i2000SR IM: Service Manual For The i2000SR Interface Module

Service Manual i2000SR interface module
i2000SR IM
Service Manual for the i2000SR Interface Module
Document name: 625798100.APS.5.doc

Last revised(ISO 8601): 2007-10-31
625798100.APS.5.doc Page 1 of 212

i2000SR interface module Service Manual
SUMMARY
Overview ..........................................................4
Identification Data .......................................................................... 4
Warnings Concerning Safety........................................................... 4
Laser Safety .................................................................................... 5
Description .......................................................7
i2000SR Interface Module ............................................................... 7
Tube Lanes ................................................................................................................. 9
Input and Output Areas ............................................................................................ 10
Path of the APS Carriers ........................................................................................... 10
Path of the i2000SR IM Carriers................................................................................ 11
Input and Output Areas ............................................................................................ 11
Process Controls ....................................................................................................... 12
Stop Gates ................................................................................................................ 12
Brief description of the stop gate devices ................................................................ 13
Off-line Carriers ........................................................................................................ 15
On-Line Carriers........................................................................................................ 15
Diverters Description................................................................................................ 17
IM Antenna and Optical Sensors............................................................................... 19
i2000SR Instrument Indicator Light (IM pole lamps) functioning .. 20
RED LAMP ON: Error or Initializing............................................................................ 20
RED LAMP Blinking: SCC CLI communication error................................................... 20
YELLOW LAMP Blinking: ............................................................................................ 20
GREEN LAMP ON: Running, Paused or Pausing ........................................................ 21
Modes of Operation....................................................................... 21
i2000SR IM Pneumatics Components............................................ 23
i2000SR IM Electrical Components................................................ 25
MASTER CAN Board Description.................................................... 26
MASTER CAN Board Segment Indicator .................................................................... 28
SLAVE 0 CAN Board Description.................................................... 28
SLAVE 0 CAN Board Segment Indicator.................................................................... 29
SLAVE 1 CAN Board Description.................................................... 29
SLAVE 1 CAN Board Segment Indicator.................................................................... 31
Electrical Panel Connectors........................................................... 32
i2000SR IM Electrical Box startup ................................................. 34
Starting i2000SR IM in APS Mode ............................................................................. 35
Starting i2000SR IM in Standalone Mode ................................................................. 36
i2000SR IM Track Initialization ...................................................... 37
Rebuilding queues .................................................................................................... 38
Standalone mode initializing......................................................... 38
APS mode initializing..................................................................... 38
i2000SR IM exercise mode............................................................ 38
Instructions for Assembly ................................40

i2000SR IM Parts Shipped ............................................................. 40
Parts Shipped for a New Installation......................................................................... 41
Parts Shipped for a Retrofit Installation.................................................................... 41
The 21 i2000SR IM Off-Line Carriers ........................................................................ 41
Assembly Procedure ..................................................................... 42
Prerequisite .............................................................................................................. 42
Installation of the Instrument Indicator Light (pole lamps) ...................................... 42
Installation of the i2000SR IM ....................................................... 43
Pneumatic Connections ................................................................ 49
Initial i2000SR Support Procedure ................................................ 50
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Electrical Connections................................................................... 53
IM Track Interface Cable Connections.......................................................................54
IM Electrical Box Cable Connections .........................................................................54
i2000SR Ground Wire Installation .............................................................................56
AC Power connections ...............................................................................................57
i2000SR IM LUI Panel Installation Procedure.............................................................58
i2000SR / i2000SR IM Alignment Procedure..............................................................60
i2000SR IM Horizontal Positioning Check ..................................................................65
i2000SR IM Vertical Positioning Check ......................................................................66
Alignment of routine and STAT sampling probes, gates and antennae ....................68
Install the Gap Filler ..................................................................................................68
Install 7L46-01 Off-line carriers.................................................................................70
Initialize i2000SR IM ..................................................................................................71
Verify Config Wizard i2000SR Setting .......................................................................73
Modify Config Wizard for i2000SR.............................................................................73
Modify Instrument Queue for instrument following i2000SR ....................................76
Modify Instrument Setup.INI file................................................................................77
Exercise i2000SR IM ..................................................................................................78
Verify carriers movement from the APS Track to i2000SR IM ...................................80
Complete installation of i2000SR LAS .......................................................................82
Retrofit of the I/O module pneumatic panel and circuit ................ 83
IOM Pneumatic Panel Differences ................................................. 86
Replacement Procedures ................................. 88

Replacement of i2000SR IM .......................................................... 88
Replacement of i2000SR IM belts ............................................... 100
Replacement of Light Pole Lamp................................................. 111
Replacement of belts motor........................................................ 115
Replacement of motor belt group ............................................... 120
Replacement of disk motor ......................................................... 126
Replacement of belts 1 & 2 drive group...................................... 132
Replacement of belts 1 & 2 idler pulleys groups......................... 137
Replacement of belts 3 & 4 drive group...................................... 141
Replacement of belts 3 & 4 idler pulleys groups......................... 145
Replacement of i2000SR IM antennas ........................................ 149
Replacement of belt disk ............................................................ 154
Replacement of the big belt disk ................................................ 159
Replacement of the Carrier Spinning Group ............................... 164
Auxiliary Procedures ..................................... 170

Alignment of barcode reader ...................................................... 170
Alignment of routine and STAT sampling gates .......................... 176
Sample and STAT Antennae alignment verification procedure ... 182
Antennas test procedure............................................................. 187
Verification of belt tensioning ..................................................... 191
Verification of Carrier Routing..................................................... 194
Tag Reader CAN BUS Board Firmware Installation ...................... 198
Preventive Maintenance Procedures .............. 203

Lubrication of gears .................................................................... 203
Spare Parts List ............................................ 208

i2000SR IM part list ..................................................................... 208
625798100.APS.5.doc Page 3 of 212

Overview
Identification Data
Module name: i2000SR Interface Module (i2000SR IM)
Group Drawing no.: 625.100.00X
Pneumatic layout: 625.107.00X
Electrical layout: 625.800.00X
Warnings Concerning Safety
WARNING: Potential Biohazard

Identifies an activity or area where potentially infectious
material may be present. Refer to your applicable
laboratory procedures and to “Section 4 - Hazards and
Warnings” of the Accelerator Service Manual
WARNING: Electrical Shock Hazard

Field Service Engineer (FSE) may be exposed to electrical
shock hazards if engineering controls are not observed.
Turn off the power to the Workcell and disconnect the
electrical main before replacing fuses, working on motors,
switches, connectors, electric wires or other electrical
devices.
CAUTION: Lifting Hazard

Identifies an activity that may require lifting or moving a
heavy object. Obtain assistance when moving or using an
appropriate lifting device.
CAUTION: Moving Parts

The safety cover protection is not guaranteed if the
security devices are removed or bypassed. Use caution to
prevent injury caused by moving parts.
Page 4 of 212 625798100.APS.5.doc

WARNING: Pinch Hazard

FSE may be exposed to pinch hazards while working on the
i2000SR IM. Be careful around moving parts while
performing diagnostic and maintenance operations.
WARNING: Probe Sharps Hazard

Follow safe sharp practices. Do not place your hand near
the probe while it is moving. Put the instrument through a
decontamination cycle and wipe the probe with a
disinfectant prior to touching or working near the probe.
Laser Safety
The laser classification scheme is used to describe the capability
of the laser or laser system to cause injury to personnel. The
higher the classification number, the greater the potential hazard.
The lasers on this workcell include Class 2 lasers.
During normal operation, the protective covers and access door
are to remain in place to prevent laser light exposure. The
protective covers and access door are to be removed only during
the servicing by qualified personnel. Do not remove the protective
cover laser warning labels. They must remain legible. The
protective housing label (label on instrument) is shown below. The
label consists of black lettering against a yellow background.
Do not remove, damage or obliterate any of the laser warning

labels. If any of the labels become damaged and/or illegible,
replace them.
LAB0033 is an illustration of the label recommended by Abbott

Safety to be placed on the i2000SR and i2000SR IM closeout
cover.
DANGER:
Class 2 Laser Radiation when open. Do not stare into beam.
Avoid eye exposure to laser light
625798100.APS.5.doc Page 5 of 212

DANGER: Laser Hazard

Field Service Engineer (FSE) may be exposed to direct laser
emissions in the i2000SR IM area with the i2000SR cover
shields removed; be careful when performing diagnostics
and maintenance operations with i2000SR cover shields
removed.
The source of the laser beam is located in the barcode
reader device. Do not look directly into the aperture of the
emitted laser beam. The maximum radiant power at the
aperture of the laser barcode reader is 1 mW or less.
Page 6 of 212 625798100.APS.5.doc

Description
This chapter contains a general description of the module and its

technical characteristics. An explanation of the principles of
operation is also provided.
i2000SR Interface Module

The purpose of the i2000SR Interface Module (IM) is to transport
samples to the ARCHITECT i2000SR instrument as a standalone
unit or interfaced with an Automated Processing System (APS). As
a standalone unit the i2000SR IM (Figure 1) is capable of
processing sample tubes without any functionality from the APS.
As an autonomous instrument it is equipped with its own power
supply, controller unit, and Laboratory Automated System (LAS)
connections.
Figure 1 i2000SR Interface Module
No. Description
1 i2000SR Interface Module with 4 tube lanes
2 Barcode reader
3 Instrument Indicator lamps
4 APS track with instrument interface module
5 i2000SR IM electrical box group
6 i2000SR IM pneumatic group
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NOTE:
Although the i2000SR IM can process samples independent
of the APS, the IM cannot be installed independent of the
APS.
The IM is controlled by a set of microcontrollers. The

microcontrollers are interfaced to the APS via the CAN bus and
are similar to the Tag Reader boards used to manage the
functions of the track.
The operator side contains a local user interface keypad, two
colored Input Status LEDs (green and yellow) for Routine and
Priority testing, and Instrument Indicator light (IM pole lamp)
with three lamps (red, yellow and green).
IM set-up/configuration/upgrade and device control operations
can be performed either by the APS software or by a laptop
connected to the APS computer hub via TCP-IP.
Page 8 of 212 625798100.APS.5.doc

Tube Lanes
The i2000SR IM consist of four transport belts that are used to
create four tube lanes, each one dedicated to a specific task of
moving APS Workcell on-line and i2000SR IM specific off-line
carriers (See Figure 2 – Arrows show the belt spin directions):
Figure 2 – i2000SR IM top view
No. Description
1 Lane 1: The lane located closest to the i2000SR
instrument, transports carriers to sampling points for the
i2000SR sample and STAT pipettor.
2 Lane 2: Routes the carriers back to their original location
(the APS or the 4th lane of the IM).
3 Lane 3: Holds a queue of both off-line routine and off-line
priority carriers for the operator to load sample tubes.
4 Lane 4: The sample output area that can maintain a
queue of IM off-line carriers.
NOTE:
• The carriers used on the IM are a gray color and
are referred to as Off-line carriers.
• The off-line carriers cannot be used on the track
(on-line carriers).
• The system identifies the “gray” off-line carriers
using the RFID. The IM specific Off-line carriers have a
different range of RFIDs.
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Input and Output Areas

With reference to the Figure 2
A Priority sample input area (queue of 6 off-line carriers)
B Routine sample input area (queue of 11 off-line carriers)
C Sample output area (queue of 4 off-line carriers)
D Entry Gate Queue (queue of 8 on-line carriers)
Path of the APS Carriers

Figure 3 – Carriers paths
The following is the path of the Carriers routed to the i2000SR IM

from the APS track
1. Carriers with sample for the i2000SR are diverted from
the main track to the i2000SR IM Entry Queue.
2. As the carriers enter the i2000SR IM track, the sample
tube barcode and RFID are read; the i2000SR IM sends
information to the APS where the link between the RFID and
sample SID is verified. If there is a match, the i2000SR IM sends
the i2000SR SCC the “prepare to sample” message. If the RFID
and SID do not match, a Carrier Mismatch error occurs.
3. After carriers are released from the barcode gate they are
routed to the i2000SR STAT pipetting location. The i2000SR IM
sends the SID to the i2000SR. The i2000SR performs a host query.
If the sample has a STAT test assay ordered, the i2000SR STAT
pipettor will aspirate the required volume for each assay to be
processed.
4. After the last STAT assay aspiration, the carrier is released
and is routed to the i2000SR routine sample pipettor. As the
carriers enter the sample pipettor aspiration point, the i2000SR
IM sends the SID to the i2000SR. The i2000SR performs a host
query and if the sample has a routine assay test ordered, the
i2000SR sample pipettor aspirates the required volume for each
assay to be processed. After the last aspiration, the carrier is
released and routed to the gate at the end of lane #2.
5. If the carrier is an On-line carrier, it is rerouted to the
main track.
Page 10 of 212 625798100.APS.5.doc

Path of the i2000SR IM Carriers

The following is the path of the i2000SR IM carriers processed on
the IM.
1. During initialization, carriers are organized into two
queues (Routine and Priority) along Lane 3.
2. As soon as a sample tube is placed into the first carrier of
either the Priority or Routine position, it is routed from Lane 3 to
Lane 2. At the right end of Lane 2 is a gate and diverter that is
used to route the carrier to Lane 1.
3. At the entry to Lane 1, the tag reader reads the RFID and
the barcode scanner reads the label on the tube. The i2000SR IM
links the RFID and the scanned SID. The i2000SR IM sends the
i2000SR SCC the “prepare to sample” message.
4. After carriers are released from the barcode gate they are
routed to the i2000SR STAT pipetting location. The i2000SR IM
sends the i2000SR the SID. The i2000SR performs a host query
and, if the sample has a STAT test assay, the i2000SR STAT
pipettor will aspirate the required volume for each assay to be
processed.
5. After the last aspiration of the STAT assay, the carrier is
released and routed to the i2000SR routine sample pipettor. As
the carriers enter the sample pipettor aspiration point, the
i2000SR IM sends the SID to the i2000SR. The i2000SR performs
a host query and if the sample has a routine assay test ordered,
the i2000SR sample pipettor aspirates the required volume for
each assay to be processed. After the last aspiration, the carrier is
released and routed to the gate at the end of Lane #2.
6. The carrier RFID is read. As the carrier is from the IM, the
carrier is rerouted to Lane 4.
7. Lane 4 is used to manage a queue to re-supply off-line

carriers to the Routine and Priority queues on Lane 3.
Input and Output Areas

The IM offers three areas for manual operation with a total of 21
available carriers arranged in the following order after IM
initialization:
• Priority sample input area with 6 Priority Carriers (A).
• Routine sample input area with 11 Manual Carriers (B).
• Sample output area with 4 Output Carriers (C)
The IM carriers, identified as Off-line Carriers, are gray in color

differentiating them from the black ones used on the Workcell.
The Off-line carriers have different RFID tags than those on the
Workcell. The IM reads the RFID and ensures that the Off-line
carriers are never routed into the Workcell.
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During the APS operational mode, Workcell carriers identified as

On-line Carriers can be processed along with the Off-line
carriers. As the IM Off-line and Workcell On-line carriers have
different RFID tags the IM routes all Off-line carriers to Lane 4
and the On-line carriers back to the Workcell, after processing.
NOTE:
If an IM Off-line carrier enters the APS track, the APS
identifies the off-line carrier at the next RFID gate tag
reader position and the APS carrier movement stops.
Process Controls
Nine RFID antennae are used to identify the carriers. Seven are
on the IM module and two are on the track instrument interface.
Three optical sensors are used to sense the presence of tubes.

One is located at the routine sample input area (G7b), another at
the priority sample input area (G8) and the third at the sample
output (G6). (See Figure 4 and Figure 6)
Two additional optical detectors located near disk D3 are used to
verify that On-line carriers are routed back to the APS Workcell
and Off-line carriers are routed to Lane 4.
Stop Gates
The IM Stop Gates and Diverters are pneumatic devices controlled
by the firmware (F/W) in the Master and Slave Tag Reader boards
located in the IM electrical box. These devices control carrier
traffic on IM lanes and the associated instrument interface.
There are three different types of stop gates:
Type 1 Gate – avoids interference with other carriers that are
arriving on the next lane.
Type 2 Gate – waits for an optical sensor to detect either the
insertion or removal of a tube.
Type 3 Gate – waits for the carrier to be identified using the RFID
tag reader.
Page 12 of 212 625798100.APS.5.doc

Figure 4 – Stop gates (G#) and diverters (D#)
Brief description of the stop gate devices

Refer to Figure 4 and Figure 9.
Gate 0 – (G0) is located on the APS Track and is operated by
electro valve EV1. This Type 3 gate operates when the carrier
moving along the APS main track is either diverted into the
i2000SR IM or continues along the APS track. If the carrier is
diverted, Gate 0 and the standard track diverter (D0) activate to
route the carrier to the IM. The diverter (D0) is operated by
electro valve EV2.
Gate 0 is also used to maintain the number of carriers in the

queue of the i2000SR IM instrument interface.
NOTE:
The number of carriers queued at the Instrument Gate (G0)
is set by the value in the Instrument Gate parameter of the
Config Wizard Track Layout. The value of the standard
instrument interface queue is ten (10).
Gate 1 – (G1) is the Entry gate and is located on the Pit Stop lane
of the APS track and is operated by electro valve EV3. This Type 1
gate operates when the i2000SR IM is used with the APS. The
gate is normally closed and will only open to allow carriers from
the track to enter Lane 1 when there is no possibility that it would
interfere with an Off-line carrier from the IM lane 3.
NOTE:
The number of carriers queued at the Entry Gate (G1) is set
by the value in the Return/Entry Gate parameter of the
Config Wizard Track Layout screen. Typically the value is
set to eight (8) as that is the number of carriers that can
physically be placed in the area. (Refer to figure 1)
625798100.APS.5.doc Page 13 of 212

Gate 2 – is a set of three (Barcode) BCR Type 3 gate devices (G2

Æ a, b, and c) located on the i2000SR IM Lane 1. The set stops
and reads the carrier RFID tag and rotates the carrier to allow the
Barcode reader to scan and identify the label on the tube. For On-
line carriers from the APS track, the link between the SID and
RFID is verified by the APS. Samples that are manually inserted
into Off-line carriers at either a Routine or Priority location are
scanned and a link is created between the RFID and SID.
G2a Electro valve EV5 controls the gate that stops the carrier
at the barcode reader.
G2b Electro valve EV6 controls the roller that drops on the
carrier that causes the carrier to spin.
G2c Electro valve EV7 controls the stop gate before the spin
area. To prevent drag on the spinning carrier, the G2c gate stops
the second carrier before the spin area.
NOTE:
Since the off-line carriers do not leave the i2000SR IM,
their SID is communicated via the Master Tag Reader
board.
Gate 3 – (G3) is the STAT Sampling Gate located on Lane 1 and is

operated by electro valve EV8. This Type 3 gate stops the carrier
for tube sampling in front of the i2000SR STAT sampling position.
Tube identification is obtained by reading the RFID. The i2000SR
IM Mater Tag Reader board sends the corresponding SID to the
i2000SR. The i2000SR performs a host query to determine the
test ordered. Prior to each aspiration, the RFID is read.
NOTE:
Should the RFID change before the carrier is released, a
sample presentation error is generated and in standalone
the i2000SR system run is stopped
Gate 4 – (G4) is the Routine Sampling Gate located on Lane 1 and

is operated by electro valve EV9. This Type 3 gate stops the
carrier in front of the i2000SR routine sampling position. Tube
identification is obtained reading the RFID. The i2000SR IM sends
the corresponding SID to the i2000SR. The i2000SR performs a
host query to determine the test ordered. Prior to each aspiration,
the RFID is read.
NOTE:
Should the RFID change before the carrier is released, a
sample presentation error is generated and in standalone
the i2000SR system run is stopped
Gate 5 – (G5) is located on Lane 2 and is operated by electro

valve EV11. This Type 1 gate stops the carrier on Lane 2 to avoid
Page 14 of 212 625798100.APS.5.doc

a collision with a carrier arriving from Lane 3. Lane 3 carriers

always have precedence over those traveling on Lane 2.
At this stop gate, a Tag Reader identifies the carrier and the IM
determines which of the following three scenarios is appropriate:
Off-line Carriers
1. If the stopped Off-line carrier was manually loaded, the
sample just introduced at either the routine or priority sample
input areas, the D2 Diverters (Lane 2/1 and Lane 3/1) are
activated and allows the carrier to travel on the small disk and
into Lane 1. The D2 diverters are operated by electro valve EV4.
2. If the stopped carrier is an Off-line type and contains a
sample tube that has been already sampled, the D2 and D3
diverters are set to route the carrier around the large disk and
return to Lane 4 (Output Lane). The D3 diverter is operated by
electro valve EV12.
On-Line Carriers
3. If the stopped carrier is an On-line carrier from the APS
Workcell, it must be returned to the track. In this case, the
diverters D2 (Lane 2/1 and Lane 3/1) and D3 activate and allow
the carrier to go back to the APS Track.
Gate 6 – (G6) – is an Output Gate located on Lane 4 and is
operated by electro valve EV13. This Type 2 gate is controlled by
an optical tube sensor that checks for the removal of the tube
from the carrier. The empty carrier is released to Lane 3 (input
area) and to Gate 7b. Gate 6 manages the release of empty
carriers required to re-supply the carriers for the routine (G7b)
and priority (G8) gates. Gate 7b and the diverter D1 manage the
queue of carriers in the priority sample area. If there is a shortage
of carriers, the priority sample area will have the precedence.
NOTE:
For a detailed description of the queue building sequence,
refer to the Initialization Sequence section.
Gate 7b (G7b) – is the Routine Input Gate located on Lane 3 and

is operated by electro valve EV14. This Type 2 gate is located at
Routine Manual Input position and controls the routing of
manually entered routine tubes and is controlled by an optical
tube sensor located at the entry position. The sensor is used to
verify presence of a tube in the carrier. In this case, Gate 5
operates to stop any carriers moving on Lane 2 and allows the
new carrier to enter by opening the diverter Gate D1, which
routes the carrier from Lane 3 to Lane 2. The D1 diverter is
operated by electro valve EV15.
The IM controls a Green/Yellow LED associated with this gate.

