S1.biomek I-Series

Service Manual
Biomek i-Series
Laboratory Automated Workstations
B54476AB
October 2017
Beckman Coulter, Inc.

250 S. Kraemer Blvd.
Brea, CA 92821 U.S.A.
Biomek i-Series Laboratory Automated Workstations
Service Manual
PN B54476AB (October 2017)
© 2017 Beckman Coulter, Inc.
All Rights Reserved
This Service Manual contains confidential information of

Beckman Coulter, Inc. and its receipt or possession does
not convey any right to reproduce, disclose its contents, or
to manufacture, use, or sell anything it may describe.
Reproduction, disclosure, or use without specific written
authorization of Beckman Coulter, Inc. is strictly forbidden.
Beckman Coulter, Inc. makes no representation that, upon

furnishing this service manual, the holder of the manual
will have the necessary technical capabilities and know-
how to properly troubleshoot and repair any of the
equipment specified in the manual. Beckman Coulter, Inc.
assumes no liability whatsoever, including consequential
and incidental damages, resulting from improper
operation of Beckman Coulter instruments after
maintenance of Beckman Coulter instruments has been
performed by persons not employed by Beckman Coulter,
Inc. Furthermore, Beckman Coulter, Inc. assumes no
liability whatsoever for any personal injury or property
damage resulting from maintenance and/or repair of
Beckman Coulter instruments performed by persons not
employed by Beckman Coulter, Inc.
Trademarks
Beckman Coulter, the stylized logo, and the Beckman
Coulter product and service marks mentioned herein are
trademarks or registered trademarks of Beckman Coulter,
Inc. in the United States and other countries.
All other trademarks, service marks, products, or services

are trademarks or registered trademarks of their
respective holders.
Beckman Coulter, Inc.

250 S. Kraemer Blvd.
Brea, CA 92821 U.S.A.
Original Instructions
Revision History
Initial Issue, AA/2017
Biomek Software Version 5.0
Issue AB, 10/2017

Changes were made in the following:
• Revised General Safety

• Added Electrostatic Discharge (ESD) Protection
• Revised Chemical and Biological
• Revised Laser Warning Labels
• Revised CHAPTER 2, SAMI EX Software
• Added list of ALPs manuals, 2.2, Standard Components, Deck
• Revised , System Architecture
• Revised 2.3, Electronics and Wiring:
• Revised 2.5, Software
• Added 3.3, i-Series Table Installation
• Added 3.4, Mobile Workstation Installation
• Added 3.5, Unpacking and Inspecting the Mobile Workstation
• Added 3.6, Assembling the Mobile Workstation Accessories
• Added 3.7, Installing the Workstation Monitor Arm
• Revised 3.8, Unpacking and Inspecting the Biomek i-Series Instrument:
• Revised 3.9, Preparing and Placing the Biomek i-Series Instrument:
• Revised 3.10, Making Connections and Powering On:
• Revised 3.11, Windows 10 Automation Controller Installation
• Revised 3.12, Software Configuration and Accessory Installation
• Revised 3.13, Biomek i-Series Installation Flow Chart
• Revised 3.15, Span-8 Bottles and Tubing Setup
• Revised 3.18, SAMI EX Software Installation
• Revised 3.19, zSAMI EX Hardware Key Installation
• Revised 3.21, Cytomat 2C with Conveyor Installation
• Revised 3.25, Cytomat Electrical and Communications Connections
• Revised 3.28, Cytomat 2C Setup and Configuration in Biomek Software
• Added 3.43, HEPA Filter Installation and Service
• Revised 4.100.1, General Guidelines
• Added 4.100.2, Automation Controller Backup/Restore
• Revised 4.100.3, Covers Removal and Replacement:
• Added 4.100.4, LED Status Light Segment Removal and Replacement on Open Enclosure
• Revised 4.100.5, LED Light Segment Removal and Replacement on Closed Enclosure
B54476AB iii
Revision History
• Added 4.200.1, Magnet Top Cover Removal and Replacement Procedure

