the belts are

not aligned:
• Remove the cover over the Alinity spur

return assembly.
• Loosen the fixing screws (A) and adjust
the idler pulleys by acting on the
indicated screws (B).
• Tighten the fixing screws (A).
• Repeat the adjustment until the belts
spin properly.
g. Press the “Belt motor” button and select “Off” to stop the belts.
h. Restore the cover.
a. Not necessary
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33.9.3.5 Aspiration gate position adjustment

– Reference Pointer Tool (p/n 0A00013794.00)

– The aspiration gate is composed by an antenna, a gate and a sensor connected each other in a unique
assembly.
Operating procedure
Common procedures section).
b. Insert the Reference pointer tool (A) (p/n

0A00013794.00) into a carrier (B).
c. Remove the screw (C) from the tool.

The screw (C) help you only during the
pointer tool insertion and removal.
You must not place the carrier on the
Spur with the screw inserted.
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d. Remove the cover over the sampling point.
e. Place the carrier with the Reference pointer

tool on the Spur aspiration lane against the
Module Aspiration Gate.
Ensure that the carrier with the tool is
not released back to the Main Track.
f. Restore the cover.
g. Press the “Overview” button.
h. Press the “Alinity c” button.
i. From the Diagnostics options select “Diagnostics”.
j. Press the “Belt motor” button and select “On” to start the belts.
k. Perform the alignment of the Analyzer sample aspiration probe.

Referring to the Analyzer documentation to perform the probe alignment.
l. If the Analyzer alignment is not enough to

reach the aspiration position, adjust the
aspiration gate as follow:
• Press the “Belt motor” button and select

“Off” to stop the belts.
• Remove the cover over the sampling
point.
• Loosen the indicated fixing screws and
adjust the position of the group as
indicated.
• Tight the fixing screws.
• Restore the covers.
• Press the “Belt motor” button and select
“On” to start the belts.
• Repeat the alignment of the Analyzer
sample aspiration probe.
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m. Press the “Belt motor” button and select “Off” to stop the belts.
n. Remove all the carrier with the tool from the Interface Module.
o. Restore the removed covers.
a. Not necessary
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33.9.3.6 Alinity Spur Return Disk adjustment

– Reference Pointer Tool (p/n 0A00013794.00)

– The following procedure is intended to collect the guidelines to proper adjust the Spur return disk.
Operating procedure
b. Remove the safety cover above the devices group to be aligned.
c. Remove the indicated covers.
d. Disconnect the pneumatic tubings from the

fittings (A) and mark the support plate
position (B).
Ensure tubing is marked to enable
correct reconnection.
e. Remove the gate / diverter assembly by

unscrewing the indicated fixing screws.
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Operating procedure
f. Rotate the motor shaft until the set screw is
reachable from the hole, as shown aside.
g. Loosen the set screw and adjust the bushing

until the disk is completely in contact with the
belts on both sides. Then tighten again the set
screw.
h. Follow the "Alinity Spur Return: U-Turn gate and diverter replacement" (par. 33.7.2.9) procedure to restore
the gate / diverter assembly position.
a. Not necessary.
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33.9.3.7 Digital pressure switch settings

State: – Power on
Equipment: – Not necessary

– The Digital Pressure Switch is able to check the current air pressure and other parameters for a correct
functioning of the Module.
– Use this procedure to check the parameters to the existing switch or in case of replacement.
Operating procedure
a. Remove the track lateral panel under the
Module to locate the pressure switch
mounting location.
b. Set the parameters as follows:
– [F0] Unit selection function

• UNI=Mpa
– [F 1] Setting of OUT1
• OU1 = Win
• lot=1_p
• P1L=0.45
• P1H=0.65
• H_1=0.005
• Col=Sog
– [F 3] Response time
• Res= 100
For further informations about how to
set the parameters, please refer to the
Digital Pressure Switch Operation
Manual, available on the Inpeco
sharepoint website (after Log In):
https://inpeco.sharepoint.com/sites/flex
lab3.6/default.aspx -> All modules ->
Other documentation section.
a. Not necessary.
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33.9.3.8 How to solve the Worklist Incorrect Information warning

(S0059)
The following steps explains how to add a delay in the Alinity ci firmware to get the belt
of the spur moving correctly by editing an SDO value to solve the warning S0059
(Worklist Incorrect Information).
1. Login as FSE (see the “Login and Logout” procedure, chapter “Common
Maintenance Operations”, Auxiliary procedures section).
2. Set the Module off-line (see the “Module off-line procedure”, chapter “Common
Maintenance Operations”, Common procedures section).
3. From the GUI, click on System, select the Hidden button and then SDO R/W:
4. Insert the Node ID of the Alinity module in the “Node ID” field and check that the
module name is correctly showed.
5. Set the following value:
• Index = 8000
• subindex = 1B
6. Press the button “Read” and check the value showed, it should be DC050000
(which means 1500ms).
7. Set the value “C8000000” (which means 200ms) in the “Value” field and press the
“Write” button.
8. Press the “Read” button and check that the value has really changed to
“C8000000”.
9. Reboot the Q7 carrier board.
10. Before return the Automation System to the Operators, execute the logout.
11. Verify that pallets/tubes are correctly diverted into the Buffer lane of the spur and
no more warning S0059 occurs.
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33.9.3.9 Setting the Buffer Lane version