When the LED is yellow, the carrier at the gate is routed to the
Priority Input area (G8). Tubes must not be manually inserted
625798100.APS.5.doc Page 15 of 212

into an empty carrier at this time. When the LED is green, tubes
can be manually loaded into the carrier located at this gate.
Gate 7a – (G7a) is on Lane 2 and is operated by electro valve
EV10. This Type 1 gate stops the carrier on Lane 2 to avoid a
collision with a carrier that is being introduced from the Lane 3
Routine Manual input area gate (G7b). The Routine Manual Input
samples from Lane 3 have precedence over carriers running on
Lane 2. The opening of the diverter D1 (Lane 3/2 Diverter) drives
the closing of Gate 7a and prevents collisions as a new tube
carrier enters from the manual input gate. (See Gate 7b).
Gate 8 (G8) – is the Priority Input Gate located on Lane 3 and is
operated by electro valve EV16. This Type 2 gate is located at the
Priority Manual Input position and is controlled by an optical tube
sensor located at the entry position. The sensor is used to verify
the presence of a tube in the carrier. The Priority Input position is
used to insert priority samples, calibrators and controls. The
carrier will be introduced onto the large disk and routed via the
pair of D2 diverters to Lane 1. The D2 diverters are the Lane 3/1
and Lane 2/1 Diverters and are operated by electro valve EV4.
The Lane 3/1 Diverter is positioned to prevent the carrier from
being routed to the Main APS track. The Lane 2/1 Diverter opens
to allow the carrier to enter Lane 1.
NOTE:
When introducing calibrators and other tubes that need to
be processed according to a specific order, they must be
loaded in order at the Priority Input queue. The last
calibrator to be processed is placed into the appropriate
carrier to the left of the entry point. For a six (6)-point
calibration, the last calibrator “F” is loaded into sixth
carrier to the left. The remaining calibrators are loaded in
sequence as illustrated below. The first calibrator to be
aspirated is “A” and is loaded at the Priority Entry point.
(See Figure 5) When the first tube is detected the entire
set of tubes will move in to be processed.
Figure 5 – Calibrator Load (Six point)
Gate 9 (G9) – This Type 1 gate is located on the APS main track
and is operated by electro valve EV17. An optical sensor is
positioned to detect that the On-line carrier was routed from the
large disk and was returned to the main track. The optical carrier
Page 16 of 212 625798100.APS.5.doc

detect sensor that controls Gate 9 is on the main track at the

output of the large disk. Gate 9 is activated to stop carriers on the
Workcell Main Track and prevent collision with On-line carriers
leaving the IM.
On-line carriers released by G5 are routed around the large disk
to the Main track by opening the D2a (Lane 3/1) and closing the
D3 (Lane 4/Track) diverters. As the carrier passes the D3 diverter,
it is detected by the optical carrier detector and gate G9 is closed
to prevent a collision.
Diverters Description
Diverter Gates (D0-D1-D2a-D2b-D3) – These gates are used to
route a carrier into a different lane. The IM has five Diverter
Gates named D0, D1, D2a, D2b and D3. The diverters D1, D2a,
D2b and D3 are unique to i2000SR IM and have a different design
than those used on the main track. They are driven by the F/W
and used to control the routing carriers to the final destination.
Below is a description of each diverter and its function in
association with a gate.
D0 – Standard Track Diverter – is located at Gate G0 and is
activated by EV2 to divert tubes from the main track that are to
be processed by the i2000SR. The carriers bypass the i2000SR as
the diverter is normally in the open position.
Diverter Control Description Reference
Main track
D0 EV2 IM entry
diverter
D1 – Lane 3/2 Diverter – is located at Gate G7b and is activated by

EV15 and has two functions 1) In the inactivated state, carriers
with sample tubes are released from Routine Input Gate G7b
where they are diverted from Lane 3 to Lane 2. 2) When Priority
Carriers are used, D1 is activated to allow carriers to continue to
move along Lane 3 to the Priority Input gate queue. The carriers
are diverted to Lane 2 as the diverter is normally open.
625798100.APS.5.doc Page 17 of 212

Lane 3/2
D1 EV15
Diverter
D2b – Lane 3/1 Diverter – is located in the area of the gate G8 and
the large disk. It is controlled by EV4 and is activated to route
carriers from Lane 3 to Lane 1 via the opening created by D2a.
The diverter is normally retracted to allow carriers to travel
around the large disk.
EV4 Lane 3/1

D2b
CYL1 Diverter
D2a – Lane 2/1 Diverter – is in the area of the gate G8 and the
large disk. It is controlled by EV4 and opens a path between Lane
2 and Lane 1. When closed, it prevents carriers from entering
Lane 1. When opened with the activation D2b diverter, it allows a
carrier from Lane 3 to be directed in to Lane 1
EV4 Lane 2/1

D2a
CYL2 Diverter
Page 18 of 212 625798100.APS.5.doc

D3 – Lane 4/Track Diverter – is in the area of the large disk. It is

controlled by EV12 and is activated to block carriers traveling on
the large disk from entering Lane 4. Carriers are then routed to
the Main Track. The diverter is normally retracted and allows
carriers to travel around the large disk.
Lane
D3 EV12 4/Track
Diverter
IM Antenna and Optical Sensors

The i2000SR IM uses RFID Antenna and optical sensors to detect
the presence of a carrier and/or sample tube. These devices are
controlled by the F/W in the Master/Slave board located in the IM
electrical box.
An antenna is located at each of the nine gates and is used to
detect the RFID of the carrier located at the associated gate
location.
There are three tube sensors that are used to detect the presence
of a tube in a carrier. When a tube is placed into the first carrier
of a routine (G7b) or priority (G8) input location, it is detected by
the associated tube sensor. As the tube is routed to the Exit Gate
(G6), the tube sensor at that location is used to ensure that the
carrier does not contain a tube before it is routed to a tube input
queue.
The routine (G7b) and priority (G8) inputs have green and yellow
LEDs used to notify the user of the status of the carrier located at
the gate. A green LED illuminates to indicate the carrier is ready
for a tube to be inserted. A blinking yellow LED indicates that the
carrier is scheduled to move and a steady yellow LED illuminates
to indicate a moving carrier.
If the carrier on the disk is an On-line carrier, an optical sensor is
located on the main track near D3 to detect that the large disk to
the main track properly routs the carrier. The sensor is also used
to activate the main track gate (G9) to prevent a collision.
A second carrier sensor is located at the large disk near D2b to

detect that the Off-line carrier is properly routed to lane 4.
625798100.APS.5.doc Page 19 of 212

Figure 6 – Optical sensors and antennas
i2000SR Instrument Indicator Light (IM pole lamps) functioning

The i2000SR Instrument Indicator Light is a pole attached to the
track with three colored lamps that are used as an interface
device to communicate to the operator the status i200SR IM. (See
Figure 1)
RED LAMP ON: Error or Initializing

The red lamp illuminates to indicate that either the IM and/or
analyzer are either not fully initialized or an error condition
requiring operator attention has occurred.
RED LAMP Blinking: SCC CLI communication error

A blinking red lamp indicates that the i2000SR System Control
Center (SCC) is not initialized, or CLI communication was not
established.
The red lamp will remain blinking until the SCC is in the Snapshot
screen, and the IM has been reset and communication has been
established via the CLI port.
YELLOW LAMP ON: Exercise mode
The yellow lamp is illuminated to indicate the system in exercise
mode. Exercise mode is used to carrier movement operations and
is described in the Modes of Operation.
YELLOW LAMP Blinking:

While in Standalone mode, a blinking yellow lamp is used to
inform the operator of a sample presentation error. To prevent
erroneous results, the IM via the CLI port will issue the i2000SR
analyzer a Stop command.
Page 20 of 212 625798100.APS.5.doc

In the event of a sample presentation error while running in APS

mode, the sample will be flagged with a sample presentation error
and the i2000SR will continue processing. The yellow lamp will
not be illuminated or be blinking.
NOTE:
A Sample Presentation error is generated when the RFID
read at the end of the aspiration differs from that read at
the beginning. If the end RFID reading is missing, a sample
presentation error is generated. If another RFID is read,
the first sample will be flagged with a sample presentation
error and the second carrier will be flagged with a sample
queue error.
When in the Standalone mode, in the event of a sample

presentation error the yellow lamp will begin blinking and the red
lamp will be turned ON. The IM will issue a stop command to the
CLI port to prevent the i2000SR analyzer from processing samples
GREEN LAMP ON: Running, Paused or Pausing

The green lamp is illuminated to indicate that the i2000SR and IM
are operating without error and the communication link between
i2000SR and IM is established.
Modes of Operation
Run:
Standalone mode – the user presses the Run button on the

keypad. Samples loaded at either the Routine or Priority Inputs
with test orders scheduled on the i2000SR analyzer are
processed.
APS mode – the i2000SR instrument(s) is selected to be on-line.
With the appropriate i2000SR IM initialized and analyzer running
(IM pole light Green), the APS will process and route samples with
i2000SR-configured tests to the IM.
Pause:
Standalone mode – the user presses the PAUSE button on the

keypad. The IM track will stop processing samples. Standalone
sample processing will resume when the RUN button on the LUI
panel is pressed.
APS mode – at the APS GUI the user selects Diagnostics, Track,
Transportation Module – RFID Tag Reader Instrument and then
PAUSE. Samples on the IM will stop being processed until the IM
is RESET.
Exercise:
Standalone – at the LUI panel the user presses and holds the RUN
key then presses the Pause key. Off-line carriers are moved within
the IM track. On-line carriers are routed to the main APS track.
625798100.APS.5.doc Page 21 of 212

APS mode – IM Exercise mode cannot be performed while in APS

mode. The APS Track Exercise will not pass carriers to the
i2000SR IM.
A detailed description of the movement of carriers while in

exercise mode is contained in the i2000SR IM exercise mode
description section.
Stop:
Standalone – at the LUI panel the user presses the Stop button.
All carriers on the IM will stop moving.
APS mode – at the APS GUI the user selects Diagnostics, Track,
Transportation Module – RFID Tag Reader Instrument and then
STOP. All carriers on the IM will stop moving.
Figure 7 – Interface devices
No. Description
1 Instrument Indicator Light lamp (Pole lamp)
2 Routine input status LEDs
3 Priority input status LEDs
Page 22 of 212 625798100.APS.5.doc

i2000SR IM Pneumatics Components

Figure 8 – i2000SR IM pneumatic panel
EV Description Gate Port EV Description GatePort

1 Instrument i2000SR Gate G0 A 11 Exit Gate G5 A
Instrument i2000SR Divert
2 D0 AB 12 D3 AB
Gate Divert to Track
Output Gate – release off-line
3 Entry Gate G1 A 13 G6 A
carriers to lane 3
4 Divert Gates at end of lane 3 D2 AB 14 Routine Entry G7b A
5 BCR Stop Gate G2a B 15 Routine Entry diverter – L3 to L2 D1 AB
Priority off-line carrier entry
6 BCR Carrier Rotation G2b B 16 G8 A
gate
Stop Gate to prevent carrier
7 BCR 2nd carrier Stop Gate G2c A 17 G9 B
collision on APS Track
8 i2000SR STAT Pipetting Gate G3 A
9 i2000SR Sample Pipetting Gate G4 A
Routine Entry Anti-collision
10 gate – lets in the off-line G7a B
routine samples to L2
625798100.APS.5.doc Page 23 of 212

Figure 9 – i2000SR IM pneumatic layout
Page 24 of 212 625798100.APS.5.doc

i2000SR IM Electrical Components

Figure 10 – i2000SR IM electrical block diagram
625798100.APS.5.doc Page 25 of 212

MASTER CAN Board Description

Table 1 – Master CAN Board Outputs
Pin Function Device Electro Port Antenna LED Control Description
Valve Command
Out – 1 STAT G3 EV8 A A3 1 STAT - Activates the gate at
Pipettor Pass the STAT Pipettor
Gate
(Pass A)
Out – 2 All Belt K1 Diag – Bit 1 Activates relay K1 to
and Disk (Motors) supply +24 VDC to
Motors 1 = ON the 2 Belt and Large
Disk motors
0 = OFF
Out – 3 Sample G4 EV9 A A4 2 Routine - Pass Activates the gate at
Pipettor the Sample Pipettor
Gate
(Pass B)
Out – 4 Post Lamp K2 Diag – Bit 3 Activates relay K2 to
– Green (Green Lamp) turn on the Green
1 = ON lamp (indicates
operational status)
0 = OFF
Out – 5 Post Lamp K3 Activates relay K3 to
– Red turn on the Red lamp
(indicate non
operational status
Out – 6 Main G9 EV17 B Exit Carrier Activates gate G9 on
Track Detector the main track to
carrier Activates prevent a collision
return with a carrier
anti- returning from IM.
collision (Pass)
gate
Out – 7 Priority Diag – Bit 6 Activated to indicate
Tube (Priority Green that the condition is
Insertion LED) correct to insert tube
Green LED 1 = ON at priority location
0 = OFF
Out – 8 Priority Diag – Bit 7 Activated to indicate
Tube (Priority Yellow that the conditions
Insertion LED) are not correct to
Yellow 1 = ON insert tube at priority
LED location
0 = OFF
Page 26 of 212 625798100.APS.5.doc

Table 2 – Master CAN Board Inputs

Pin Function Devic Electro Port Antenna LED Control Description
e Valve Command
In – 1 Carrier Diag – Bit 0 A carrier detected as
Presence 1 = ON it has exited the large
(SICK) disk and entered
0 = OFF Lane 4
sensor at
Lane 4
large disk
In – 2 LUI – Pause Diag – Bit 1 The keypad Pause
button 1 = ON button was pressed.
0 = OFF
Keypad
In – 3 LUI – Stop Diag – Bit 2 The keypad Stop

button 1 = ON button was pressed
0 = OFF
Keypad
In – 4 Carrier Diag – Bit 3 A carrier was

Presence 1 = ON detected as it exited
(SICK) the large disk and
sensor at 0 = OFF returned to the main
IM exit to track. Used to
track activate the anti-
collision gate G9
(G10)
In – 5 +24 VDC Diag – Bit 4 Detects the presence
from APS 1 = ON of +24 VDC from the
workcell APS workcell
0 = OFF
In – 6 +24 VDC Diag – Bit 5 Detects the presence
from the IM 1 = ON of +24 VDC from the
electrical IM electrical box
box 0 = OFF
In – 7 LUI – Run Diag – Bit 6 Keypad – Run button

button 1 = ON has been pressed
0 = OFF
Keypad
Exp. Not Used Not Used

Out 1 –
8
Exp. In Not Used Not Used
1-7
625798100.APS.5.doc Page 27 of 212

MASTER CAN Board Segment Indicator

LED Indicator Carrier at G3 Carrier at G4
STAT Probe Sample Probe
0
1 Yes
2 Yes
3 Yes Yes
SLAVE 0 CAN Board Description

Table 3 – Slave 0 CAN Board Inputs - Outputs
Pin Function Device Electr Port Antenna LED Control Description
o Command
Valve
Out – 1 Instrument G0 EV1 A A0 1 Divert Gate Activated to either pass a
Gate - Pass carrier along the main
(Pass A) track or in conjunction with
diverter D0 route it to IM
entry
Out – 2 Pit stop D0 EV2 A&B Divert Gate Activated to divert a
- Pit Stop carrier into the IM entry
(Pit Stop)
Out – 3 Gate at G2a EV5 B A2 2 BCR Pass Activated to pass a carrier
BCR at the BCR reader.
Out – 4 Lock Gate G2b EV6 B BCR Lock Activated to lock carrier at
at BCR BCR to cause it to spin.
Out – 5 Gate before G2c EV7 A Activated to prevent next
BCR carrier from impacting the
spinning of a carrier at the
BCR.
Out – 6 Routine Diag – Bit Activated to indicate that
Tube 13 (Routine the condition is correct to
Insertion Green LED) insert tube at routine
Green LED 1 = ON location
0 = OFF
Out – 7 Entry gate G1 EV3 A A1 4 Pass Activated to release
Entry Pass carriers from the IM entry
to Lane 1
Out – 8 Routine Diag – Bit Activated to indicate that
Tube 15 (Routine the conditions are not
Insertion Yellow LED) correct to insert tube at
Yellow LED 1 = ON routine location
0 = OFF
In – 1 Not Used Not Used
to 7
Expans LUI – Pause Keypad Keypad – Pause LED
ion button LED illuminated
Out –1
Expans Post Lamp K4 Diag – Bit 3 Activates relay K4 to turn
ion Out – Yellow (Yellow on the Yellow lamp
–2 Lamp) (indicate non operational
1 = ON status that requires
operator attention)
0 = OFF
Page 28 of 212 625798100.APS.5.doc

SLAVE 0 CAN Board Segment Indicator

LED Carrier at G0 Carrier at Carrier at G1
Indicator G2a
0
1 Yes
2 Yes
3 Yes Yes
4 Yes
5 Yes Yes
6 Yes Yes
7 Yes Yes Yes
SLAVE 1 CAN Board Description

Table 4 – Slave 1 CAN Board Inputs
Valve Devices
In – 1 Tube G6 Diag – Tube detected at the output
Presence Bit 16 (left end of Lane 4)
1 = ON
0 = OFF
In – 2 Tube G7 Diag – Tube detected at Routine Input
Presence Bit 17
1 = ON
0 = OFF
In – 3 Tube G8 Diag – Tube detected at Priority Input
Presence Bit 18
1 = ON
0 = OFF
In – 4 to Not Used Not Used
7
Exp. Not Used Not Used
Out – 1
to 8
Exp. In – Not Used Not Used
1 to 7
625798100.APS.5.doc Page 29 of 212

Table 5 – Slave 1 CAN Board Outputs

Valve Devices
Out – 1 G7b EV14 A A7 1 Routine Controls the carriers at the
Input – Routine sample input.
Pass/Pit A carrier with a Routine sample
Stop tube is diverted to Lane (Pass)
Releases carriers to supply
(Pass A) Priority Input carriers (Pit Stop).
Out – 2 D1 EV15 A Routine Located at Routine input.
and Input – Routes carriers from Routine
B Pit stop sample input to Lane 2.
When activated, routes empty
(Pit Stop carriers from routine input to
A) priority input queue.
Out – 3 G6 EV13 A A6 2 Output – Controls carriers exiting Lane 4