• Revised 4.200.2, MC Pod Removal and Replacement:
• Added 4.200.3, D-Axis Ball Screw Assembly and Motor Removal/Replacement
• Added 4.200.4, MC Pod Rotation Adjustment Procedure
• Revised 4.300.1, MC Head Removal and Replacement:
• Added 4.400.1, Span-8 Pod Probe Alignment
• Added 4.400.2, Probe Guide Assembly Removal and Replacement Procedure
• Added 4.400.3, Span-8 Probe Correlate Axes Procedure
• Added 4.500.1, Gripper Assembly Removal and Replacement
• Added 4.500.2, Gripper Grip Motor Removal and Replacement
• Revised 4.500.3, Gripper Finger Assembly Removal and Replacement
• Added 4.500.4, Gripper Motion Board(s) Removal and Replacement for Multichannel Arm
• Added 4.500.5, Gripper Motion Board(s) Removal and Replacement for Span-8 Arm
• Added 4.500.6, Gripper Rotate Motor Removal and Replacement
• Added 4.500.7, Gripper Rotate Belt Removal and Replacement
• Added 4.500.8, Gripper Z-Rail and Bearings Removal and Replacement
• Added 4.500.9, Gripper Grip Axis Finger Rails and Linear Rail Removal and Replacement
• Added 4.500.10, Gripper Y-Axis Motor Removal and Replacement
• Added 4.500.11, Y-Axis Belt Removal and Replacement
• Added 4.500.12, Y-Axis Idler Pulley Removal and Replacement
• Added 4.500.13, Y-Axis Linear Rail and Bearings Replacement
• Added 4.500.14, Z-Motor Removal and Replacement
• Added 4.500.15, Z-Axis E-chain Removal and Replacement
• Revised 5.000.1, Preventive Maintenance Checklist
• Revised 5.100.2, 4 Post Framing Tool Procedure
• Revised 5.100.3, Service Check Out Method
• 5.100.4, Instrument Function Checklist Procedure, deleted row in Table 5.100.4-1, Instrument
Function Checklist Procedures
• Revised 6.1, Engineering Documents
• Added 7.2, Light Curtain Troubleshooting Procedure
• Added 7.3, Master Controller Log Collection
This document applies to the latest software listed and higher versions. When a subsequent software
version affects the information in this document, the changes will be summarized on a Notice of
Information Update form and will be released by Service Mod.
iv B54476AB
Safety Notice
Alert Definitions for Warning and Caution
All Warnings and Cautions in this document include an exclamation point, framed within a triangle.
The exclamation point symbol is an international symbol which serves as a reminder that all safety
instructions should be read and understood before installation, use, maintenance, and servicing are
attempted.
WARNING and CAUTION alert you as follows:
DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could
CAUTION
CAUTION indicates a potentially hazardous situation, which, if not avoided, may
result in minor or moderate injury. It may also be used to alert against unsafe
practices.
Safety Symbols
Safety symbols are placed on the instrument to alert you to potentially dangerous conditions as
follows:
Electrical shock hazard. Operate with caution!
Biohazardous material
B54476AB v
Safety Notice
Safety Precautions
Possible laser radiation inside.
Pinch Hazard
Safety Precautions
IMPORTANT For safety precautions specific to this instrument, refer to Heading 1.2, Safety Precautions.
Read all product manuals and consult with Beckman Coulter-trained personnel before attempting
to operate instrument.
Beckman Coulter, Inc. urges its customers and employees to comply with all national health and
safety standards such as the use of barrier protection. This may include, but it is not limited to,
protective eyewear, gloves, and suitable laboratory attire when operating or maintaining this or any
other automated laboratory instrument.
vi B54476AB
Contents
Revision History, iii

Safety Notice, v
Alert Definitions for Warning and Caution, v
Safety Symbols, v
Safety Precautions, vi
Introduction, 1-1
1.1 Manual Description, 1-1
Scope, 1-1
Customer Documents, 1-1
Service Manual Updates, 1-2
Intended Audience, 1-3
Organization, 1-3
Numbering Format, 1-4
Signal Words and Special Headings , 1-4
IMPORTANT, 1-5
NOTE, 1-5
Conventions, 1-5
1.2 Safety Precautions , 1-7
Special, 1-7
General Safety, 1-8
Lifting the Instrument, 1-14
Electrical, 1-14
Equipment Ratings, 1-14
Warning and Cautions, 1-14
Electrostatic Discharge (ESD) Protection, 1-15
Disposal of Electronic Instrumentation, 1-16
Chemical and Biological, 1-17
Moving Parts, 1-19
Laser, 1-19
Laser Beam Hazard, 1-19
Laser Warning Labels, 1-20
Troubleshooting, 1-20
Instrument Description, 2-1

2.1 Introduction to the Biomek i-Series Automated Laboratory
Workstation, 2-1
Summary, 2-1
Instrument Overview, 2-1
vii
Contents
System Components, 2-1