State: – Off-line

– The following procedure is intended to collect the guidelines to set the buffer lane version (Standard or HT)
installed for this Module.
– The procedure is to be carried out at first installation of the Module as well as in case of replacement of the
Q7 Carrier Board.
Operating procedure
c. Press the “Overview” button.
d. Press the “Alinity c” button.
e. From the Diagnostics options select “Settings”.
f. Press “Input Type” and select:

• “Divert Gate” for STD automation system.
• “No-Stop Divert” for HT automation system.
g. Reboot the Module - see “Module reboot” procedure, chapter “Common maintenance operations”,
h. Set the Module to on-line.
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33.9.3.10 Alinity ci IM Antennas test procedure (Standard version)


– This procedure is intended to collect the guide-lines about testing and aligning the antennas located on the
Interface Module.
– The procedure is subdivided in:
• "Antennas reading Map" (par. 33.9.3.10.1)
• "Reading test" (par. 33.9.3.10.2)
• "Antenna alignment" (par. 33.9.3.10.3)
• "Reading range verification" (par. 33.9.3.10.4)
33.9.3.10.1 Antennas reading Map

Fig. 67 - Antennas and Drivers locations map
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Tab. 6 - Antenna Boards LED map
Antenna TAG Antenna

Antenna board LED map Assembly LED lit up
board engaged
Buffer Lane Diverting groups 5A1 6A2 #1
(Fig. 67) 6A3 #2
Buffer Lane Routine Queue 4A1 6A1 #1
(Fig. 67)¹
9A1 #1
8A1
9A2 #2
Interface Module Spur (Fig. 67)
6A1 #1
5A1
6A2 #2
- - - -
- - - -
- - - -
- - - -
¹ Not available for a retrofit installation on a existing Buffer Lane.
33.9.3.10.2 Reading test

Operating procedure
a. Carry out the “Reading test” procedure, “TMA” service manual chapter, Auxiliary procedures section.
33.9.3.10.3 Antenna alignment
Operating procedure
a. Carry out the “Antennas alignment” procedure, “TMA” service manual chapter, Auxiliary procedures
section.
33.9.3.10.4 Reading range verification
Operating procedure
a. Carry out the “Reading range verification” procedure, “TMA” service manual chapter, Auxiliary procedures
section.
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33.9.3.11 Alinity ci IM Antennas test procedure (HT version)


– This procedure is intended to collect the guide-lines about testing and aligning the antennas located on the
Interface Module.
– The procedure is subdivided in:
• "Antennas reading Map" (par. 33.9.3.11.1)
• "Reading test" (par. 33.9.3.11.2)
• "Antenna alignment" (par. 33.9.3.11.3)
• "Reading range verification" (par. 33.9.3.11.4)
33.9.3.11.1 Antennas reading Map

Fig. 68 - Antennas and Drivers Location Map
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Tab. 7 - Antenna Boards LED map
Antenna TAG Antenna

Antenna board LED map Assembly LED lit up
board engaged
NSD 5A1 (Fig. 68) 5A1 NSD 5A1 NSD #1
board ² antenna
NSD 5A2 (Fig. 68) 5A2 NSD 5A2 NSD #1
board ² antenna
Routine Queue antenna (Fig. 68) 4A1 6A1 #1
9A1 #1
8A1
9A2 #2
Interface Module Spur (Fig. 68)
6A1 #1
5A1
6A2 #2
- - - -
- - - -
- - - -
- - - -
² For further information about the NSD components, please refer to the service chapter “TMA - Track Module Assembly”.
33.9.3.11.2 Reading test

Operating procedure
a. Carry out the “Reading test” procedure, “TMA” service manual chapter, Auxiliary procedures section.
33.9.3.11.3 Antenna alignment
Operating procedure
a. Carry out the “Antennas alignment” procedure, “TMA” service manual chapter, Auxiliary procedures
section.
33.9.3.11.4 Reading range verification
Operating procedure
a. Carry out the “Reading range verification” procedure, “TMA” service manual chapter, Auxiliary procedures
section.
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33.9.3.12 Local energy lockout and tagout

State: – Power Off
– Personal Lockout and Tagout Kit

– Perform this local lockout procedure whenever requested by a maintenance operation, to prevent any risk
in case of accidental energy restoring on the main electrical switches and/or compressed air valves.
– The FSE shall be equipped with a personal

Lockout and Tagout kit (the image is for
representative purposes only):
• Circuit breaker locking device (A)
• Padlock (B)
• ID tag (C)
– Set the module offline:

• In “Status” screen of the module you are working on, click the “Off-line” button and select “Flush
Carriers”.
• Wait until the module sets to offline.
– Perform the “Cutting off energy supplies” procedure - see chapter “Common maintenance operations”,
33.9.3.12.1 Local energy lockout / tagout procedure
Operating procedure
a. Locate on the Module electrical panel the main Circuit Breaker.
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b. Switch off the circuit breaker (A) and insert
the lockout device (B).
Refer to the kit instructions for a proper
installation.
c. Insert the personal padlock and the ID Tag in

their respective holes (A, B).
d. Locate the pneumatic lockable manual valve

on the Module pneumatic panel.
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e. Rotate to close the manual valve.
f. Insert the padlock and the personal ID tag.
– Check that any electrical device LED of the automation is powered-off.
– Check on the pressure gauge indicator for no compressed air presence.
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33.9.3.12.2 Restoring local energy
Operating procedure
Do not perform the controlled power up of the Automation System before executing the following
procedure.
a. Open and remove your own padlock (A) and

the ID tag.
b. Remove the lockout device (B) and switch on

the circuit breaker (A).
c. Open and remove your own padlock and the

ID tag from the pneumatic lockable valve.
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d. Rotate to open the manual valve.
– None.
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33.9.3.13 Test run procedure

State: – Automation System paused
Material: – Unused sample tubes

– None
Operating procedure
a. Power up of the Automation System - see “Restoring Power after a shutdown” procedure, chapter
b. Ensure that the Analyzer probe is properly aligned.
c. Login as FSE - see the “Login and Logout” procedure, chapter “Common Maintenance Operations”,
d. Press the “Start” button to start the Automation System and verify the correct execution of the process.
e. Monitor the carriers as they move from the secondary lane of the TMA to the IM and back to the secondary
lane of the TMA for smooth transitions and ensure that there are no pinch locations where carrier movement
will be restricted.
f. Check that carriers move properly and they are correctly processed.
g. Search the screen for error messages.

If no error code was reported the procedure has successfully completed.
h. Before return the Automation System to the Operators, execute the log out.
a. Not necessary.
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Alinity ci Interface Module

33. INTERFACE MODULE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

33.5.8 - Installing the Module straight version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

33.9.3 - Auxiliary procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

Automation System – Operations Manual

Alinity ci Interface Module – Wiring diagram

Tab. 1 - Release notes

33. Interface Module Assembly

33.1 Identification Data

33.2 Identification Labels

Fig. 1 - Alinity Spur End Cap identification label

Fig. 2 - Alinity ci Interface Module electrical plate identification label

Fig. 4 - Optional Alinity Spur L-Turn identification label

33.3 Technical and Environmental Specifications

33.4.1 Module purpose

33.4.2 Interface Module Components

Fig. 5 - Alinity ci IM main components straight configuration

A - Alinity ci IM with three lanes

B - Aspiration point for CC Analyzer

C - Aspiration point for IA Analyzer

D - Module buffer lane

Fig. 6 - Alinity ci IM main components Alinity Spur L-Turn

A - Alinity ci IM with three lanes

B - Aspiration point for CC Analyzer

C - Aspiration point for IA Analyzer

D - Alinity Spur L-Turn (if present)

E - Module buffer lane

33.4.3 Buffer lane

Fig. 7 - Buffer lane Carrier Path

C- Spur exit lane.

Fig. 8 - Buffer lane with STAT Carrier Path

C- Spur exit lane.

33.4.3.2 Process Controls

33.4.3.2.1 Buffer lane - Standard version

Fig. 10 - Buffer lane with STAT devices - STD version

33.4.3.2.2 Buffer lane - High Throughput version

Fig. 12 - Buffer lane with STAT devices - HT version

33.4.3.3 Buffer lane pneumatic system

33.4.3.3.1 Standard version

Tab. 2 - EV board - STD version (Sheet 1 of 2)

EV Cable Description Device

Tab. 2 - EV board - STD version (Sheet 2 of 2)

EV Cable Description Device

Fig. 14 - Buffer lane with STAT pneumatic diagram - STD version

Tab. 3 - EV board - STD version (Sheet 1 of 2)

EV Cable Description Device

Tab. 3 - EV board - STD version (Sheet 2 of 2)

EV Cable Description Device

33.4.3.3.2 High Throughput version

Tab. 4 - EV board - HT version

EV Cable Description Device

Fig. 16 - Buffer lane with STAT pneumatic diagram - HT version

Tab. 5 - EV board - HT version

EV Cable Description Device

33.4.4 Interface Module

Fig. 17 - Path of the carriers on Alinity ci IM straight version

A - Alinity Spur Main lane

B - Alinity Spur Sampling Bay aspiration lane

C - Alinity Spur exit lane.

Fig. 18 - Path of the carriers on Alinity ci IM with Alinity Spur L-Turn

A - Alinity Spur L-Turn Main lane

B- Alinity Spur Main lane

C- Alinity Spur Sampling Bay aspiration lane