Pass
(Pass B)
Out – 4 D2 EV4 A Output – Controls both D2a and D2b
and Pit Stop diverters.
B When activated, opens Lane
1/3 and positions Lane 2/3 to
route carriers with new
samples from G7a or G8 to
Barcode gate G2.
When closed, routes carriers
with completed samples from
G5 to either the 4th lane (Off-
line) or Main track (On-line).
Out – 5 D3 EV12 A Routes Off-line carriers to main
and track
B
Out – 6 G8 EV16 A A8 8 Priority Controls the carriers at the
Input – Priority sample input.
Pass
(Pass)
Out – 7 G5 EV11 A A5 4 Exit – Controls the routing of carriers
Pass exiting Lane 2. Determines if:
The On-line carrier should be
(Pass) routed to the APS track
The Off-line carrier with a new
sample should be routed to
Lane 1 for sampling.
The Off-line carrier with a
completed sample is routed to
Lane 4.
Out – 8 G7a EV10 B Routine Located at Routine input area
Input – Controlled by release of
Pass/Pit carriers at G7a to prevent
Stop collisions
(Return)
Page 30 of 212 625798100.APS.5.doc

SLAVE 1 CAN Board Segment Indicator

LED Carrier at Carrier at Carrier at Carrier at
Indicator G7b G6 G5 G8
0
1 Yes
2 Yes
3 Yes Yes
4 Yes
5 Yes Yes
6 Yes Yes
7 Yes Yes Yes
8 Yes
9 Yes Yes
A Yes Yes
B Yes Yes Yes
C Yes Yes
D Yes Yes Yes
E Yes Yes Yes
F Yes Yes Yes Yes
625798100.APS.5.doc Page 31 of 212

Electrical Panel Connectors

Figure 11 – Electrical Panel connectors
No. Description
A0 & A1 Track module antennas A0 and A1
A2 to A8 i2000SR IM antennas from A2 to A8
i2000SR IM three Motors (Lane 1 & 2 motor, Lane 3 &
J1
4 motor, and Disk motor)
J2 Instrument Indicator light (IM Status pole lamps)
J3 Track CAN bus power supply 24 V DC
J4 i2000SR 230 VAC power supply
J5 IM to Track CAN-BUS
J6 Future remote display/keyboard
J7 Track CAN bus SICK barcode
LAS i2000SR Interface (Master tag reader RS-232 port
J8
1) SCC Edgeport Port 4 (Com 6)
J9 Priority, Routine LEDs and Keypad
J10 Electro valves on pneumatic panel
J11 i2000SR IM power switch
Carrier Detector (SICK optical sensor) detects that a
J12 carrier was returned to track. Active track anti-
collision gate (G9)
i2000SR IM G6 G7 G8 D3 Carrier Detector (SICK
J13
optical sensor) gates
Optional - To be used to program IM Track barcode
J14
reader
J15 Not used, Optional
J16 Not Used
J17 Not Used
i2000SR CLI Interface (Master tag reader RS-232 port
J18
2) SCC Edgeport Port 1 (Com 3)
+24 VDC return connected to i2000SR system
J19
LLS/Process Path Ground.
Page 32 of 212 625798100.APS.5.doc

In the Electrical box A3 and A4 antennas are connected to

MASTER CAN-BUS board.
A0, A1 and A2 antennas are connected to SLAVE 0 CAN-BUS
board.
A5, A6, A7 and A8 antennas are connected to SLAVE 1 CAN-BUS
board.
Figure 12 – i2000SR IM electrical box
No. Description
1 Main switch – Circuit breaker for power supply
2 Power supply +24/5 V DC (Note: 5 VDC is not used.)
3 Master Tag Reader Board
4 SLAVE 0 Tag Reader Board
5 SLAVE 1 Tag Reader Board
6 Relays & Connectors (Device control)
Relays:
K1 – Motors – Output bit 1 – Master pin 2
K2 – pole lamp Green – Output bit 2 – Master Pin 4
K3 – pole lamp Red – Output bit 3 – Master Pin 5
K4 – pole lamp Yellow – Output bit 4 – Slave 0 Expansion
Pin 2
Fuse:
F1: Main power fuse
7 Connectors (Power Distribution)
8 CAN-BUS line balancing diodes (D1 & D2)
Resistances to avoid current return (R1 & R2)
(added for IMQ conformance).
625798100.APS.5.doc Page 33 of 212

i2000SR IM Electrical Box startup

Figure 13 – i2000SR IM main switch
Figure 14 – i2000SR Keypad
No. Description
RUN button
PAUSE button with pause LED
STOP button
i2000SR IM can be started in Standalone Mode or in APS Mode.
Page 34 of 212 625798100.APS.5.doc

Starting i2000SR IM in APS Mode

1. To start i2000SR IM in APS mode, perform the following:
2. With the APS Shutdown and OFF, turn the i2000SR / APS
switch to the APS position. Turn ON the APS Workcell UPS ON.
• This will supply +24 VDC from the CAN-board power bus
to the IM electrical box via J3.
3. The following actions occur during initialization:
• The IM barcode scanner beeps once and performs its
POST initialization check.
• The IM barcode scanner is configured and beeps twice.
• The IM Tag boards are initialized.
• IM Red Status lamp turns ON and then begins to blink.

• Routine input gate yellow LED is ON.
• Routine input gate green LED is OFF.
• Priority input gate yellow LED is ON.
• Priority input gate green LED is OFF.
• The communication between the IM Master Tag Reader
board communication port 1 and the LAS COM port on the
SCC of the i2000SR is established. The i2000SR SCC LAS
communication is via Edgeport port 4 (Com 6).
• The Red Lamp stops blinking and remains ON when the
communication between the IM Master Tag Reader board
communication port 2 and the CLI COM port on the SCC
of the i2000SR is established. The i2000SR SCC CLI
communication is via Edgeport port 1 (Com 3).
4. Turn on the APS computer.
NOTE:
During ACCELERATOR APS logo screen, the LEDs on the
Power Distribution will illuminate and the IOM pneumatic
air valve will open. As i2000SR IM air supply is routed from
the IOM pneumatic panel manifold, its air supply is not
routed through the air valve.
5. At the Accelerator APS GUI screen, if the i2000SR

Analyzer is On-Line the i2000SR IM Track will be initialized. Refer
to i2000SR IM track Initialization.
NOTE:
During the APS mode the IM is controlled by the APS GUI
and the samples are entered at the IM routine and priority
inputs. Although the IM Local User Interface (LUI) keypad is
active it should not be used.
625798100.APS.5.doc Page 35 of 212

Starting i2000SR IM in Standalone Mode

The standalone mode is used when the APS Workcell is not
operational.
To start i2000SR IM in i2000SR Standalone Mode (i2000SR),
perform the following steps:
1. Put the i2000SR IM main switch in “i2000 SR” position.
• When the switch is in “i2000SR” position, the +24 VDC
power supply in the i2000SR IM Electrical Box is used to
supply the IM devices. The IM +24 VDC power supply is
supplied by external AC power via J4. When the cable
connected to J4 is connected to an AC power source, the
+24 VDC power supply remains ON.
NOTE:
The power to the +24 VDC power supply in the electronic
box remains on at all times and is not controlled by the
i2000SR/0/APS switch. This power supply is protected by
the circuit breaker in the electronic box. It is recommended
to use the same AC power source for both the i2000SR
analyzer and IM systems. A UPS is advised.
2. The IM Electrical Box is initialized.
• The IM barcode scanner beeps once and performs its

POST initialization check.
• The IM barcode scanner is configured and beeps twice.
• The IM Tag boards are initialized.

• The IM Red Status lamp turns ON
• The Routine input gate yellow LED is on.
• The Routine input gate green LED is off.
• The Priority input gate yellow LED is on.
• The Priority input gate green LED is off.
• The communication between the IM Master Tag Reader
board communication port 1 and the LAS COM port on
SCC of the i2000SR is established. The i2000SR SCC
Edgeport connection is communication port 4.
• Pause LED is on the i2000SR keypad is ON (See Figure
14).
3. The operator control is provided by the LUI (Local User
Interface) keypad. The APS software is not used.
4. To initialize the i2000SR IM, press the Green START
button on the LUI keypad.
NOTE:
During standalone operation, the APS system must be OFF.
Page 36 of 212 625798100.APS.5.doc

However during FSR troubleshooting, it will be required to

cycle the power of the APS. This action may impact the
standalone operation and the i2000SR will need to be
reset.
i2000SR IM Track Initialization
NOTE:
During initialization, all APS On-line carriers on the i2000SR
IM Lanes are routed to the APS Main Track. If the APS track
belts are not running, the carriers will collect at the large
disk at the output of the IM and impact the movement of
the D3 diverter.
To initialize the system in Standalone mode, press the RUN button

on the LUI keypad (See Figure 14). During IM initialization the
following occurs:
1. The IM Master Tag Reader Com port 1 establishes

communication with the i2000SR via the SCC LAS port. If the
communication is established, the LAS icon will be displayed on
the i2000SR SCC snapshot screen.
NOTE:
In the event of a misrouted carrier at either the Sample
(G4) or STAT (G3) aspiration point, the IM will communicate
with the i2000SR to stop the sample processing via the
Master Tag Reader board Port 2 and CLI port on the
i2000SR CLI port.
The communication link between port 2 and the i2000SR is not

verified during initialization.
2. Carriers on Lane 2 Gate G5 are routed so that all On-line

carriers are sent to the Main Track and all Off-line carriers to G6
at the left end of Lane 4
3. The carriers at Routine G7b and Priority G8 Input gates on

the Lane 3 are routed to Lane 4 gate G6.
4. The carriers at G6 on Lane 4 are released and routed via
G7b and D1 to build a queue of six (6) carriers at the Priority
Input gate G8.
5. After the Priority queue of six (6) carriers is built, a queue
of eleven (11) Routine Input carriers is collected at the Routine
Input gate (G7b). The remaining four (4) carriers are staged at the
Output gate (G6) on Lane 4. The expression “queues rebuilding” is
displayed putting the carriers in the condition shown in Figure 2.
6. All carriers at Gates G3 and G4 on Lane 1 are routed to
Lane 2 gate G5. The on-line carriers are then routed to the main
track and off-line carriers to gate G6 on lane.
625798100.APS.5.doc Page 37 of 212

7. The IM module verifies the communication with the

i2000SR analyzer via Master tag reader board port 1 and the
green lamp on the lamp pole will be turned ON.
8. When both the Priority and Routine Input Gate Status

LEDs are green and the IM pole lamp is green, the system is
ready to accept local tubes.
Rebuilding queues
Standalone Mode – press the STOP and then the RUN keys. At this
point, the LED under the PAUSE button on the keypad is turned
off and queues rebuilding starts.
APS Mode – Use the APS GUI Diagnostics Track screen,
Transportation Module – RFID Tag Readers – Instrument # screen
button to Reset IM.
Standalone mode initializing

In standalone mode, after the completion of the i2000SR IM
Electrical Box startup, the operator must press RUN on the LUI
panel to initialize the i2000SR IM track. After initialization, the IM
Master Tag Reader board monitors the i2000SR operational
status. When the analyzer is running and ready to process
samples, the Green Instrument Indicator Light on the pole is ON.
In this status, the IM is able to process tubes. The status of the IM
is monitored by the Firmware in the tag reader boards. The status
is communicated to the operator via the Routine and Priority
Input Status LEDs and the Instrument Indicator Light on the pole.
APS mode initializing

In APS mode, after the completion of the i2000SR IM Electrical
Box startup and i2000SR IM track initialization, the RUN
command is sent from APS software via the CAN bus. The APS
decides when to establish a communication link with the i2000SR
analyzer and enable the i2000SR IM RUN state.
The status of the IM is monitored by the Firmware in the tag

reader boards. The status is communicated to the operator via the
APS software, Routine and Priority Input Status LEDs, and the
Instrument Indicator Light on the pole.
i2000SR IM exercise mode

The exercise mode is used to test the functionality of the gates,
antennae, diverters, belts, and Input Gate Status LEDs. The IM
component and devices on the main track (G0, A0, D0, G1, A1 and
D3) are not exercised.
Exercise mode is enabled by first completing the i2000SR IM
Electrical Box startup in Stand Alone mode, initializing the
i2000SR IM track (pressing the RUN button) and then pressing
and holding the RUN button as the PAUSE button is pressed.
Page 38 of 212 625798100.APS.5.doc

The following is a description of the carrier movement until the

exercise is stopped:
1. Carriers are in their initial queues.
2. Lane 3 – Priority (G8) releases a carrier to Lane 4 (G6)

3. Lane 3 – Routine (G7b) releases a carrier to Lane 2 (G5)
4. Lane 3 – Priority (G8) releases a carrier to Lane 4 (G6)
5. Lane 3 – Routine (G7b) releases a carrier to Lane 2 (G5)
6. Lane 2 (G5) alternately routes a carrier between Lane 1
and Lane 4. This process continues until the exercise is stopped.
• Lane 1 – As carriers arrive on Lane 1 Barcode gate (G2a)
they are released to STAT Pipettor (G3) and then to
Routine Pipettor (G4).
• Lane 2 – As carriers arrive at Lane 2 (G5), they are routed
to Lane 4 (G6).
• Lane 4 – As carriers are routed to Lane 4 (G6) they are
released to Routine Input (G7b)
7. Lane 3 – Routine (G7b) releases 16 carriers to Lane 2 (G5)
8. Lane 3 – Routine (G7b) releases 1 carrier (#18) to Priority
(G8)
9. Lane 3 – Routine (G7b) releases 1 carrier to Lane 2 (G5)
10. Lane 3 – Routine (G7b) releases 1 carrier (#20) to Priority
(G8)
11. Lane 3 – Routine (G7b) releases 1 carrier to Lane 2 (G5)
625798100.APS.5.doc Page 39 of 212

Instructions for Assembly
This chapter describes the operations for opening the supplied

packing, removing protective packing, assembling parts and
guards, and safely restoring electrical and pneumatic connections.
Refer to the Abbott Accelerator APS Acceptance Testing
section in Appendix C of the Accelerator APS Service Manual.
During the installation of the i2000SR and i2000SR IM, ensure
that all checks have been verified.
i2000SR IM Parts Shipped

The i2000SR IM is shipped in one dedicated closed crate and
labeled as LN 07L32-01 (IBL0045). The pallet contains all the
components needed to install i2000SR Interface Module on a
Workcell with a properly configured track interface. The crate
may contain up to two i2000SR IM assemblies.
The content of the shipping crate varies depending on the type of
installation.
• For a new installation, the i2000SR IM Pneumatic panel
and i2000SR IM electrical box is shipped with the associated track
Tack Module Assembly (TMA) module and will not be included in
the crate.
• For a retrofit or upgrade of a site installed APS system, the
Pneumatic panel and the electrical box is shipped with the crate.
Table 6 – Case overall dimensions
Depth Width Height
mm (in) mm (in) mm (in)
1980 (77.95) 900 (35.43) 1010 (39.76)
Table 7 – Case weights

Case Content Total
kg (lbs) kg (lbs) kg (lbs)
18 (40) [i2000SR IM] 150 (331)
16 (35) [Electrical box] (if one module)
100 (220)
6 (13) [Pneumatic panel] 200 (441)
10 (22) [accessories] (if two modules)
Page 40 of 212 625798100.APS.5.doc

Parts Shipped for a New Installation

For a new installation, the following parts are shipped:
• i2000SR Interface Module
• Instrument Indicator Lamps (Status lamps with pole)
• IM Electrical cables
• Cap filler kit
• i2000SR IM Off-Line Carriers
• Accessories and documents
Parts Shipped for a Retrofit Installation

For a retrofit on a Workcell with a configured track interface, in
addition to the parts shipped for a new installation, the following
are also supplied:
• Electrical box
• Pneumatic panel
The 21 i2000SR IM Off-Line Carriers

Do not mix these pallets with the Workcell pallet.
Figure 15 – i2000SR IM Off-Line Carrier
NOTE:
The i2000SR IM comes with its own set of 21 carriers.
These carriers have the top plane painted gray to
distinguish them from track carriers.
These carriers must move only into the i2000SR IM lanes.
625798100.APS.5.doc Page 41 of 212

Assembly Procedure
Prerequisite
The i2000SR IM is designed to be supported by the i2000SR
instrument. The following procedures must be performed on the
i2000SR:
Refer to the Architect i2000SR Service documentation
• Calibrate Processing area robotics
• Install LAS support bracket
• Move the i2000SR into the APS installation area
NOTE:
Before moving the i2000SR IM, ensure the i2000SR support
bracket is fully seated (down) into the front panel pockets.
If the bracket is mounted too high, the ability to aspirate
the minimum sample volume will be impacted.
NOTE:
Refer to the i2000SR service documentation as required.
• It is recommended to install the following parts on the

i2000SR before moving into position at the i2000SR IM:
− LLS Sample bracket and antenna
− LLS STAT bracket and antenna

− LLS antennae cover
− Window Closeout with Process module LUI Keypad
− Right and Left side covers

• Reference the provided Workcell layout schematic, at the
TMA to determine the location that the i2000SR IM is to be
installed.
Installation of the Instrument Indicator Light

(pole lamps)
• Shift the side top panel to the right to make space for the
pole support mounting (See Figure 16).
• Remove the Instrument Indicator Light (pole lamps) group
from the shipping platform.
• Attach the pole on the lateral side of the track extrusion
using the two bolts provided (See Figure 16).
• The status lamp connection cables should pass along the

track wire guide to the electrical box.
• Connect the Lamp R/Y/G cable to J2 on the electrical box.
Page 42 of 212 625798100.APS.5.doc

Figure 16 – Pole mounting
No. Description
1 Side top cover to shift
2 Instrument Indicator Light (Light pole assembly)
3 i2000SR IM installation point
4 Electrical box
Installation of the i2000SR IM

The installation of the i2000SR IM to the TMA module
requires two service personnel: one person to hold the
i2000SR IM module and the other to fasten bolts. The
i2000SR IM gross weight is 18 kg (40 lbs).
• Before starting the assembly on the i2000SR IM, verify the

position of the cable exiting from the optical sensor on the main
track. It must be oriented as shown in Figure 17.
• Using the screws provided, mount the Disk upper
protection [1] and fasten it to the TMA upper profile (See Figure
18).
• The Disk upper protection [1] has two slots that allow its
position to be adjusted horizontally.
• Remove the i2000SR IM group from the shipping pallet
and remove from the packaging material.
• Before installing the IM, locate the pneumatic multi
connectors base and remove it by unscrewing its two (2) M4 fixing
625798100.APS.5.doc Page 43 of 212

screws. (See Figure 20). This action allows the IM mounting

screws to be accessed more easily.
Figure 17 – Right orientation of the optical sensor cable
No. Description
1 Optical sensor body (on the main track)
2 Diverter lever (after i2000SR IM installation)
3 Optical sensor cable
Figure 18 – Disk protection
No. Description
1 Disk upper protection
2 TMA profile
Page 44 of 212 625798100.APS.5.doc

Figure 19 – i2000SR IM mounting bolts
No. Description
1 Metal Screws. For Seismic protection, these metal screws
are replaced with plastic screws
2 Square Spring Nuts
3 i2000SR IM
4 Large Autotex disk
Figure 20 - i2000SR IM pneumatic multi connectors
No. Description
1 Pneumatic multi connectors
2 Pneumatic multi connectors fixing screws
625798100.APS.5.doc Page 45 of 212