Main Components, 2-2
Configurations for the Biomek i-Series, 2-3
Biomek i5 Instrument, 2-4
Biomek i7 Instrument, 2-4
Software, 2-4
Biomek Software, 2-4
SAMI EX Software, 2-5
2.2 Standard Components, 2-7
Chassis, 2-7
Arms, 2-7
Gripper, 2-8
Deck, 2-8
ALPs, 2-8
Deck Observation System, 2-9
Protective Barriers, 2-9
Status Indicator Light Bar, 2-9
Interior Deck Lighting, 2-9
Enclosures, 2-9
2.3 Electronics and Wiring, 2-11
Command, Control, and Communication, 2-11
Electrical Requirements, 2-11
System Architecture, 2-12
Chassis Board, 2-14
Transport Supervisor Board, 2-19
Motion Board, 2-20
Tower Board, 2-22
Indicator Lights, 2-23
Syringe Pump Bank Controller Board, 2-24
Light Curtain and Light Curtain Emitter Board, 2-25
2.4 Fluidics System, 2-27
Source Fluid, 2-27
Mandrels, 2-28
Wash Station Tubing/Waste Bottle , 2-28
2.5 Software, 2-29
2.6 Labware and Accessories, 2-31
Purpose, 2-31
Labware, 2-31
Optional Devices, 2-31
Installation Procedures, 3-1

3.1 Pre-Site Inspection, 3-1
3.2 Preinstallation Checks, 3-3
Biomek i-Series Instrument Preinstallation Requirements, 3-3
3.3 i-Series Table Installation, 3-5
Tools/ Supplies Needed, 3-5
viii
Contents
Moving the Shipping Crate, 3-5

Unpacking the i-Series Table, 3-6
3.4 Mobile Workstation Installation, 3-9
Preinstallation Checklist, 3-10
, 3-10
3.5 Unpacking and Inspecting the Mobile Workstation, 3-11
Tools/Supplies Needed, 3-11
Preparation, 3-11
Location for Unpacking the Mobile Workstation, 3-11
Unpacking the Mobile Workstation, 3-12
OPTIONAL: Use The Ramp From The Biomek i-series Instrument
Packing to unload the Mobile Workstation, 3-13
Manually Removing The Mobile Workstation From The
Pallet, 3-14
3.6 Assembling the Mobile Workstation Accessories, 3-15
Side Tray, 3-15
Adjustable Shelves, 3-16
Sliding Doors, 3-17
Cable Routing, 3-17
Removing the End Panels, 3-18
Reversing the Biomek i5 Workstation Configuration, 3-18
3.7 Installing the Workstation Monitor Arm, 3-21
Monitor Arm- Innovative Brand, 3-22
Monitor Arm- Ergortron StyleView Sit Stand Combo Arm, 3-27
3.8 Unpacking and Inspecting the Biomek i-Series Instrument, 3-29
Preparation, 3-29
Location for Unpacking the Biomek i-Series instrument, 3-29
Unpacking the Biomek i-Series Instrument, 3-30
Inspecting the Biomek i-Series Instrument, 3-42
Moving the Biomek i-Series Instrument to the Installation Site, 3-42
3.9 Preparing and Placing the Biomek i-Series Instrument, 3-43
Preparing the Biomek i-Series Instrument and Placing It on the
Bench, 3-43
3.10 Making Connections and Powering On, 3-51
Making Connections and Powering On, 3-51
3.11 Windows 10 Automation Controller Installation, 3-53
Windows 10 Automation Controller Installation, 3-53
Monitor Installation, 3-53
3.12 Software Configuration and Accessory Installation, 3-55
ix
Contents
Purpose, 3-55
Configure Customer Accessories, 3-56
Finish Software Setup, 3-56
3.13 Biomek i-Series Installation Flow Chart , 3-59
Biomek i-Series Installation Flow Chart, 3-59
3.14 Multi-Channel Wash Station, 3-61
3.15 Span-8 Bottles and Tubing Setup, 3-63
Purpose, 3-63
Tools and Supplies Needed, 3-63
Tubing and Bottle Setup Preparation, 3-63
Tubing and Bottle Setup Procedure, 3-63
3.16 Instrument Operation, 3-65
Purpose, 3-65
Procedure, 3-65
3.17 PROService RMS, 3-67
3.18 SAMI EX Software Installation, 3-69
Purpose, 3-69
Prerequisites, 3-69
Procedure, 3-69
3.19 zSAMI EX Hardware Key Installation, 3-73
Purpose, 3-73
Prerequisites, 3-73
Procedure, 3-73
3.20 Cytomat 2C Incubator Integration for Biomek i-Series, 3-77
Purpose, 3-77
Items Provided, 3-77
Prerequisites, 3-78
3.21 Cytomat 2C with Conveyor Installation, 3-79
Purpose, 3-79
Procedure, 3-79
3.22 Cytomat 2C Directly Accessed by Biomek Gripper Installation, 3-83
Purpose, 3-83
Procedure, 3-83
3.23 Conveyor Installation, 3-87
Purpose, 3-87
Procedure, 3-87
3.24 Bar Code Reader Installation, 3-89
Purpose, 3-89
Procedure, 3-89
x
Contents
3.25 Cytomat Electrical and Communications Connections, 3-91