• Locate the i2000SR IM five metal and five plastic

mounting screws and matching spring nuts (See Figure 19).
The metal screws are initially installed and for seismic protection
they are replaced during the installation with plastic screws.
NOTE:
There are two grooves along the side of the TMA. These will
hold the mounting spring nuts. Insert the tabs at the end of
the IM into the grooves and secure it to the TMA using
screws.
The spring nuts and screws are shipped attached to the IM
assembly.
• At the i2000SR IM opening, insert into the upper groove

three (3) square spring nuts and two (2) in the lower. (See Figure
21).
NOTE:
At the right end of the IM, the Large Disk is exposed. Use
care to ensure that the disk is not damaged as the i2000SR
IM module is mounted.
• Guide the right end of the i2000SR IM in a manner that

directs the tabs into the groove on the track.
• While holding the IM in position, use the five (5) metal
screws to fasten the i2000SR IM to the TMA. DO NOT tighten the
screws.
Figure 21 – i2000SR IM
No. Description
1 Top groove
2 Bottom groove
Page 46 of 212 625798100.APS.5.doc

• Using the track opening [1] as a reference, move the IM

extrusion left and right as required to align its extreme edges [2
and 3] to the track opening [1] (See Figure 23)
Figure 22 – i2000SR IM first alignment
• Refer to Figure 23 Note that the Disk upper protection [1]

is in alignment with the guide between tracks 1 and 2 [2].
• Use the Oversized Pallet tool (P/N 475.110.031) to verify
that both input and exit lanes are equal in width and that the
carrier template can move freely.
• With reference to the Figure 18 adjust the position of the
Disk protection until the alignment condition shown in Figure 23
is verified.
• To secure the position, when the two guides are aligned,
tighten the five (5) screws.
NOTE:
When the Disk upper protection is in alignment with the
Lane 1 / 2 track guides, a carrier is able to move to and
from the track and IM.
625798100.APS.5.doc Page 47 of 212

Figure 23 – i2000SR IM first alignment
• To assemble the i2000SR IM, use the metal screws fixed to

the interface module. Once the analyzer and spur are positioned
in a conclusive way, all metallic screws must be replaced with
plastic screws. In the event of a seismic event (earthquake), these
screws allow the IM to breakaway from the track.
Figure 24 – Metallic and plastic screws
No. Description
1 Metallic screws
2 Plastic screws
NOTE:
Please, replace screws one by one to avoid spur
displacement.
• Assemble the pneumatic multi connector [3] bracket to the

IM extrusion.
Page 48 of 212 625798100.APS.5.doc

Pneumatic Connections
Figure 25 – Pneumatic panel and electrical panel
No. Description
1 Electrical box
2 Pneumatic panel
4 i2000SR IM track
5 Antennas connectors on electrical box
6 Cables for future CAN-BUS development that are not
currently used
• If the installation of the i2000SR IM is a new workcell

installation, the pneumatic panel is already installed and the only
operation required is to assemble the two pneumatic multi
connectors.
• If the installation is an upgrade, mount the pneumatic
panel in a position in front of the i2000SR IM. In this manner,
when the valve solenoid is manually pressed, the valve action can
be observed.
Figure 26 – Multi connectors and pneumatic panel
625798100.APS.5.doc Page 49 of 212

• Refer to the pneumatic drawing provided with the

workcell. As an aid, each pneumatic tube is identified with a label
on each end of the tube that corresponds to the appropriate
device.
Initial i2000SR Support Procedure
NOTE:
Before moving to the track position, ensure that the
i2000SR support bracket is fully seated (down) into the
front panel pockets. If the bracket is mounted too high, the
ability to aspirate the minimum sample volume will be
impacted.
• Check the tension of the i2000SR IM belts.
NOTE:
As the belt tension procedure will hang a weight on the
belts, it is recommended that an assistant support the IM
during the procedure.
• Remove the metal screws used to secure the i2000SR IM

to the workcell and replace them with the plastic screws supplied.
These plastic screws are required to ensure that in the event of
seismic activity (earthquake), the analyzer will not cause damage
to the workcell.
Figure 27 – Positioning i2000SR instrument
No. Description
1 i2000SR sample points
2 i2000SR insert spur rail cut-off
3 i2000SR IM assembly cut-out extreme limits
4 Carriers at sampling stop gate points
Page 50 of 212 625798100.APS.5.doc

• Move the i2000SR with the LAS support bracket installed,

under the i2000SR IM.
• With the i2000SR pulled forward, ensure the two tabs on
the i2000SR bracket [2] are centered between the corresponding
notches on the instrument side of Lane 1 [3]. (See Figure 28).
Figure 28 – Positioning i2000SR instrument
No. Description
1 i2000SR insert spur rail
2 i2000SR insert spur rail cut-off
3 i2000SR IM assembly cut-out extreme limits
4 i2000SR slider spur supports
5 i2000SR IM assembly cut-out
6 i2000SR bracket attachment
• At the i2000SR LAS support bracket, adjust the two

knurled knobs [1] in a manner that applies support to the i2000SR
IM. (See Figure 29)
Figure 29 – i2000SR Support Bracket
625798100.APS.5.doc Page 51 of 212

NOTE:
As the support bracket is adjusted, ensure that the support
feet [2] are aligned with the extrusion and are not in
contact with the belts. (See Figure 29)
Page 52 of 212 625798100.APS.5.doc

Electrical Connections
Figure 30 – Electrical components
No. Description
1 Electrical box
2 IM Connector panel
3 Antennae, power, and control connectors
• If the installation of the i2000SR is a retrofit, install the

electrical box on the TMA in a location that the TAG Reader LEDs
can be observed as carriers are placed on an antenna.
• If the installation of the i2000SR is a new installation, the

electrical box is already installed on the TMA.
• electrical connections.
Figure 31 – Electrical connections
625798100.APS.5.doc Page 53 of 212

IM Track Interface Cable Connections

No. Description
J1 Motors
J2 Entry Gate LEDs & keypad
J3 Tube and Carrier (SICK) sensors
J4 Future CAN-BUS development cable
IM Electrical Box Cable Connections

No. Description
1 Antennas connectors on electrical box
2 Workcell CAN-BUS 24 V DC AUX power
3 Barcode Reader cable
4 i2000SR UPS 230 V AC main power
Page 54 of 212 625798100.APS.5.doc

Figure 32 – Electrical panel top connectors
No. Description
A0 & A1 Track module antennas A0 and A1
A2 to A8 i2000SR IM antennas from A2 to A8
J1 i2000SR IM three Motors
(Lane 1 & 2 motor, Lane 3 & 4 motor, and Disk motor)
J2 Instrument Indicator light (IM Status pole lamps)
J3 Track CAN bus power supply 24 V DC
J4 i2000SR 230 VAC power supply
J5 IM Track CAN-BUS
J6 Future remote display/keyboard
J7 Track CAN bus barcode
J8 LAS i2000SR Interface – (Master tag reader RS-232 port 1) to cable 036810251 to
i2000SR SCC Edgeport Port 4 (Com 6)
J9 Priority, Routine LEDs and Keypad
J10 Electro valves on pneumatic panel
J11 i2000SR IM power switch
J12 Carrier Detector (SICK optical sensor) detects that a carrier was returned to track
and activates the track anti-collision gate (G9)
J13 i2000SR IM G6 G7 G8 D3 Carrier Detector (SICK optical sensor) gates
J14 Optional - To be used to program IM Track barcode reader
J15 Not used. Optional
J16 Not Used
J17 Not Used
J18 i2000SR CLI Interface - (Master tag reader RS-233 port 2) to cable 625810280 to
i2000SR SCC Edgeport port 1 (Com 3)
+24 volt return wire extended from the i2000SR IM via a hole at J19. Routed to
J19 interface with a process path ground wire installed on the i2000SR IM (i2000SR
Ground Wire)
625798100.APS.5.doc Page 55 of 212

i2000SR Ground Wire Installation

• Locate the 0.8 m length of 18 AWG ground wire. The wire
will have a terminal for a screw on one end and a faston
connection on the other.
Figure 33 – The 0.8 m 18 AWG wire
• At the underside of the i2000SR IM locate the opening in

the i2000 SR front panel used to route the STAT LLS cables and
insert the screw terminal end of the wire.
• From the inside of the i2000SR, continue routing the wire
to the left and along the front of the process path toward the
process path ground connection located near the base of the
Sample Pipettor.
Figure 34 – i2000SR Ground Wire Installation
Page 56 of 212 625798100.APS.5.doc

• Ensure that the wire is routed in a manner that it does not

impact the removal and replacement of the Sample and STAT
wash cups or the movement of the Sample Pipettor
• At the underside of the i2000SR IM support bracket, route

the wire in a manner that it does not come in contact with the
belt.
• Connect the end of the wire to the J19 i2000SR LLS
ground wire.
AC Power connections
• Route the stand-alone power cable from electrical box J4
to the same AC power source as the i2000SR system.
NOTE:
The desired AC power source is the UPS used to support
the i2000SR system. As the Uninterruptible Power Supply
(UPS) used in the United States have twist lock connectors,
a straight blade (NEMA 6-15) connector and UPS adapter
cable (204030) is supplied in order to remove power easily.
• In the United States, replace the standard European plug

with the supplied NEMA 6-15.
Figure 35 – United States NEMA 6-15 Power Connector
• Connect the NEMA 6-15 connector into the UPS adapter

cable (204030).
625798100.APS.5.doc Page 57 of 212

i2000SR IM LUI Panel Installation Procedure

• At the left end of the i2000SR IM, use two screws [1] (P/N
100474-001) M5X0.8, 20MM to mount the 202992 SPUR CAP
PLATE [2]. Refer to Figure 36.
Figure 36 – Spur Cap Plate
• Use two screws [2] (P/N 100474-001) M5X0.8, 20MM, to

mount the 3 Button LUI Bracket (P/N 203998) [1] to the Spur Cap
Plate. Refer to Figure 37
NOTE:
Do not fully tighten the screws until 3 BUTTON LUI
HOUSING (P/N 202997) is installed.
Figure 37 – 3 Button LUI Bracket
• Use two 112-40 screws (P/N 14494-004) [1] to secure the 3

Button LUI Keypad (P/N 203914) [2] to the LUI bracket. Refer to
Figure 38.
Page 58 of 212 625798100.APS.5.doc

Figure 38 – 3 Button LUI Keypad
• Connect the LUI Panel Cable to the keypad.

• Slip the 3 Button LUI Housing (P/N 202997) [2] over the
LUI bracket. Use two 190-32 screws (P/N 14494-306) [1] to secure
the cover. Refer to Figure 40.
Figure 39 – 3 Button LUI Housing
• Secure the bracket and cover by tightening the two screws

[3]. Refer to Figure 40.
• Ensure the LUI Keypad cable [4] is free of the motor
pulley.
625798100.APS.5.doc Page 59 of 212

Figure 40 – 3 Button LUI Bracket
i2000SR / i2000SR IM Alignment Procedure

Alignment is acceptable when the following conditions have been
met:
• The support bracket feet do not touch a belt, tubing, or
cable. Refer to Figure 49.
• The difference between the left ends of the i2000SR and
i2000SR IM is 145 +/- 3 mm (5.75 +/- 0.125”). Refer to Figure 44.
• The support bracket alignment tabs are flush against the

IM rear surface. Refer to Figure 42.
• The tabs on the top surface of the IM are in the groove of
the tabs of the support bracket. Refer to Figure 43.
• The top surfaces of the IM and APS track belts are equal.
Refer to Figure 39.
• The IM and Workcell tracks must be level. Refer to Figure

45 and Figure 46.
• The left/right and front/back planes of the i2000SR and the
IM are level. Refer to Figure 47 and Figure 48.
• On-line carriers move from the workcell to and from the
IM without interference.
• Off-line carriers must move between all gate positions
without interference.
NOTE:
Adjust the height of the i2000SR by raising or lowering the
feet. To ensure the IM is being supported without applying
too must pressure, adjust the knurled knobs [1] on the
bracket as required.
Page 60 of 212 625798100.APS.5.doc

Figure 41 – i2000SR Height Adjustments
NOTE:
Because laboratory floor surfaces vary, it may necessary to
remove the wheels/casters to lower the i2000SR to the
height. For this procedure, refer to Architect i2000SR
service documentation.
• Adjust the i2000SR feet and support bracket knurled

knobs, as required, to position the i2000SR to meet the following
conditions:
Action Reference
Figure 42 – Support Bracket Reference Tabs

Support Bracket Tabs [2]
are flush against the side
of the IM track [1].
The IM track [1] is
positioned vertically so
that the track top surface
is within the groove on
the support bracket tabs
[2].
625798100.APS.5.doc Page 61 of 212

Figure 43 – Support Bracket Reference Tabs Align

Support Bracket Tabs [2]
are flush against the side
of the IM track [1].
The IM track [1] is
positioned vertically so
that the track top surface
is within the groove on
the support bracket tabs
[2].
Figure 44 - Differences between left ends of i200SR and IM

The difference between
the left end of the
i2000SR IM and i2000SR
frame [1] is 145 mm +/- 3
mm (5.75” +/- 0.125”)
Page 62 of 212 625798100.APS.5.doc

Action Reference
Figure 45 – Level i2000SR IM with track

The i2000SR IM track is
level with the track on the
Workcell.
Place a TM Carrier
Leveling Aid (P/N
403.600.150 (202182)
into the APS main track
and a second aid on the
i2000SR IM track. Insert a
level between the two as
a reference.
Figure 46 – Level i2000SR IM

The i2000SR IM is level.
Figure 47 – Level i2000SR Front/Back

Place a level across the
top of the i2000SR
Sample and R1 pipettor
to indicate front to back
level of the i2000SR.
Adjust the feet of the
i2000SR as required until
the processing area is
level.
625798100.APS.5.doc Page 63 of 212

Action Reference
Figure 48 – Level i2000SR Left/Right

Place a level across the
top of the i2000SR
Sample and STAT pipettor
to indicate left to right
level of the i2000SR.
Adjust the feet as
required until the
i2000SR is level.
Figure 49 – Bracket Feet Clearance

The support bracket feet
do not pinch tubing or
cables and does not come
in contact with a belt.
Figure 50 – Belt surface difference

Confirm the surfaces of
Lane 1 and 4 belts are at
the same height as the
main track belt.
If it is not possible to
obtain a level condition,
loosen the five (5) bolts
used to attach the IM to
the workcell and adjust
the position of the IM.
Page 64 of 212 625798100.APS.5.doc

i2000SR IM Horizontal Positioning Check
REMARK
This check should be executed only after i2000SR IM
leveling (See Figure 46).
It is important to verify that the gap between the 1st lane belt and
the profile of the main track is between 0.5 & 1.0 mm. If the gap
is too small, there may be interference between lane 1 belt and
main track profile. If the gap is too large, a carrier may not route
properly to the interface module lane 1.
Figure 51 – IM belt/ Track profile horizontal gap verification
Figure 52 – IM belt – Track profile gap adjusting
If needed, adjust this gap by loosening the four screws shown in

Figure 52, and move the Interface Module horizontally until it will
reach the right position. A 1 mm gauge can be used to ensure that
625798100.APS.5.doc Page 65 of 212

there is a proper gap between the IM belt and the main track
profile.
Ensure that the profiles of the i2000 IM and Main Track remain
square.
Tighten the four screws.
i2000SR IM Vertical Positioning Check
REMARK
This check should be executed only after i2000SR IM
leveling (See Figure 46).
It is 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 in the ± 0.3 mm range. If this condition is not
verified when the spur is leveled, carriers may not pass properly
from the track lane to the interface module 1st lane.
Figure 53 - IM belt/ Track belt level
If needed, adjust this level as follow:

• Loosen the two screws shown in Figure 54 to remove the
pneumatic multi connector and gain access to the first lane idler
pulley adjusting screws.
• Loosen the two screws shown in Figure 55 to adjust the
vertical position of the idler pulley belt group.
Page 66 of 212 625798100.APS.5.doc

Figure 54 – Multi connector removing
Figure 55 – Idler pulley adjusting
At the end of the adjusting procedure, it is required to check the

clearance between the i2000SR IM first lane belt and the main
track secondary lane. To do this:
• Try to push the flexible Spur Positioning tool (P/N

475.110.320 (204148)) through the space between the track
profile and the first lane spur belt. The flexible tool should pass
through and under the belt as indicated by the blue arrows
illustrated in the belt clearance in Figure 56. If the test tool
cannot pass through both sections check the spur leveling, then
repeat the test.
625798100.APS.5.doc Page 67 of 212

Figure 56 – Belt clearance
Alignment of routine and STAT sampling probes,

gates and antennae
GOAL:
During aspiration, the sample and STAT probes must only
touch the fluid at the bottom of the tube. During z-axis
travel the probe must stay centered in the tube. Adjust the
probe(s), gate(s), antenna, analyzer feet, and support
bracket as required to center the probe at both the upper
and lower positions.
• Perform the Alignment of routine and STAT sampling

2
gates procedure.
Install the Gap Filler

The Gap Filler is a component designed to eliminate the space
between the i2000SR cover and the APS Main Track cover.
It must be assembled to the APS Main Track cover following the
assembling sequence illustrated in Figure 57 Figure 58 and
Figure 59.
The Gap Filler and its flange must match with the i2000SR cover.
The flange is assembled to the Main Track cover by means of two
screws inserted in two horizontal slots. Those slots permit
horizontal adjustment. In the same manner the gap filler has two
vertical slots to permit the part to be vertically adjusted (See
Figure 60).
The combination of horizontal and vertical adjustment assures the
gap filler will match the i2000SR cover.
Page 68 of 212 625798100.APS.5.doc

Figure 57 – Track cover assembly
Figure 58 – Flange assembly
Figure 59 – Gap filler assembly
625798100.APS.5.doc Page 69 of 212

Figure 60 – Gap filler and flange adjustment
Install 7L46-01 Off-line carriers

• At the Routine Input gate (G7b), insert the 21 (P/N 7L46-
01) i2000SR IM off-line carriers. Ensure only carriers with a gray
ring are installed.
Figure 61 – i2000SR IM Carriers
Page 70 of 212 625798100.APS.5.doc

Initialize i2000SR IM
NOTE:
If the Workcell is operating, the APS CAN bus
communication will be impacted and the operation of the
track will be affected.
• Turn the i2000SR IM mode select switch to the i2000SR

position.
• After the pole lamp turns red and begins blinking, turn on
the System Control Center for the i2000SR analyzer.
• Verify i2000SR IM Electronic Box Initialization
1. Bar Code Scanner beeps once then twice.
2. Pole Instrument Indicator Light turns RED
3. Tag Reader LEDs turn on.

4. Pole RED lamp blinks until the Master Slave to i2000SR
SCC communication check is passed.
5. SCC CLI Edgeport port 1 (com 3)

6. Master Slave Port 2 (CLI)
7. SCC LAS Edgeport port 4 (com 6)
8. Master Slave Port 1 (LAS)
NOTE:
The i2000SR IM will not initialize unless the cable check is
passed.
• After the Snapshot screen on the System Control Center is

displayed, press the green Run button on the keyboard.
Figure 63 – i2000SR IM LUI Keypad
• Verify the carriers move smoothly without interference. If

interference is observed, provide the necessary corrective action.
625798100.APS.5.doc Page 71 of 212

− Remove obstacle
− Adjust carrier guides
• The i2000SR support bracket feet must not come in
contact with a belt, cable, or tube.
• Check the tension of belts 1, 2, 3 and 4.
Refer to the Verification of belt tensioning procedure.
3
• Check the track height.

− Check that the surface of the IM belt and track belts are
equal. Refer to the i2000SR IM Horizontal Positioning
3
Check and i2000SR IM Vertical Positioning Check.

Figure 64 – Belt surface difference
• Moving belts must be centered on the lane

− Refer to the Replacement of belts 1 & 2 idler pulleys
groups procedure.
• Quality of spinning disk
− Leading edges are flush with track belts
− Disks do not have defects
− When a carrier is not on the disk the spin rate is
consistent.
− Carriers do not stall as they transfer from the belt to the
disk.
− When a carrier is on the disk, the disk continues to spin
• Gate action
− Allows only one carrier to pass through at a time.
− When idle with a carrier over an antenna, the appropriate
LED numerical value must consistently be displayed. The value
must be constant and should not change.
− When a carrier is held at a gate, the carrier must be held
still. A small position shift can cause the RFID value to be sent
twice and result in presentation or carrier errors.
• Diverter action
− Diverter movement is smooth and without hesitation
Page 72 of 212 625798100.APS.5.doc

− Diverter is activated once per carrier.

• Queues are properly built.
− Six (6) carriers at the Priority Gate (G8)
− Eleven (11) carriers at the Routine Gate (G7b)

− Four (4) carriers at Output Gate (G6)
Verify Config Wizard i2000SR Setting
NOTE:
Configuration parameters may change. To inform the field
of the change, a service advisory will be released. To
ensure that the APS is in the latest configuration refer to
the current service documentation release.
Modify Config Wizard for i2000SR
NOTE:
In the following, the symbol # is used to reference the
workcell instrument number of the i2000SR being installed.
• Login as FSE.
• Diagnostics
• Automation
• Blank Button
• Config Wizard
• In the Config Wizard, select the following:
a. Analyzers
Instrument # Type - i2000SR

Configure #
NOTE:
05X is the CAN bus address of the Master Tag Reader in the
IM electronic box. The Tag Reader board has two RS-232
communication ports. :1 is used to indicate that the
i2000SR LAS communication is connected to port 1. Port 2
is not used for LAS communication.
i2000SR CAN # Dip Switch

1 50 2,5,6
2 51 1,2,5,6
3 52 3,5,6
4 53 1,3,5,6
625798100.APS.5.doc Page 73 of 212

b. CAN Boards
NOTE:
The i2000SR IM Master Tag Reader board in the Electronic
Box(s) is not listed. Only Track CAN bus boards are listed.
For each Track CAN bus boards Address Parameter:

• A indicates the antenna connected to CN12 of the Tag
Reader board.
• B indicates the antenna connected to CN13 of the Tag
Reader board.
c. Track Layout
• Use the ¿À arrows to select the Instrument # Gate of the

i2000SR.
• In the following fields, use the arrows to select the

desired queue parameter.
Instrument Gate
QUEUE
Instrument # Gate (i2000SR Instrument #)

NEXT QUEUE
Instrument #+1 Gate (Next Instrument) or instrument # is the
last instrument, enter the next module diverter gate.
NOTE:
Typically the next module is the Recapper. Select the
Recapper Diverter Gate
ALTERNATIVE NEXT QUEUE

Return/Entry Gate (Instrument #)
QUEUE LENGTH
8
Sampling Gate
QUEUE
Sampling Gate # (i2000SR Instrument #)
NEXT QUEUE
Return/Entry Gate (Instrument #)

Not Connected
QUEUE LENGTH
Page 74 of 212 625798100.APS.5.doc

10
Return/Entry Gate
QUEUE
Return/Entry Gate # (i2000SR Instrument #)
NEXT QUEUE
Instrument #+1 Gate (Next Instrument) or instrument # is the
last instrument, enter the next module diverter gate.
NOTE:
Typically the next module is the Recapper. Select the
Recapper Diverter Gate

Not Connected
QUEUE LENGTH
8
NOTE:
After the i2000SR IM Gate Queues lengths are changed, the
change will not take affect until the i2000SR IM power has
been cycled.
625798100.APS.5.doc Page 75 of 212

Modify Instrument Queue for instrument

following i2000SR
Action Reference
NOTE:
The instrument queue for the track non-
i2000SR instrument that follows i2000SR
must be adjusted.
1. Using the Configuration Wizard
select the Track Layout tab.
2. Use the ¿À arrows to select the
Instrument Gate of the non-i2000SR
instrument that follows an i2000SR.
(Example: If i2000SR is instrument #5
and #6 is a c8000, select Instrument 6
Gate)
3. Edit the QUEUE LENGTH to equal
15.
NOTE:
Should there be multiple i2000SR
systems, change the instrument queue
length of each following instrument that
is not an i2000SR. Refer to the reference
illustration. Note that as there is
separation between the i2000SRs, the
instrument queue for #3 is also set at
15.
NOTE:
After the i2000SR IM Gate Queues
lengths are changed, the change will not
take affect until the i2000SR IM power
has been cycled.
Page 76 of 212 625798100.APS.5.doc

Modify Instrument Setup.INI file

Action Reference
1. Navigate to the D:\Accelerator \INI NOTE
directory. Open the Instrument-Setup.ini file. The following are examples of the other
2. Ensure that the contents for the module types.
i2000SR is as below: [NCCLS]
[I2000sr] Instrument Type = NCCLS
Instrument Type = I2000sr Instrument Display Name = NCCLS
Instrument Display Name = I2000sr Instrument Family = Immunochemistry
Instrument Family = Immunochemistry Instrument Type Code = NCCLS
Instrument Type Code = I2000sr Buffer Overload Count = 999[
Parent Instrument Type Code = I2000 I2000]
Routine Queue Length = 7 Instrument Type = I2000
STAT Queue Length = 2 Instrument Display Name = I2000
Buffer Overload = 999 Instrument Family = Immunochemistry
NOTE: Definitions: Instrument Type Code = I2000
ROUTINE Queue is number of carriers that Buffer Overload Count = 999
can be queued at the Routine Gate (G4). [c8000]Instrument Type = c8000
Changing this parameter will write a new
Instrument Display Name = c8000
value to the Master Tag Reader board and
change the Standalone function of the IM. Instrument Family = Clinical Chemistry
STAT Queue is number of carriers that can Instrument Type Code = c8000
be queued at the STAT Gate (G3). Changing Buffer Overload Count = 999
this parameter will write a new value to the [Fusion]
Master Tag Reader board and change the
Instrument Type = Fusion
Standalone function of the IM.
Instrument Display Name = Fusion
Buffer Overload is the maximum number of
carriers that remain in reserve for use on Instrument Family = Clinical Chemistry
the track for that particular analyzer type. Instrument Type Code = Fusion
This feature is not currently fully Instrument LAS Timeout = 60 5 300
implemented and will be enabled in a future
release of the APS software. Order These Tests Despite Zero Inventory =
950 951 952
Buffer Overload = XXX Refer to the latest
release of the APS software. Buffer Overload Count = 999
NOTE: [c16000]
After the i2000SR IM Gate Queues lengths Instrument Type = c16000
are changed, the change will not take affect Instrument Display Name = c16000
until the i2000SR IM power has been cycled Instrument Family = Clinical Chemistry
Instrument Type Code = c16000
Buffer Overload Count = 30
Parent Instrument Type Code = c8000
If any of the above settings were incorrect and changed, reload all
INI files
• Shutdown the APS Software
• Turn Off the IOM UPS
• Wait 2 minutes
• Turn On the IOM UPS
625798100.APS.5.doc Page 77 of 212

• Turn On the IOM Computer

• Login as FSE
• Diagnostics
• Automation
• Blank Button
• Commands
• Reload all INI files
Exercise i2000SR IM
GOAL: Use the i2000SR IM Track Exercise feature to check that IM
devices move off-line carriers properly within the lanes.
This exercise routine should be allowed to run continuously
for a minimum of 3 hours. During the exercise, verify that
all carriers and devices move properly.
• Power on the i2000SR IM in the Standalone mode by

turning the i2000SR IM power switch to the i2000SR position.
NOTE:
If the Workcell is operating the APS CAN bus

− Bar Code Scanner beeps once then twice.
− Pole Instrument Indicator Light turns RED
− Tag Reader LEDs turn on.

− Pole RED lamp blinks until the Master Slave to i2000SR
• SCC CLI Edgeport port 1 (com 3)
• Master Slave Port 2 (CLI)
• SCC LAS Edgeport port 4 (com 6)

• Master Slave Port 1 (LAS)
Page 78 of 212 625798100.APS.5.doc

NOTE:
passed.

displayed, press the green Run button on the keyboard.
NOTE:
If communication check fails (Blinking Red Lamp) and RUN
button is pressed, all Off-line carriers are routed to lane 4.
Queues at Routine and Priority gates are not built.
Figure 66 – i2000SR IM LUI Keypad
• Activate the i2000SR IM Exercise Mode by pressing and

holding the Green RUN button on the keypad as the PAUSE
button is pressed.
NOTE:
If communication check fails (Blinking Red Lamp) and IM
Track Exercise is initiated, all Off-line- carriers are routed
to Routine gate and track exercise begins. Carriers are
routed to lanes 2, 1, and 4. Priority queue is tested but at a
lower rate.
• As carriers are moved, check the following:
− Belts
• Belts must travel along the center on the lane. If
not, refer to the Replacement of belts 1 & 2 idler pulleys
groups and Replacement of belts 3 & 4 idler pulleys
groups procedure.
− Movement is consistent
If not, refer to the Verification of belt tensioning procedure.

− Support bracket feet do not touch the belt.
− Disk spin is consistent.
− Carriers do not stall as they transfer from the belt to the
disk.
− When a carrier is not on the disk, the spin rate is
consistent. It is normal for the speed to slow down when a
carrier is on it.
625798100.APS.5.doc Page 79 of 212

− When a carrier is on the disk, the disk continues to spin

− Gate Activation
− During activation, a single carrier is released
− Diverter movement
− One complete smooth movement with every carrier release
• Check Disk 5 SICK Sensor
− Stop a carrier released from Lane 2 G5 before it reaches
the large disk.
− As a carrier is held, ensure that no other carriers are
released by G5.
− Release the carrier. After the carrier completes the travel
around the large disk it is detected by the carrier detector
(SICK sensor) on lane 4
− After the carrier is detected, G5 will again release
carriers.
Verify carriers movement from the APS Track to

i2000SR IM
GOAL: Carriers must move properly from the track to the i2000SR
IM. To verify, the diverter D0 state is changed to route all
carriers from the main APS track into the i2000SR IM. As
the on-line carriers arrive at IM entry queue, gate G1 will
divert them to the IM. Verify that carriers enter and exit
the IM without any interference.
• At the i2000SR IM Pneumatic Panel, reverse the tubing

connections for Diverter DO EV2. This will divert all carriers
moving along the workcell to the i2000SR IM.
• At the APS, ensure that the workcell is Shutdown and
turned OFF.
• At the i2000SR IM, turn the mode switch to the APS
position.
• At the APS, turn ON the UPS.
NOTE:
If the Workcell is operating the APS CAN bus
Page 80 of 212 625798100.APS.5.doc

− Bar Code Scanner beeps once then twice.

− Pole Instrument Indicator Light turns RED
− Tag Reader LEDs turn on.
− Pole RED lamp blinks until the Master Slave to i2000SR

• SCC CLI Edgeport port 1 (com 3)
• Master Slave Port 2 (CLI)
• SCC LAS Edgeport port 1 (com 6)
• Master Slave Port 1 (LAS)
NOTE:
passed.
displayed at the APS, turn on the computer.
− During initialization, verify that the i2000SR IM Track is
initialized and the carrier queues are properly built.
− Instrument Indicator Red Lamp is illuminated

− Six (6) carriers at the Priority Gate (G8)
− Eleven (11) carriers at the Routine Gate (G7b)
− Four (4) carriers at Output Gate (G6)
• At the APS, LOGIN as FSE
• Select Configuration, System screen turn all Instrument
Off-line.
• Select Diagnostics, Track, Track Exercise.
• Enable Track Exercise and Random Use of Pit Lanes
• Select Start and then RUN.

• As carriers move along the track and enter the i2000SR
IM, verify the following:
− As carriers arrive at Instrument Gate G0 they are released.
− Carriers are smoothly diverted into the IM pit lane.
− As carriers arrive at Entry Gate G1, the IM belts are
turned ON and the carriers are released and routed into
IM Lane 1.
− Verify that the carriers move from track to Lane 1 without
interference.
625798100.APS.5.doc Page 81 of 212

− Verify that as the carriers are released Lane 2 Gate G5,

the large disk diverter D3 is activated and the carriers are
routed back to main track.
− As the carriers enter the main track, verify the Main track
carrier detector (SICK Sensor) activates main track anti-
collision gate.
− As a carrier is released by Gate G5, stop the carrier while
it is at the top section of the large disk and hold the carrier
still. Verify that diverter D3 remains activated.
− Release the carrier. As the carrier completes its movement
around the disk and is detected by the Main track carrier
detector (SICK Sensor) and enters the main track, the
diverter is closed.
• Continue APS track exercise until all carriers have been
cycled through the IM at least once.
• At the i2000SR IM Pneumatic Panel, reverse the tubing

connections for Diverter DO EV2. This will restore normal diverter
operation.
Complete installation of i2000SR LAS

Using the ARCHITECT Service documentation, perform the
following:
• Installation of the i2000SR LAS Covers
• i2000SR LAS Verification procedure
• SCC Installation Verification procedure

The Accelerator APS i2000SR IM is complete.
Return to the Accelerator APS workcell installation procedure.
Refer to the Abbott Accelerator APS Acceptance Testing
section in Appendix C of the Accelerator APS Service Manual.
Ensure that all i2000SR IM checks have been verified.
Page 82 of 212 625798100.APS.5.doc

Retrofit of the I/O module pneumatic panel and circuit

To support the i2000SR, the pneumatic panel at the IOM must
continuously supply air to the i2000SR IM when the APS workcell
is shutdown and power is OFF. To provide this source of air, the
IOM pneumatic panel has a manifold with a bank of manual
valves.
The following steps are required only if the i2000SR IM is
installed on a Workcell with original IOM pneumatic panel (P/N
510.500.001) (See Figure 68)
• At the APS, shutdown the system.
• At the site air supply distribution to the Accelerator APS
turn OFF the air supply valve.
• Remove the pneumatic panel (P/N 510.500.001) from the
I/O Module.
Figure 68 – IOM Pneumatic Panel (old style)
Item Function Item Function

1 Air supply line 4 To IOM Robot
2 Output to tank 5 From IOM Robot to Festo
Sensor
3 From tank 6 Control Interface
• Replace with the pneumatic panel (P/N 510.500.002)

(203848).
625798100.APS.5.doc Page 83 of 212

Figure 69 – IOM Pneumatic Panel (new style)
Item Function Item Function

1 Air supply line 6 IOM Panel Output Gauge
2 Output to tank 7 i2000SR IM [A] (See
Figure 69)
3 From tank 8 Storage Retrieval Module
4 To IOM Robot and 9 Control Interface
Workcell
5 To IOM Panel Output
Gauge
• At the storage module pneumatic panel, trace the input

line to its first connection.
• Using the 6 mm diameter tubing SMC TUPU0604 (P/N
PNT0003) supplied; make a connection between Storage IOM air
input and the new pneumatic panel storage connection [8].
• Using the 6 mm diameter tubing SMC TUPU0604 (P/N
PNT0003) supplied; make a connection from the IOM pneumatic
panel [7] to the i2000SR IM pneumatic panel [A] (See Figure 69).
NOTE:
The Festo Sensor is no longer being used to monitor the
movement of the Z-Axis. The tubing will be disconnected at
the Z-axis regulator.
NOTE:
If this procedure is being performed before the installation
Page 84 of 212 625798100.APS.5.doc

of the i2000SR IM, ensure that there is an additional length

of air supply tubing.
Figure 70 – Pneumatic Panel
Bypass 1. At the IOM, open the

Festo rear cover.
Sensor 2. At the left end,
Tubing locate the Input Output
Robot Z axis pressure
regulator.
3. At the side port,
follow the tubing to the TEE
fitting.
4. Disconnect the “To
Robot Z-axis” [B] tubing.
5. At the Regulator side
fitting, disconnect the
tubing and connect the “To
Robot Z-axis [B]
6. Remove and discard
the TEE fitting.
7. Using tape, label the
“To Festo Sensor on
Pneumatic Panel” [D] as
“Not Used”.
• At the site air supply, turn ON the air valve.
625798100.APS.5.doc Page 85 of 212

IOM Pneumatic Panel Differences

Below are schematics of the original (P/N 510.500.001) and new
(P/N 510.500.002) Pneumatic Panels
Figure 71 – Pneumatic Panel (Original) P/N 510.500.001
No. Description
A Compressed air IN (from 0.7 to 0.9 MPa >150 Nl/min)
B ON/OFF Valve
C Solenoid Valve for IOM and Workcell
D Silencer
E Micro Filter
F Pressure regulator
G Pressure indicator
H Minimum Pressure Switch (0.52 MPa)
J Micro filter
K No return valve
L Tank
M ON/OFF valve
N To the I/O Module Robot
O To the Track Module
To provide the i2000SR IM with an air source that is independent

of the IOM air valve, a manifold has been added. After the site air
is filtered [E], regulated [F] and stored in the TMA tank [L], the
air is routed to a manifold [R] with manual distribution valves [P &
Q] and port to the IOM air valve [C].
Page 86 of 212 625798100.APS.5.doc

Figure 72 – Pneumatic Panel (New) P/N 510.500.002
No. Description
P i2000SR IMs (max 3)
Q I/O Storage (1)
Future modules (2)
R Pneumatic Manifold
Figure 73 – New pneumatic panel group
No. Description
1 Input 10 mm diameter pipe
2 Output 8 mm diameter pipe to the tank
3 Input 8 mm diameter pipe from the tank
4 Output 6mm diameter pipe to the i2000SR IMs and free
5 To the I/O Module 6 mm diameter pipe
6 To the Track Module 6 mm diameter pipe
625798100.APS.5.doc Page 87 of 212

Replacement Procedures
This chapter describes the procedures to execute the removal and

replacement operations required to keep the Workcell in efficient
working condition and to verify it is operating correctly.
Replacement of i2000SR IM
REPLACEMENT PROCEDURE SCHEDULE no. 1
Operation: i2000SR IM replacement

Working area: i2000SR IM Mechanical Group: 625.100.00X
Electrical Group: 625.800.00X Part no. 625.100.00X
Machine Status: Controlled shutdown and power disconnected

Skill Required: 2-FSE’s (Field Service Engineers)
Time Required: TBD (To Be Determined)
Special Tools Required: None
Activity Type: Setting Control Cleaning ; Replacement
Intervention kind: ; Electrical ; Mechanical Fluidic ; Pneumatic
Daily Weekly Monthly
Quarterly Half yearly Yearly
Frequency:
Two-year After signalizing ; Because of failure
When necessary
Page 88 of 212 625798100.APS.5.doc

WARNING: Potential Biohazard. This is an activity or area

where you may be exposed to potentially infectious
material. Refer to “Section 4 - Hazards and Warnings” of
the Accelerator Service Manual
Reduce exposure by using proper personal protection

equipment and cleaning surfaces with 0.1% sodium
hypochlorite (bleach).


Identifies an activity that may require lifting or moving a
heavy object. Obtain assistance when moving or using an
appropriate lifting device.
WARNING: Electrical Shock Hazard. Possibility of electrical

shock exists if procedural or engineering controls are not
observed.
WARNING: Pinch hazard
STEPS REFERENCES
1 Perform the controlled shutdown of Refer to the “Accelerator APS Operations Manual –
the Workcell SECTION 5 – Operating Instructions” to execute
the “Controlled power shutdown” of the Workcell.
2 Disconnect the Workcell and i2000SR
IM from the AC power source.
3 Label the power connection to
indicate that service is in progress
and power must remain
disconnected.
4 At the Workcell I/O module Track
locate and turn OFF the track air tank
valve.
5 Remove the one (1) 14494-306 .190-
32 screw, to remove the (202990
original color or 203794 gray) right
end cap.
NOTE:
The front bottom edge is captured in
the window trim between lanes 2 and
3.
625798100.APS.5.doc Page 89 of 212

STEPS REFERENCES
6 Use a 14494-306 190-32 screw to
attach the End Cap to the window
closeout.
7 Remove the screw in the Center Rail

[2]
Remove the Hinge Mount (P/N
203621) and two front covers by
removing the four (4) countersink
screws [1].
8 Remove the center cover by

loosening the four (4) ¼ turn screws.
Page 90 of 212 625798100.APS.5.doc

STEPS REFERENCES
9 At the front of the i2000SR IM,
remove the six (6) 100474-001
screws used to mount the 203624
Window Support [1] and 203718
Bracket Lower Closeout.
10 Remove the two (2) screws used to

secure the 203717 Lower Closeout to
the Window Support.
11 Refer to the pneumatic working

drawing and electrical wiring diagram
to remove pneumatic and electrical
connections. Then remove Pneumatic
panel and electrical box.
No. Description
1 Pneumatic panel
2 Electrical box
3 Electrical box fasten points
4 Pneumatic panel fasten
bolts
5 i2000SR IM body
12 At each of the four (4) i2000SR feet,
mark the position on the floor and
measure the distance between the
bottom of the frame and the floor.
625798100.APS.5.doc Page 91 of 212

STEPS REFERENCES
13 Adjust the feet as required to lower
the i2000SR and move the module
away from the IM.
As the i2000SR IM is no longer being
supported, a second person is
required to hold and support the IM.
14 Loosen the i2000SR bracket
attachment screw to release the
i2000SR IM from i2000SR. At the
underside of the IM, loosen the two-
knurled knobs to lower the support
bracket.
No. Description
1 i2000SR insert spur rail
2 i2000SR insert spur rail cut-
off
3 i2000SR IM assembly cut-
out extreme limits
4 i2000SR slider spur supports
5 i2000SR IM assembly cut-
out
6 i2000SR bracket attachment
15 Disconnect all electric and pneumatic

connections between i2000SR,
i2000SR IM and TMA.
Remove the pneumatic multi
connector bracket.
16
CAUTION: Lift Hazard
Two people are required to remove
the i2000SR IM from the workcell, one
person to hold i2000SR IM module
and the other to loosen the bolts. The
i2000SR IM gross mass is 18 kg
(~40 lbs).
Remove the five screws securing the
i2000SR IM to the TMA assembly.
Remove i2000SR IM moving it in the
direction of the arrow shown below.
No. Description
1 Screw
2 Nut
3 i2000SR IM
4 Disk
Page 92 of 212 625798100.APS.5.doc

STEPS REFERENCES
17 Loosen the two screws from TMA
assembly to remove the disk’s
metallic top protection [1].
No. Description
2 TMA assembly
18 Remove the new i2000SR IM group

from the shipping platform and
remove the packaging protection
covers.
Mount the disk’s metallic top
protection and fasten it on the TMA.
That protection’s inner profile will be
the alignment reference line for the
i2000SR IM.
No. Description
2 TMA assembly
19 To allow better access the to the

mounting screws, remove the
pneumatic multi connector bracket
by removing the two (2) M4 screws.
No. Description
fixing screws
625798100.APS.5.doc Page 93 of 212

STEPS REFERENCES
20 Locate on the i2000SR IM the five
plastic mounting bolts
NOTE:
As the i2000SR IM is mounted to the
TMA, use care to prevent damage to
the large Autotex disk.
Fasten each bolt to fix the i2000SR
IM.
No. Description
1 Screw
2 Nut
3 i2000SR IM
4 Autotex disk
.
21 Insert the five square nuts in the side
grooves of the TMA extruded profile:
three nuts in the top groove and two
in the bottom one.
No. Description
1 Top groove
2 Bottom groove
22 Locate the main track opening.

Position the IM track external profiles
[3] to align the inner surface [2] with
the main track separators [1].
Page 94 of 212 625798100.APS.5.doc

STEPS REFERENCES
23 Note that the Disk upper protection
[1] is in alignment with the guide
between tracks 1 and 2 [2].
Use the Oversized Pallet tool (P/N
475.110.031) to verify that both input
and exit lanes are equal in width and
that the carrier template can move
freely.
24 Using the floor reference marks,

reposition the i2000SR and adjust
each foot to set the proper height
25 Place two TM Carrier Leveling Aids
(P/N 403.600.150 (202182)) in a belt
track.
Position the aids so that they will
span the length of the IM.
Place a bubble level between the two
aids and check that the length of the
IM is level.
Place one aid on belt 1 and the other
on belt 4.
Use the bubble level to check the
width of the IM.
NOTE:
TM Carrier Leveling Aid (P/N
403.600.150 (202182) is not shown in
figure.
26 If it is not possible to obtain a good
level, loosen the five (5) bolts used to
mount the IM and adjust the plane of
the i2000SR IM.
625798100.APS.5.doc Page 95 of 212

STEPS REFERENCES
27 Verify that the two carriers at the
stop gate are under the vertical of
the i2000SR sample points.
If not, see Alignment of routine and
STAT sampling gates procedure.
No. Description
1 Screw to loosen for stop
gate fine positioning
2 Sample points stop gate
28 Install Pneumatic panel on the TMA.

The manufacturer has not defined the
exact position as to where to fasten
the Pneumatic panel on the TMA. The
FSE will have to look for a convenient
fixing point avoiding TMA feet
encumbrance.
Do not install the pneumatic panel at
the left of the IM or it will be
unreachable for maintenance
operations because it will be covered
by the i2000SR.
Refer to the pneumatic working
drawing to re-establish pneumatic
connections. Each pneumatic tube is
identified with two labels, one on
each tube extreme and has to be
connected to the corresponding
labeled devices.
No. Description
1 Pneumatic panel
2 Electrical box
bolts
5 i2000SR IM body
Page 96 of 212 625798100.APS.5.doc

STEPS REFERENCES
29 Install the electrical box on the Track
Module Assembly (TMA).
Do not install the electrical box at the
left of the IM or it will be unreachable
for maintenance operations because
it will be covered by i2000SR.
Refer to the electrical working
drawing to re-establish electrical
connections.
No. Description
1 Pneumatic panel
2 Electrical box
bolts
5 i2000SR IM body
30 Using two (2) screws, secure the

203717 Lower Closeout to the
Window Support.
NOTE:
Use care to ensure that all cables and
tubing are not pinched, crimped or
damaged.
31 At the front of the i2000SR IM, install

the six (6) 100474-001 screws to
mount the 203624 Window Support
[1] and 203718 Bracket Lower
Closeout.
625798100.APS.5.doc Page 97 of 212

STEPS REFERENCES
32 Install the center cover by tightening
the four (4) ¼ turn screws.
33 Install the screw in the Center Rail [2]

Install the Hinge Mount (P/N 203621)
and two front covers by installing the
four (4) countersink screws [1].
Page 98 of 212 625798100.APS.5.doc

VERIFICATION
STEPS REFERENCES
1 With the i2000SR IM in the APS Refer to the “Accelerator APS Operations Manual –
position, restore power to the SECTION 5 – Operating Instructions” to execute
workcell. the “Restoring Power after a Controlled Shutdown”
1. Turn i2000SR IM power switch of the Workcell.
to APS position
2. Power on the Accelerator APS
UPS
No. Description
1 Bar Code Scanner beeps
once then twice.
2 Pole Instrument Indicator
Light turns RED
3 Tag Reader LEDs turn on
4 Pole RED lamp blinks until
the Master Slave to i2000SR
SCC communication check is
passed
1. SCC CLI Edgeport
port 1 (com 3)
2. Master Slave Port 2
(CLI)
3. SCC LAS Edgeport
port 4 (com 6)
(LAS)
NOTE:
The i2000SR IM will not initialize
unless the cable check is passed.
2 Check the APS screen for error
messages.
3 Perform the i2000SR IM Horizontal
3
Positioning Check
4 Perform the i2000SR IM Vertical
Positioning Check
5 Perform i2000SR IM Carrier If no error messages or abnormal carrier
Movement Verification. movements were noted, the procedure has
Verify that all Off-line and On-Line successfully completed.
carriers move properly
Ensure that all appropriate
Instruments are On-line
6 Return APS operation to users.
625798100.APS.5.doc Page 99 of 212

Replacement of i2000SR IM belts

Operation: i2000SR IM belts replacement

PFD0304 (belt #1)

PFD0302 (belt #2)
Electrical Group: 625.800.00X Part no.
PFD0301 (belt #3)
PFD0303 (belt #4)
Skill Required: FSE (Field Service Engineer)
Special Tools Required: 475.110.190 (weight + hook)
Intervention kind: Electrical ; Mechanical Fluidic Pneumatic
Frequency:
When necessary




observed.
CAUTION: Class 2 Laser Radiation when open. Do not stare

into beam. Avoid eye exposure to laser light.
Page 100 of 212 625798100.APS.5.doc

STEPS REFERENCES
1 Perform the controlled shutdown of Refer to the “Accelerator APS Operations Manual –
the Workcell SECTION 5 – Operating Instructions” to execute
the “Controlled power shutdown” of the Workcell.
disconnected.
valve.
5 Remove the one (1) 14494-306 .190-
end cap.
NOTE:
3.
6 Use a 14494-306 190-32 screw to

closeout.

[2]
screws [1].
625798100.APS.5.doc Page 101 of 212

STEPS REFERENCES


the Window Support.
Page 102 of 212 625798100.APS.5.doc

STEPS REFERENCES
11 Follow i2000SR Replacement
procedure to disassemble the
i2000SR Track. Put it on a suitable
working table.
12 Remove the metal cover by loosening

the two screws.
13 Refer to the figure for terminology

used in this procedure.
625798100.APS.5.doc Page 103 of 212

STEPS REFERENCES
14 Disconnect the three connectors of
the orange cables shown in the figure
and remove the cable supports from
assembly.
The gray and maroon wires will be
not disconnected. Their length will
control the distance that the two
sections can be separated.
15 Raise the 2nd line belt to access the

screws shown in the figure and
remove them to separate Lane 1-2
section from Lane 3-4 section.
16 Remove the Belt 3 & 4 motor.
Page 104 of 212 625798100.APS.5.doc

STEPS REFERENCES
17 Refer to the figure for terminology
used in this procedure.
The correct belt tensioning order is:
Belt 1 – 2 – 3 – 4
18 Belt 1 Replacement – PFD0304

Remove the pneumatic multi
connector bracket to access the
screws shown in the figure.
Starting from the Lane 1-2 section,
remove the screws shown in the
figure to remove the barcode reader
bracket.
19 Loosen the first screw of the central

separator to avoid interference with
the disk rotation nut.
625798100.APS.5.doc Page 105 of 212

STEPS REFERENCES
20 Remove the screws indicated in the
figure to remove tension from the
belt of Lane 1 and replace it.
21 Belt 1 Tensioning
Install the new belt and use the
screws shown in the figure to apply
tension to the belt of Lane 1.
Follow the Verification of belt
tensioning procedure to verify the
belt tension.

Remove the two screws shown in the
figure to remove the connector panel.
Page 106 of 212 625798100.APS.5.doc

STEPS REFERENCES
23 Loosen the screws shown in the
figure to remove from the belt of
Lane 2.
tension to the belt of the Lane 2.
belt tension.
24 Assemble the connector panel.

25 Start to work on the Lane 3-4 section
on the working table
Loosen the screws shown in the
figure to remove tension from Lane 3
belt.
screws to apply tension to the belt of
Lane 3.
belt tension.
27 Remove switch cover by removing

the screws shown in the figure.
625798100.APS.5.doc Page 107 of 212

STEPS REFERENCES
Remove the two screws that fasten
Lane 4/Track Diverter Group and
remove it.
29 Loosen the screws shown in the

figure to remove the tension from the
Lane 4 belt and replace it.
Belt 4 Tensioning
tension to the belt of Lane 4.
belt tension.
30 Replace the switch cover.

Raise the 2nd line belt to access the
three holes and place three screws
into the holes shown in the figure to
secure the Lane 1-2 section to the
Lane 3-4 section.
Assemble the Belt 3& 4 motor and
the pneumatic multi connectors.
Page 108 of 212 625798100.APS.5.doc

STEPS REFERENCES
31 Assemble the head cover.
32 Follow the replacement of the

i2000SR IM procedure to assemble
the i2000SR Track.
625798100.APS.5.doc Page 109 of 212

VERIFICATION
STEPS REFERENCES
to APS position
UPS
No. Description
once then twice.
Light turns RED
passed
1. SCC CLI Edgeport
port 1 (com 3)
(CLI)
3. SCC LAS Edgeport
port 4 (com 6)
(LAS)
NOTE:
messages.
3
Positioning Check
Positioning Check
Verify that all Off-line and On-Lane successfully completed.
Page 110 of 212 625798100.APS.5.doc

Replacement of Light Pole Lamp

Operation: Light Pole Lamp replacement

Electrical Group: 625.800.00X Part no. MEL0010

Intervention kind: ; Electrical Mechanical Fluidic Pneumatic
Frequency:
When necessary




observed.

625798100.APS.5.doc Page 111 of 212

STEPS REFERENCES
1 Perform the controlled shutdown of Refer to the “Operations Manual – SECTION 5 –
the Workcell Operating Instructions” to execute the “Controlled
power shutdown” of the Workcell.
3 Locate the pole lamp near the
i2000SR IM.
The pre-assembled 45 mm diameter
indicator banks XVM is comprised of:
1 – Top cover.
2 – Three colored illuminated units
(red at the top, orange in the middle,
green at the bottom).
3 – Each illuminated unit is fitted with
an incandescent bulb lamp.
4 – Base unit.
5 – Pole.
Each element can be disassembled or
assembled by rotating one element
with respect to another.
The bulb lamp is fastened with a
bayonet lamp holder.
Page 112 of 212 625798100.APS.5.doc

VERIFICATION
STEPS REFERENCES
to APS position
UPS
No. Description
once then twice.
Light turns RED
passed
1. SCC CLI Edgeport
port 1 (com 3)
(CLI)
3. SCC LAS Edgeport
port 4 (com 6)
(LAS)
NOTE:
2 Press the START button. Wait until
the IM carriers are in initialized
location.
3 At the i2000SR IM LUI keypad,
activate IM exercise by pressing and
holding the START key while the
PAUSE button is pressed.
Verify that the YELLOW lamp comes
ON.
4 Allow the carriers to complete one
cycle.
5 At the i2000SR, use the SCC to place
the i2000SR in RUN.
Verify that after the i2000SR is in
RUN, the GREEN lamp is ON.
6 Turn the i2000SR IM switch to the O
position.
7 Turn the i2000SR IM switch to the
APS position.
625798100.APS.5.doc Page 113 of 212

VERIFICATION
STEPS REFERENCES
8 Restore power to the workcell. Refer to the “Accelerator APS Operations Manual –
SECTION 5 – Operating Instructions” to execute
the “Restoring Power after a Controlled Shutdown”
of the Workcell.
9 Observe the screen for error If no error message was displayed the procedure
messages. has successfully completed.
Page 114 of 212 625798100.APS.5.doc

Replacement of belts motor

Operation: Belts motor replacement


Intervention kind: ; Electrical ; Mechanical Fluidic Pneumatic
Frequency:
When necessary




observed.

625798100.APS.5.doc Page 115 of 212

STEPS REFERENCES
3 Remove the one (1) 14494-306 .190-
32 screw to remove the (202990
end cap.
NOTE:
3.
4 Use a 14494-306 190-32 screw to

closeout.

[2].
screws [1].
Page 116 of 212 625798100.APS.5.doc

STEPS REFERENCES


the Window Support.
625798100.APS.5.doc Page 117 of 212

STEPS REFERENCES
9 At the end of the track, locate the two
belt drive motors.
10 Remove the two power wires from

the motor connectors.
Unscrew the two bolts that fasten the
motor bracket to the driver group and
remove the motor.
11 Replace the motor with a new one

and fasten the two bolts.
belt tension.
12 Use the steps above to reassemble
covers.
Page 118 of 212 625798100.APS.5.doc

VERIFICATION
STEPS REFERENCES
to APS position
UPS
No. Description
once then twice.
Light turns RED
passed
1. SCC CLI Edgeport
port 1 (com 3)
(CLI)
3. SCC LAS Edgeport
port 4 (com 6)
(LAS)
NOTE:
messages.
625798100.APS.5.doc Page 119 of 212

Replacement of motor belt group

Operation: Motor belt group replacement


Frequency:
When necessary




observed.

Page 120 of 212 625798100.APS.5.doc

STEPS REFERENCES
3 Remove the one (1) 14494-306 .190-
end cap.
NOTE:
3.
4 Use a 14494-306 190-32 screw to

closeout.

[2]
screws [1].
625798100.APS.5.doc Page 121 of 212

STEPS REFERENCES


the Window Support.
Page 122 of 212 625798100.APS.5.doc

STEPS REFERENCES
9 Follow i2000SR Service Manual to
remove the i2000SR IM bottom
covers.
10 Loosen the two bolts that fasten the

motor bracket to the driver group,
allowing the motor pulley to ease off
from the motor belt.

the two screws.
625798100.APS.5.doc Page 123 of 212

STEPS REFERENCES
12 Raise the Lane 1 & 2 belts to replace
Lane 1 & 2 motor belt group or raise
Lane 3 & 4 belts to replace Lane 3 &
4 motor belt group.
This operation allows you to access
the two motor belt group fixing
screws.
Remove them to replace the motor
belt group.
13 Remove the motor belt group by

pulling it up.
14 Replace the belt group and

reassemble by performing the above
steps in reverse order.
Page 124 of 212 625798100.APS.5.doc

VERIFICATION
STEPS REFERENCES
to APS position
UPS
No. Description
once then twice.
Light turns RED
passed
1. SCC CLI Edgeport
port 1 (com 3)
(CLI)
3. SCC LAS Edgeport
port 4 (com 6)
(LAS)
NOTE:
messages.
625798100.APS.5.doc Page 125 of 212

Replacement of disk motor

Operation: Disk motor replacement


Special Tools Required: Loctite (Glue)
Frequency:
When necessary




observed.

Page 126 of 212 625798100.APS.5.doc

STEPS REFERENCES
3 Remove the one (1) 14494-306 .190-
end cap.
NOTE:
3.
4 Use a 14494-306 190-32 screw to

closeout.

[2].
screws [1].
625798100.APS.5.doc Page 127 of 212

STEPS REFERENCES


the Window Support.
Page 128 of 212 625798100.APS.5.doc

STEPS REFERENCES
9 Locate the disk motor.
10 Remove the two screws to remove

the disk top cover.

the disk holder and the disk.
625798100.APS.5.doc Page 129 of 212

STEPS REFERENCES
12 Loosen the shaft anti-spin screw. Be
careful because that screw was glued
to avoid loosening.
Remove the motor shaft.
Remove the two power wires from
motor connectors.
Finally loosen the two screws that
fasten the motor body to its support.
13 Replace the assembly and

reassemble by performing the above
steps in reverse order. Use Loctite to
secure the screws.
VERIFICATION
STEPS REFERENCES
to APS position
UPS
No. Description
once then twice.
Light turns RED
passed
1. SCC CLI Edgeport
port 1 (com 3)
(CLI)
3. SCC LAS Edgeport
port 4 (com 6)
(LAS)
NOTE:
Page 130 of 212 625798100.APS.5.doc

VERIFICATION
STEPS REFERENCES
messages.
Instruments are On-line.
625798100.APS.5.doc Page 131 of 212

Replacement of belts 1 & 2 drive group

Operation: Belts 1 & 2 drive group replacement


Frequency:
When necessary




observed.

Page 132 of 212 625798100.APS.5.doc

STEPS REFERENCES
disconnected.
valve.
5 Remove the one (1) 14494-306 .190-
end cap.
NOTE:
3.
6 Use a 14494-306 190-32 screw to

closeout.

[2].
screws [1].
625798100.APS.5.doc Page 133 of 212

STEPS REFERENCES


the Window Support.
11 Place the IM on a suitable working

table.
12 Follow i2000SR IM belts replacement
procedure to separate the two spur
sections.
Page 134 of 212 625798100.APS.5.doc

STEPS REFERENCES
13 Loosen the four screws to move the
belt 1 & 2 drive group in the direction
of the arrow.
Remove belts from lanes 1 & 2.
14 Remove the four screws shown in the

figure to replace belt 1 & 2 drive
group.
15 Use the i2000SR IM replacement

procedure to assemble.
16 Refer to the Replacement of i2000SR
IM belts procedure to set belts
tension.
625798100.APS.5.doc Page 135 of 212

VERIFICATION
STEPS REFERENCES
to APS position
UPS
No. Description
once then twice.
Light turns RED
passed
1. SCC CLI Edgeport
port 1 (com 3)
(CLI)
3. SCC LAS Edgeport
port 4 (com 6)
(LAS)
NOTE:
messages.
3
Positioning Check
Positioning Check
Page 136 of 212 625798100.APS.5.doc

Replacement of belts 1 & 2 idler pulleys groups

Operation:
Belts 1 & 2 idler pulleys groups
replacement
579.440.00X
579.450.00X
Frequency:
When necessary




observed.

625798100.APS.5.doc Page 137 of 212

STEPS REFERENCES
disconnected.
valve.
5 Follow Replacement of i2000SR IM
procedure to remove the i2000SR IM
Track.
6 Then move the assembly on a
suitable working table.
sections.
8 Loosen the four screws to move the
of the arrow.
Remove belts from lane 1 & 2.
9 Remove the two screws shown in the

figure to remove the belt 1 idler
pulley group.
10 Install a new assembly.
Page 138 of 212 625798100.APS.5.doc

STEPS REFERENCES
figure to remove the belt 2 idler
pulley group.
12 Install a new assembly

13 Perform the steps above in reverse
order to reassemble the i2000SR IM
tension.
625798100.APS.5.doc Page 139 of 212

VERIFICATION
STEPS REFERENCES
to APS position
UPS
No. Description
once then twice.
Light turns RED
passed
1. SCC CLI Edgeport
port 1 (com 3)
(CLI)
3. SCC LAS Edgeport
port 4 (com 6)
(LAS)
NOTE:
messages.
3
Positioning Check
Positioning Check
Page 140 of 212 625798100.APS.5.doc

Replacement of belts 3 & 4 drive group

Operation: Belts 3 & 4 drive group replacement


Frequency:
When necessary




observed.

625798100.APS.5.doc Page 141 of 212

STEPS REFERENCES
disconnected.
valve.
5 Follow Replacement of i2000SR IM
procedure to remove thei2000SR
Track. Place it on a suitable working
table.
sections.
7 Loosen the two screws shown in the
figure to move the belt 3 idler pulley
group in the direction of the arrow.
Remove belt from lane 3.
8 Remove the three screws shown in

the figure to remove the i2000SR IM
power switch cover.
Page 142 of 212 625798100.APS.5.doc

STEPS REFERENCES
9 Loosen the two screws that fasten
Lane 4/Track Diverter Group and
remove it.

figure to move the belt 4 idler pulley
group in the direction of the arrow.
Remove lane 4 belt.
11 Remove the four screws to move the

of the arrow and replace it.
12 Perform the procedures above in

reverse order to reassemble the
i2000SR IM.
tension.
625798100.APS.5.doc Page 143 of 212

VERIFICATION
STEPS REFERENCES
1 With the i2000SR IM in the APS Refer to the “Operations Manual – SECTION 5 –
position, restore power to the Operating Instructions” to execute the “Restoring
workcell. Power after a Controlled Shutdown” of the
Workcell.
messages.
3
Positioning Check
Positioning Check
Page 144 of 212 625798100.APS.5.doc

Replacement of belts 3 & 4 idler pulleys groups

Operation:
Belts 3 & 4 idler pulleys groups
replacement
579.440.00X
579.450.00X
Frequency:
When necessary




observed.

625798100.APS.5.doc Page 145 of 212

STEPS REFERENCES
3 Follow the belts 3 & 4 drive group
replacement procedure and go to the
next step.
figure to remove disk motor group.

figure to remove belt 3 idler pulley.

7 Reassemble the disk motor group.
figure to remove belt 4 idler pulley.
Page 146 of 212 625798100.APS.5.doc

STEPS REFERENCES
10 Note:
After idler pulley is replaced, as the
belt rotates it may drift to one side.
If the belts drift to one side, loosen
the screw shown in the figure and
adjust the idler pulley as required to
correct the movement.

order to reassemble the i2000SR IM.
12 See the Replacement of i2000SR IM
belts procedure to set the belts
tension.
625798100.APS.5.doc Page 147 of 212

VERIFICATION
STEPS REFERENCES
to APS position
UPS
No. Description
once then twice.
Light turns RED
passed
1. SCC CLI Edgeport
port 1 (com 3)
(CLI)
3. SCC LAS Edgeport
port 4 (com 6)
(LAS)
NOTE:
messages.
3
Positioning Check
Positioning Check
Page 148 of 212 625798100.APS.5.doc

Replacement of i2000SR IM antennas

Operation: Antennas replacement


Frequency:
When necessary
625798100.APS.5.doc Page 149 of 212





observed.


Page 150 of 212 625798100.APS.5.doc

STEPS REFERENCES
3 Remove the one (1) 14494-306 .190-
end cap.
NOTE:
3.
4 Use a 14494-306 190-32 screw to

closeout.

[2]
screws [1].
625798100.APS.5.doc Page 151 of 212

STEPS REFERENCES
7 i2000SR IM antenna locations are

shown in the figure. Track antenna
locations are shown in Figure 6.
The antenna can be accessed by
raising the appropriate belt.
To prevent interference from radio
frequencies, metal shields are used to
protect all i2000SR IM antenna
electrical connections.
8 Before removing the antenna coil,

trace the profile around the antenna
base using a pencil or other suitable
marker to mark its position. This
mark will be useful to quickly
reposition if the antenna base should
be moved during replacement.
NOTE:
The location of the antenna is very
critical. To prevent occurrence of
Sample Presentation errors, the
installed antenna needs to be
centered under the probe or stopped
carrier.
9 Unscrew shield screw to remove

shield.
10 Unscrew board screw to remove
antenna board and connector.
11 Install a new antenna board and
reassemble the board and shield.
Page 152 of 212 625798100.APS.5.doc

VERIFICATION
STEPS REFERENCES
to APS position
UPS
No. Description
once then twice.
Light turns RED
passed
1. SCC CLI Edgeport
port 1 (com 3)
(CLI)
3. SCC LAS Edgeport
port 4 (com 6)
(LAS)
NOTE:
messages.
4 For STAT and Sample Antennae,
perform the Sample and STAT
Antennae alignment verification
procedure.
625798100.APS.5.doc Page 153 of 212

Replacement of belt disk

Operation: Belt disk replacement

625.102.18X
625.102.99X
Frequency:
When necessary




observed.

Page 154 of 212 625798100.APS.5.doc

STEPS REFERENCES
2 Remove the one (1) 14494-306 .190-
end cap.
NOTE:
3.
3 Use a 14494-306 190-32 screw to

closeout.

[2]
screws [1].
625798100.APS.5.doc Page 155 of 212

STEPS REFERENCES


the Window Support.
Page 156 of 212 625798100.APS.5.doc

STEPS REFERENCES
8 Remove the cap with a bladed tool.
Unscrew the auto-locking screw.
Remove spacer, spring and then the
disk.
9 Install a new disk.

625798100.APS.5.doc Page 157 of 212

VERIFICATION
STEPS REFERENCES
to APS position
UPS
No. Description
once then twice.
Light turns RED
passed
1. SCC CLI Edgeport
port 1 (com 3)
(CLI)
3. SCC LAS Edgeport
port 4 (com 6)
(LAS)
NOTE:
messages.
Page 158 of 212 625798100.APS.5.doc

Replacement of the big belt disk

Operation: Big belt disk replacement


Frequency:
When necessary




observed.

625798100.APS.5.doc Page 159 of 212

STEPS REFERENCES
2 Remove the one (1) 14494-306 .190-
end cap.
NOTE:
3.
3 Use a 14494-306 190-32 screw to

closeout.

[2]
screws [1].

Page 160 of 212 625798100.APS.5.doc

STEPS REFERENCES

the Window Support.

the disk top cover.
625798100.APS.5.doc Page 161 of 212

STEPS REFERENCES
the disk holder and disk.
10 Install a new disk.

Page 162 of 212 625798100.APS.5.doc

VERIFICATION
STEPS REFERENCES
to APS position
UPS
No. Description
once then twice.
Light turns RED
passed
1. SCC CLI Edgeport
port 1 (com 3)
(CLI)
3. SCC LAS Edgeport
port 4 (com 6)
(LAS)
NOTE:
messages.
Instruments are On-line.
625798100.APS.5.doc Page 163 of 212

Replacement of the Carrier Spinning Group

Operation: Carrier Spinning Group replacement


Special Tools Required: 475.110.320 (204148) Calibrated thickness tool
Intervention kind: ; Electrical ; Mechanical Fluidic ; Pneumatic
Frequency:
When necessary




observed.

Page 164 of 212 625798100.APS.5.doc

STEPS REFERENCES
and power service must remain
disconnected.
4 Remove the one (1) 14494-306 .190-
end cap.
NOTE:
3.
5 Use a 14494-306 190-32 screw to

closeout.

[2]
screws [1].
625798100.APS.5.doc Page 165 of 212

STEPS REFERENCES


the Window Support.

valve.
Page 166 of 212 625798100.APS.5.doc

STEPS REFERENCES
11 Access the rear of the carrier
spinning group.
NOTE:
This task may require the removal of
the i2000SR.
Use a 3 mm Allen key to remove the
two screws shown in figure.
12 Disconnect the three air lines from

the gates and spinner (S07A, S06B
and S05B).
13 Remove the barcode reader from the

spinning group bracket using a 3 mm
Allen key.
14 Attach the barcode reader on the new

carrier spinning group.
15 Assemble the new group on the
i2000SR IM assembly. Do not fasten
the two screws at this point.
625798100.APS.5.doc Page 167 of 212

STEPS REFERENCES
16 Use the Spur Positioning tool (P/N
475.110.320 (204148)) to test the
distance between the i2000SR
assembly and the bottom side of the
Pass Cylinder Head.
17 That thickness must be equal to

0.3 mm with +0.00 –0.02 mm of
tolerance.
If the thickness is bigger, the cylinder
head could rotate around itself
causing carrier rotation to fail. If it is
smaller, a movement fault may occur
due to the probable friction between
the cylinder head and the first lane
belt.
18 Loosen the two screws in the figure to

adjust the vertical position of the
spinning group.
19 Restore pneumatic connections.
20 Restore electric power to the

Workcell and i2000SR IM.
Page 168 of 212 625798100.APS.5.doc

VERIFICATION
STEPS REFERENCES
to APS position
UPS
No. Description
once then twice.
Light turns RED
passed
1. SCC CLI Edgeport
port 1 (com 3)
(CLI)
3. SCC LAS Edgeport
port 4 (com 6)
(LAS)
NOTE:
messages.
3 Perform Alignment of barcode
reader.
625798100.APS.5.doc Page 169 of 212

Auxiliary Procedures
This chapter describes the procedures to safely execute the

alignment operations required for performing service and
maintenance operations on the Workcell.
Alignment of barcode reader

ALIGNMENT PROCEDURE SCHEDULE no. 15
Operation: Barcode reader alignment

BARCODE SICK
Electrical Group: 625.800.00X Part no. SCANNER CLV
422-0010
Machine Status: Operating
Activity Type: ; Setting ; Control Cleaning Replacement
Frequency:
Two-year After signalizing Because of failure
; When necessary
Page 170 of 212 625798100.APS.5.doc





observed.

STEPS REFERENCES
1 Initialize the i2000SR IM in either
the APS or Standalone modes.
2 Remove the one (1) 14494-306
.190-32 screw, to remove the
(202990 original color or 203794
gray) right end cap.
NOTE:
The front bottom edge is captured
in the window trim between lanes 2
and 3.
3 Use a 14494-306 190-32 screw to

closeout.
625798100.APS.5.doc Page 171 of 212

STEPS REFERENCES
4 Remove the screw in the Center
Rail [2]
screws [1].

loosening the four (4) ¼ turn
screws.
6 Put a carrier with a tube in it at the

barcode reader (BCR) gate stop.
CAUTION: Laser radiation

DO NOT STARE INTO BEAM
Page 172 of 212 625798100.APS.5.doc

STEPS REFERENCES
8 Place a tube without a barcode
label into a routine input carrier.
When the carrier is routed to the
barcode position, a red beam will be
emitted.
Move the body of the BCR around
its axis to orient it.
The right alignment of the BCR is
obtained when the red laser beam
strikes the center of the tube
cylinder
9 If scan time was not enough to

complete alignment, repeat the
process.
9a Alternate Method The CLV Assist software for the 422-0010 scanner
The following steps can be used to can be obtained from the following SICK website.
aid in the alignment by using the http://www.sick.com/home/factory/downloads/dow
SICK CLV Assistance application. nloads_auto_ident/en.html
NOTE:
Web sites change over time and in the future the
above location may change. As SICK is an
established vendor, an alternate location and/or
application can be resourced from their site. If
desired, contact your local Accelerator APS area
support group.
9a. Connect Laptop RS-232 cable to J14
1 on the electronic box.
Requires a PC running BARCODE
SICK SCANNER CLV 422-0010
software and a standard serial null
modem cable connected between
PC serial port and J14 on top of the
electrical box.
During the procedure, follow
software instructions
9a. At laptop open SICK CLV Assistant

2 software.
NOTE:
Do not open the CLV Setup V 4.X
application
625798100.APS.5.doc Page 173 of 212

STEPS REFERENCES
9a. Within the Assistant application,
3 select “Test a connected scanner”
Then select “Next”
9a. At the resulting screen, select

4 “Monitoring”
9a. Using the screen image graph and

5 green indicator bar, adjust the
position of the scanner in a manner
that it yields consistently good
reading.
After adjustment is complete, select
“Stop”
Disconnect the RS-232 cable at J14.
Page 174 of 212 625798100.APS.5.doc

STEPS REFERENCES
10 Verify that the screw shown in the
figure is firmly fastened to avoid
movement of the BCR .
VERIFICATION
STEPS REFERENCES
1 Order tests on five sample tubes for
each barcode type being used.
2 Verify that the barcodes are correctly
read and samples are processed.
3 If i2000SR IM is in standalone mode, Requires a PC running BARCODE SICK SCANNER
the BCR alignment can be checked CLV 422-0010 software and a standard serial null
using the Alternate Method procedure modem cable connected between PC serial port
above. and J14 on top of the electrical box.
During the procedure, follow software instructions
625798100.APS.5.doc Page 175 of 212

Alignment of routine and STAT sampling gates

Operation:
Routine and STAT Sampling gates
alignment
Machine Status: Operating in standalone mode

Special Tools Required: 475.110.031 (oversized carrier tool)
Activity Type: ; Setting Control Cleaning Replacement
Frequency:
; When necessary



GOAL:
During sample aspiration, the sample and STAT probes
must only touch the fluid at the bottom of the tube.
During the z-axis travel the probe must stay centered on
the tube. Adjust the probe(s), gate(s), antenna, analyzer
feet, and support bracket as required to center the probe
at both the upper and lower positions.
Page 176 of 212 625798100.APS.5.doc

STEPS REFERENCES
1 Stop the i2000SR IM. Refer to the “Operations Manual – SECTION 5 –
Operating Instructions” chapter to stop the
i2000SR IM in standalone or Workcell controlled
mode.
[2]
screws [1].

4 At the i2000SR SCC, perform the

1155 Probe Straightness Test to
ensure that the probe is straight.
Diagnostics, Pipettors, 1155 Probe
Straightness Test.
625798100.APS.5.doc Page 177 of 212

STEPS REFERENCES
5 At the i2000SR SCC, perform Sample
and STAT probe calibrations
Maintenance, As Needed, the
appropriate probe to calibrate.
1111 Sample Probe Calibration

1117 STAT Probe Calibration
NOTE:
At the following screen prompt;
Use the (p/n 204021) LAS pipettor

calibration tool illustrated in the
reference area.
6 Place the LAS Probe calibration tool

(P/N 204021) into the IM track at the
appropriate sampling location.
Ensure that the tool [2] is pressed
firmly against the gate [1]. If it is not,
the alignment will be compromised.
7 Follow the i2000SR screen menu

options to select the LAS probe
alignment option.
8 Follow the screen menu options to
position the probe over the center of
the tool [2].
As the probe must be precisely
centered, a combination of probe and
gate position adjustments may be
required.
Page 178 of 212 625798100.APS.5.doc

STEPS REFERENCES
9 If a gate adjustment is needed,
remove the filler cap on the slab near
the gate using a blade tool and
access the gate fixing screw with a
screwdriver.
Loosen the gate positioning screw
and move the gate left or right to
search the right position.
10 At the i2000SR SCC, reposition the

probe and gate as required to
precisely center probe. When
precisely centered, use SCC screen
commands to save the probe
position.
11 When the right position is reached, it
will be necessary to reposition
antenna.
Refer to the Sample and STAT
Antennae alignment verification
procedure.
Raise the belt and use the oversized
carrier tool (P/N 475.110.031
(203815)) to adjust the antenna to
the right position.
12 Repeat the above for the other probe.
As the i2000SR probe seeks fluid, it
must not touch the sides of the tube.
Use the following to adjust the
relationship of the analyzer to IM to
ensure the probe is perpendicular to
the tube.
13 At the i2000SR SCC, select
Maintenance, As Needed, and then
select the appropriate probe to
calibrate.
1111 Sample Probe Calibration
1117 STAT Probe Calibration
625798100.APS.5.doc Page 179 of 212

STEPS REFERENCES
14 Place the Probe Calibration High Tool
(P/N 204022), into the IM track at the
appropriate sampling location. Ensure
that the tool is pressed firmly against
the gate.
If not, the alignment will be
compromised.

options to select the Probe Move
option.
In the probe move option both probes
are moved over the calibrated probe
location.
options to lower the probe over the
tool.
17 Verify that both the i2000SR Sample

and STAT probes are aligned
perpendicular to the tube (center of
the tool).
If the rear feet are too low, the probe
will touch the back of the tool/tube
[2]. Adjust the feet to raise the back
of the analyzer.
If the rear feet are too high, the probe
will touch the front of the tube/tool
[3]. Adjust the feet to lower the back
of the analyzer.
NOTE:
This tool is only used by an FSR.
Please ensure that this tool is stored
on site in a secure location.
Page 180 of 212 625798100.APS.5.doc

STEPS REFERENCES
18 At the i2000SR feet, use the nut to
lock the feet.
VERIFICATION
STEPS REFERENCES
1 Perform a control run on any routine
and STAT assay.
2 Verify that probe enters the sample
tube in a manner that ensures that it
does not come in contact with the
side of the tube.
3 If no error messages occur and the
relationship between the probe is
centered on the tube, the procedure
has successfully completed.
4 Reinstall the removed covers.
625798100.APS.5.doc Page 181 of 212

Sample and STAT Antennae alignment verification procedure

Operation:
Verification of the alignment of the
Sample and STAT antennae
027.200.00X
027.100.00X
Activity Type: Setting ; Control Cleaning Replacement
Frequency:
; When necessary
Page 182 of 212 625798100.APS.5.doc





observed.


STEPS REFERENCES
[2]
Remove the Hinge Mount (P/N 203621)
and two front covers by removing the
four (4) countersink screws [1].
625798100.APS.5.doc Page 183 of 212

STEPS REFERENCES
2 Remove the center cover by loosening
the four (4) ¼ turn screws.
3 Open the front panel of the i2000SR IM

electrical box and locate the MASTER,
SLAVE 0, and SLAVE 1 CAN-BUS board
7-segments red displays.
4 Switch on the i2000SR IM in

standalone mode. (Power switch in
“i2000 SR” position).
Page 184 of 212 625798100.APS.5.doc

STEPS REFERENCES
5 Start a track i2000SR IM Track
Exercise.
Press the STOP button on the LUI Panel
when at least two carriers have been
released and routed to belt #1
(Sample (A4) and STAT (A3) pipettor
locations)
6 In the carrier guide area between belts NOTE:

1 and 2 and adjacent to the Sample If the carrier detection at a sampling gate
(A4) and STAT (A3) gates, place two location is erratic, a sample presentation or
pieces of tape. sample queue error will occur.
With the carrier held firmly at the
Sample gate [A4], use a pencil to mark
the location of the center of the carrier
[C].
Observe that the LED on the Master
Tag Reader Board display is two (2). If
the display is three (3), move the
carrier at STAT (A3) location to the
right.
Move the carrier at the Sample Gate
(G4) 8 cm (3 inches) to the right. The
display should be zero (0).
Ensure that the LED does not display a
two (2) until the center of the carrier is
less than 1 cm right [R] of the marked
center position.
Move the carrier to the left of the gate.
Move the carrier to the right; ensure
that the carrier does not indicate a two
(2) until the carrier is within 1 cm left
[L] of the gate [C].
Adjust the position of the gate as
required.
SAMPLE PRESENTATION ERRORS
To reduce the potential of sample
presentation errors, the center of the
antenna sense area should be
positioned in a manner that it is
justified slightly to the left of the gate.
625798100.APS.5.doc Page 185 of 212

STEPS REFERENCES
7 If it is impossible to read any number Antenna Displayed value
on the proper display, check for
antenna cable connections or replace MASTER Board
antenna. A3 1
If the number appears on a wrong
A4 2
display, or if the displayed number is
wrong, the antenna connector is
inverted with another.
8 Repeat the process above for the
STAT antenna
Page 186 of 212 625798100.APS.5.doc

Antennas test procedure

Operation: Test of antennas proper functioning

027.200.00X
027.100.00X
Activity Type: Setting ; Control Cleaning Replacement
Frequency:
; When necessary
625798100.APS.5.doc Page 187 of 212





observed.


STEPS REFERENCES
1 Open the front panel of the i2000SR
IM electrical box and locate the
MASTER, SLAVE 0, and SLAVE 1 CAN-
BUS board 7-segments red displays.
Page 188 of 212 625798100.APS.5.doc

STEPS REFERENCES
Wait until the green lamp on the light
pole comes on.
3 To access antennae located along

belts 1 and 2, the front and center
covers must be removed.
Remove the screw in the Center Rail
[2].
screws [1].

625798100.APS.5.doc Page 189 of 212

STEPS REFERENCES
5 Move an i2000SR IM carrier (not a
Workcell carrier) near the antenna to
be tested.
Refer to the figure on the right for
antenna location and numbering.
6 Manually move the carrier along the NOTE:

track towards the location of the If the carrier detection at a sampling gate location
antenna to be tested. Ensure that the is erratic, a sample presentation or sample queue
carrier is not detected until it is about error will occur.
1 cm of the antenna.
Read the number displayed on the
proper Tag Reader board.
See table below for reference:
7 If it is impossible to read any number Antenna Displayed value
on the proper display, check for
antenna cable connections or replace MASTER Board
antenna. A3 1
If the number appears on a wrong
A4 2
display, or if the displayed number is
wrong, the antenna connector is SLAVE 0 Board
inverted with another.
A0 1
A2 2
A1 4
SLAVE 1 Board
A7 1
A6 2
A5 4
A8 8
Page 190 of 212 625798100.APS.5.doc

Verification of belt tensioning

Operation: Belt tensioning verification

PFD0304
PFD0302
PFD0301
PFD0303
Special Tools Required: 475.110.190 (8-203930-01) Belt Tension Tool (weight + hook)
Activity Type: ; Setting ; Control Cleaning ; Replacement
Frequency:
; When necessary




observed.
625798100.APS.5.doc Page 191 of 212

STEPS REFERENCES
3 Loosen the two (2) screws [1] used to
secure the Lower Closeout (P/N
203717).
Slide the cover to the left to remove
the cover.
4 Disconnect all connectors that may

be in the way to perform tensioning
test.
5 Using the belt tensioning tool (P/N
475.110.190 (203930-01)) verifies
the belt tension.
6 The i2000SR IM assembly must be

placed horizontally during tensioning
verification procedure.
Page 192 of 212 625798100.APS.5.doc

STEPS REFERENCES
7 Hang the belt tensioning tool in the
center of the bottom section of the
belt to be tested.
The right tension of the belt is
obtained when the distance of
between belt and the bottom of the
extrusion is 36 mm (1” 27/64) with a
± 6 mm (15/64”) of admissible
tolerance.
8 If belt tension adjustment is required,

use the Replacement of i2000SR IM
belts procedure to access the
mounting screws.
9 Restore all electrical connections.
10 Replace all covers.
NOTE:
Use care to ensure that all cables and
tubing are not pinched, crimped or
damaged.
625798100.APS.5.doc Page 193 of 212

Verification of Carrier Routing

Verification PROCEDURE SCHEDULE no. 20
Operation: i2000SR IM carrier routing verification

Electrical Group: 625.800.00X Part no. ---
Machine Status: Controlled running

Special Tools Required: none
Intervention kind: Electrical ; Mechanical Fluidic ; Pneumatic
Frequency:
; When necessary




observed.

Page 194 of 212 625798100.APS.5.doc

STEPS REFERENCES
1 Remove the one (1) 14494-306 .190-
end cap.
NOTE:
3.
2 Use a 14494-306 190-32 screw to

closeout.

[2].
screws [1].

625798100.APS.5.doc Page 195 of 212

STEPS REFERENCES
5 Perform the controlled switching on of Refer to the “Operations Manual – SECTION 5 –
the workcell. Operating Instructions” to execute the “Restoring
Power after a Controlled Shutdown” of the
Workcell.
6 Observe the screen for error If no error message was reported the procedure
messages. has successfully completed.
7 Perform i2000SR IM Track Exercise:
At the i2000SR IM LUI keypad press
and hold the RUN button as the
PAUSE button is pressed.
As carriers are moved, check the
following:
Belts
Travel centered on the lane. If not,
refer to the Belts idler pulley
replacement procedure
Movement is consistent If not, refer to
the Belt tensioning verification
procedure
Disks
Support bracket feet are not
contacting the belt.
Disk spin is consistent.
Carriers do not stall as they transfer
from the belt to the disk.
When a carrier is not on the disk, the
spin rate is consistent.
NOTE:
It is normal for the speed to slow
down when a carrier is on it.
When a carrier is on the disk, the disk
continues to spin
Gate Activation
During activation, a single carrier is
released
Diverter movement
One complete smooth movement
with every carrier release.
Carriers do not bind on the Disk
Cover.
Carriers do not come in contact with
a diverter.
Check Large Disk Carrier Detector
(SICK) sensor.
After a carrier is released by gate G5
to the large disk, hold the carrier at
the 3 o’clock position on the large
disk.
Ensure that no additional carriers are
released by G5 until the held carrier
is released and passes carrier detect
CD1.
Page 196 of 212 625798100.APS.5.doc

STEPS REFERENCES
8 Verify that On-line carriers properly
enter and exit the i2000SR IM.
At the i2000SR IM pneumatic panel,
reverse tubing connections at valve
EV2. This will change the state of the
diverter D0 and all On-line carriers
will be routed to the IM.
At the APS GUI, ensure that all
Instruments are Off-line.
Perform Track Exercise. Select
Diagnostic, Track, Track Exercise.
Enable the following:
Random Use of Pit Lanes
Track - Exercise
As the Carriers are routed verify the
following:
As the on-line carriers arrive at IM
entry queue, gate G1 will divert them
into IM.
Verify that carriers enter the IM [1]
without any interference.
Verify carriers don’t bind on the disk
cover [3].
Verify carriers don’t bind at the Large
and Small Disks [4]
Verify carriers do not bind on
diverters D2 or D3.
Verify that carriers exit the IM [2]
without any interference.
Hold an On-line carrier as it leaves
gate G5, verify that no other carriers
are released by G5 until the carrier is
detected by CD2.
Ensure that no On-line carriers were
routed to lane #4.
At the APS, press PAUSE
Allow all On-line carriers to leave the
i2000SR and return to the main track
Restore the D0 tubing connections at
EV2
Stop Track Exercise. Select
Diagnostics, Track, Track Exercise,
Stop.
Restore Instrument status to On-Line.
625798100.APS.5.doc Page 197 of 212

Tag Reader CAN BUS Board Firmware Installation

UPGRADE PROCEDURE SCHEDULE no. 21
Operation:
Tag Reader CAN BUS Board Firmware
Installation
This procedure is to be used to upgrade the firmware on the Tag
Purpose: Reader CAN BUS Boards used on the workcell track and i2000SR
electronic box
i2000SR IM 625.102.00X
Working area: Mechanical Group:
APS Track 580.100.00X
625.800.00X
Electrical Group: Part no. N/A
580.100.00X
Machine Status: Paused
Infineon On-Chip Memory Programming Tool installed on a support
PC/Laptop (Memtool.exe)
Special Tools Required: Latest release of CAN BUS Firmware
Serial communication cables (9 pin, female/female, pins 2 and 3
reversed and pin 5 to 5)
Frequency:
; When necessary

observed.
Page 198 of 212 625798100.APS.5.doc

STEPS REFERENCES
2 On the FSE Laptop, run the Infineon
Memtool (x) program.
3 Select File then Open. Navigate to
the stored location of the new
firmware version on your PC.
NOTE:
The firmware file for the Tag Reader
CAN bus boards has name format of
_________.H86.
Below are examples of file names:
Track TagReaderHCverX_XX.H86
i2000SR
IM i2000sr Master_Slave
Master verX.XX.H86
i2000SR
IM
Slave 0 & TagReaderHCi2000sr Slave
1 XX.H86
4 Turn OFF the power supply to the Tag

Reader CAN bus board
At the i2000SR IM – turn the
i2000SR/0/APS switch to the center
OFF (0) position.
Track Tag Reader CAN bus board –
Disconnect power cable at CN1 [1].
5 Note the positions of the Dip-switch

settings (It will be used later).
6 Change the Dip-Switch settings all to
OFF.
625798100.APS.5.doc Page 199 of 212

STEPS REFERENCES
7 If connected, remove the RS232
cable connection at Tag Reader CAN
board, CN4 (Com 1).
This cable is used to communicate
with analyzers/instruments. It is
important that this cable is connected
at the end of the procedure.
8 Connect a serial cable between the

RS-232 COM port on the PC with
Memtool and CN4 (Com 1) on the Tag
Reader CAN bus board.
9 Turn ON the power to Track Tag
Reader CAN bus board.
Track Tag Reader CAN bus board –
Connect power cable at CN1 [1].
i2000SR IM – turn the i2000SR/0/APS
switch to the i2000SR position.
10 Verify that the power LED and the

digital display are ON and a zero (0)
is displayed.
11 At the Memtool, press Connect.

If the board does not connect, close
the Memtool application, check cable
connections and repeat.
Page 200 of 212 625798100.APS.5.doc

STEPS REFERENCES
12 If Remove All is displayed in the
FLASH/OTP Memory Device window,
press the Remove All button.
13 In the File window, press Select All.
14 In the File window, press

Add Sel. >>
15 In the FLASH/OTP Memory Device

window, press Program.
16 The Execute Memtool Command

window, Operation field, will display
the current process and its status.
If an error occurs, repeat steps 12 -
16.
If “success” is displayed, press Exit.
625798100.APS.5.doc Page 201 of 212

STEPS REFERENCES
17 After the board firmware is
successfully loaded, press
Disconnect.
18 At the Tag Reader Board, disconnect

the serial cable.
19 Turn OFF the power to the Tag
Reader CAN Bus board.
20 Set the Dip-Switches back to the
original configuration.
21 If appropriate, reconnect the
Analyzer/Instrument cable.
22 Turn ON the power to the Tag Reader
CAN Bus board.
23 Verify that the power LED and the
digital display are ON.
24 Repeat the procedure for each Tag
Reader CAN Bus board.
Page 202 of 212 625798100.APS.5.doc

Preventive Maintenance Procedures
This chapter provides the various system schedules and as needed

service maintenance procedures. Also included are references to
any required electrical and mechanical drawings.
Preventive maintenance procedures are to be performed at the
predefined intervals, which in turn will increase the reliability of
the system and reduce down time.
Lubrication of gears
Operation: Gears lubrication

579.420.00X
579.430.00X
Activity Type: Setting Control Cleaning Replacement
; Quarterly Half yearly Yearly
Frequency:
When necessary
625798100.APS.5.doc Page 203 of 212




prevent injury caused by moving parts..

observed.

STEPS REFERENCES
1 Stop the i2000SR IM. Refer to the “Operations Manual – SECTION 5 –
Operating Instructions” chapter to stop the
i2000SR IM in standalone or Workcell controlled
mode.
2 To access the gears located at the
ends of belts 1 and 2, the front and
center covers must be removed.
Remove the screw in the Center Rail
[2]
screws [1].
Page 204 of 212 625798100.APS.5.doc

STEPS REFERENCES
4 Remove the 3 button LUI panel

bracket [1] by removing the two
screws [2]
5 Disconnect LUI cable.
625798100.APS.5.doc Page 205 of 212

STEPS REFERENCES
6 Remove the two screws [1] to remove
the side panel [2].

the two screws.
8 Verify that the gears group has an

adequate amount of grease. If not,
use a clean cloth and remove the old
grease. Spread one milliliter of
lithium grease (P/N PFD0243
(203250)) on the gear surfaces.
Be careful to not get grease on either
the belts or disks.
9 Replace the metal cover.

10 Reinstall the LUI panel
Page 206 of 212 625798100.APS.5.doc

VERIFICATION
STEPS REFERENCES
After initialization process, press and
hold Pause and Run button on
Keypad to start the i2000SR IM in
exercise mode.
2 Verify that belts/gears rotate without

noise and there are no grease stains.
625798100.APS.5.doc Page 207 of 212

S p a r e Pa r t s L i s t
This chapter contains the list of the Workcell spare parts. The list
includes all parts that the manufacturer foresees will be
replaceable.
i2000SR IM part list

Group/Component Part Number Image Note
Pneumatic
579.370.00X pipes, electrical
i2000SR IM cables and
LN 07L32-01 connectors
included.
i2000SR IM
579.390.00X Electrical cable
Light Pole Assembly
and connector
(Instrument Indicator 8-203850-0X included.
Light)
i2000SR IM MEL0010
Light Pole (Instrument TELEMECANIQUE - DL1EDBS ---
Indicator Light) Lamp 8-203851-0X
Pneumatic
579.540.00X pipes, electrical
i2000 SR IM
cables and
Track Assembly 8-203849-0X connectors
included.
Page 208 of 212 625798100.APS.5.doc

Pneumatic
i2000SR IM 625.107.00X pipes, electrical
Pneumatic Panel cables and
Assembly 8-203846-0X connectors
included.
Electrical
625.840.00X cables, boards,
i2000SR IM
components
Electrical box Assembly 8-203847-0X and connectors
included.
i2000SR IM 579.400.00X
---
Belt side Motor 8-203835-0X
i2000SR IM 579.410.00X
---
Disk side Motor 8-203834-0X
i2000SR IM 579.570.00X
---
Motor Belt Group 8-204007-0X
625798100.APS.5.doc Page 209 of 212

i2000SR IM 579.420.00X
---
Belt 1 & 2 Drive Group 8-203836-0X
i2000SR IM 579.430.00X
---
Belt 3 & 4 Drive Group 8-203837-0X
i2000SR IM 579.440.00X Suitable for Belt

Idler Pulley for belt 1 or
8-203838-0X 1 or Belt 3
belt 3
i2000SR IM 579.450.00X Suitable for Belt

Idler Pulley for belt 2 or
8-203839-0X 2 or Belt 4
belt 4
PFD0304
Lane 1 Belt --- Welded Belt
8-203833-0X
PFD0302
8-203865-0X
PFD0301
8-203866-0X
PFD0303
8-203867-0X
i2000SR IM 579.460.00X Configured with
---
SICK Barcode Reader 8-203830-0X *.scl file

---
Master Tag Reader Board 8-203831-0X *.scl file
Page 210 of 212 625798100.APS.5.doc


---
Slave Tag Reader Board 8-203832-0X *.scl file
i2000SR IM 579.490.00X
---
Lane 3/1 Diverter Group 8-203842-0X
i2000SR IM 579.500.00X
Lane 4/Track Diverter ---
Group 8-203845-0X
Lane 2/1 Diverter 579.510.00X

---
Group/i2000SR IM 8-203844-0X
i2000SR IM 579.520.00X
---
Lane 3/2 Diverter Group 8-203843-0X
i2000SR IM 579.530.00X
--- ---
Switch Group 8-203841-0X
i2000SR IM 625.102.18X
---
BCR Disk 8-203861-0X
625798100.APS.5.doc Page 211 of 212

i2000SR IM 625.102.99X
Small disk 8-204006-0X
i2000SR IM 625.103.09X
---
Large Disk 8-203862-0X
i2000SR IM 027.200.00X
---
Antenna 8-203863-0X
625.810.18X Suitable for A0

i2000SR IM
--- A1 A2 A5 and
Short Antenna Cable 8-203858-0X A8 antennas
625.810.19X Suitable for A3

i2000SR IM
--- A4 A6 and A7
Long Antenna Cable 8-203859-0X antennas
i2000SR IM SLS0043
PNP SICK (Carrier Detect) --- With cable
Sensor 8-203840-0X
i2000SR IM MEL0012
DOMO - VL822 CG FS 024 ---
Green LED Group 8-203852-0X
i2000SR IM MEL0013
DOMO - VL822 CY FS 024 ---
Yellow LED Group 8-203853-0X
i2000SR IM
579.945.00X ---
Carrier Spinning Group
Page 212 of 212 625798100.APS.5.doc

i2000SR IM: Service Manual For The i2000SR Interface Module

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Service Manual i2000SR interface module

Service Manual for the i2000SR Interface Module

Document name: 625798100.APS.5.doc

625798100.APS.5.doc Page 1 of 212

Instructions for Assembly ................................40

Page 2 of 212 625798100.APS.5.doc

Replacement Procedures ................................. 88

Auxiliary Procedures ..................................... 170

Preventive Maintenance Procedures .............. 203

Spare Parts List ............................................ 208

625798100.APS.5.doc Page 3 of 212

Warnings Concerning Safety

WARNING: Potential Biohazard

WARNING: Electrical Shock Hazard

CAUTION: Lifting Hazard

CAUTION: Moving Parts

Page 4 of 212 625798100.APS.5.doc

WARNING: Pinch Hazard

WARNING: Probe Sharps Hazard

Do not remove, damage or obliterate any of the laser warning

LAB0033 is an illustration of the label recommended by Abbott

625798100.APS.5.doc Page 5 of 212

DANGER: Laser Hazard

Page 6 of 212 625798100.APS.5.doc

This chapter contains a general description of the module and its

i2000SR Interface Module

625798100.APS.5.doc Page 7 of 212

The IM is controlled by a set of microcontrollers. The

Page 8 of 212 625798100.APS.5.doc

625798100.APS.5.doc Page 9 of 212

Input and Output Areas

A Priority sample input area (queue of 6 off-line carriers)

B Routine sample input area (queue of 11 off-line carriers)

C Sample output area (queue of 4 off-line carriers)

D Entry Gate Queue (queue of 8 on-line carriers)

Path of the APS Carriers

The following is the path of the Carriers routed to the i2000SR IM

Page 10 of 212 625798100.APS.5.doc

Path of the i2000SR IM Carriers

7. Lane 4 is used to manage a queue to re-supply off-line

Input and Output Areas

• Routine sample input area with 11 Manual Carriers (B).

• Sample output area with 4 Output Carriers (C)

The IM carriers, identified as Off-line Carriers, are gray in color

625798100.APS.5.doc Page 11 of 212

During the APS operational mode, Workcell carriers identified as

Three optical sensors are used to sense the presence of tubes.

Page 12 of 212 625798100.APS.5.doc

Figure 4 – Stop gates (G#) and diverters (D#)

Brief description of the stop gate devices

Gate 0 is also used to maintain the number of carriers in the

625798100.APS.5.doc Page 13 of 212

Gate 2 – is a set of three (Barcode) BCR Type 3 gate devices (G2

Gate 3 – (G3) is the STAT Sampling Gate located on Lane 1 and is

Gate 4 – (G4) is the Routine Sampling Gate located on Lane 1 and

Gate 5 – (G5) is located on Lane 2 and is operated by electro

Page 14 of 212 625798100.APS.5.doc

a collision with a carrier arriving from Lane 3. Lane 3 carriers

Gate 7b (G7b) – is the Routine Input Gate located on Lane 3 and

The IM controls a Green/Yellow LED associated with this gate.

625798100.APS.5.doc Page 15 of 212

Figure 5 – Calibrator Load (Six point)

Page 16 of 212 625798100.APS.5.doc