Purpose, 3-91
Procedure, 3-91
3.26 Loading Cytomat Hotels, 3-93
3.27 Cytomat 2C Configuration Software Installation, 3-95
Purpose, 3-95
Cytomat Configuration Software Installation Procedure, 3-95
Conveyor SILAS Module Installation, 3-96
Cytomat SILAS Module Installation, 3-97
Random Access Storage Step Installation (Install only if using the
device in Biomek Software), 3-98
Purpose, 3-98
3.28 Cytomat 2C Setup and Configuration in Biomek Software, 3-99
Purpose, 3-99
Biomek Setup with Conveyor Procedure, 3-99
Biomek Setup for Biomek Gripper Direct Access Procedure, 3-101
Framing the Cytomat ALP, 3-104
3.29 Cytomat 2C Configuration Using Device Software, 3-107
Purpose, 3-107
Procedure, 3-107
3.30 Cytomat 2C Setup and Configuration the SAMI EX Installer Tool
(Optional), 3-109
Purpose, 3-109
SAMI EX Installer Tool Configuration Procedure, 3-109
3.31 Cytomat MPH Integration for Biomek i-Series, 3-111
Purpose, 3-111
Items Provided, 3-111
Prerequisites, 3-111
3.32 Cytomat MPH With Conveyor Installation, 3-113
Purpose, 3-113
Procedure, 3-113
3.33 Cytomat MPH Directly Accessed by Biomek Gripper
Installation, 3-119
Purpose, 3-119
Procedure, 3-119
3.34 MPH Transfer Station Configuration for a Conveyor, 3-123
Purpose, 3-123
Procedure, 3-123
3.35 MPH Installing Cabling, 3-125
Purpose, 3-125
xi
Contents
Procedure, 3-125
3.36 Loading Cytomat MPH Hotels, 3-127
3.37 Cytomat MPH Configuration Using Device Software, 3-129
Purpose, 3-129
Procedure, 3-129
Setup Utility, 3-129
Transfer Station Parameters, 3-130
Turning Off “Rotisserie Mode”, 3-132
Final Testing, 3-133
3.38 Installation of Software Items, 3-135
Purpose, 3-135
Conveyor SILAS Module Installation, 3-135
Cytomat MPH SILAS Module Installation, 3-136
Random Access Storage Step Installation (Install only if using the
device in Biomek Software), 3-137
Purpose, 3-137
3.39 Cytomat MPH Setup and Operation, 3-139
Purpose, 3-139
Biomek Setup with Conveyor Procedure, 3-139
Biomek Hardware Setup with Conveyor, 3-139
Biomek Configuration and Framing, 3-140
Biomek Setup for Biomek Gripper Direct Access Procedure, 3-141
Framing the Cytomat ALP, 3-144
3.40 Cytomat MPH Options, 3-147
Purpose, 3-147
Options Settings, 3-147
3.41 Cytomat MPH SAMI EX Software Setup and Configuration
(Optional), 3-149
Purpose, 3-149
SAMI EX Installer Tool Configuration Procedure, 3-149
3.42 Manual Control / Silas Module, 3-151
Action Configuration Dialog, 3-151
3.43 HEPA Filter Installation and Service, 3-153
Purpose, 3-153
Installation, 3-154
Operation, 3-157
Preventive Maintenance, 3-158
Preventive Maintenance Checklist, 3-158
Pre-filter Replacement Procedure, 3-159
HEPA Filter Replacement Procedure, 3-159
xii
Contents
Service and Repair Procedures, 4-1

4.100.1 General Guidelines, 4-1
Safety Precautions, 4-1
Accessibility, 4-1
Tools and Supplies, 4-1
Instrument Performance Verification, 4-1
System Power Down , 4-2
System Power Up, 4-2
4.100.2 Automation Controller Backup/Restore, 4-5
Purpose, 4-5
Preparation, 4-5
Backup, 4-6
Verification, 4-8
Restore, 4-8
Verification, 4-9
4.100.3 Covers Removal and Replacement, 4-11
Purpose, 4-11
Side Panel Removal and Replacement, 4-12
Removal, 4-12
Replacement, 4-14
Verification, 4-14
Front Door (if enclosure) Removal and Replacement, 4-14
Option 1 Removal, 4-14
Option 1 Replacement, 4-16
Option 2 Removal, 4-16
Option 2 Replacement, 4-17
Verification, 4-17
Rear Panels Removal and Replacement, 4-17
Removal, 4-17
Replacement, 4-17
Verification, 4-18
MC Arm Covers Removal and Replacement, 4-18
Removal, 4-18
Replacement, 4-19
Verification, 4-19
Span-8 Arm Covers Removal and Replacement, 4-19
Removal, 4-19
Replacement, 4-19
Verification, 4-19
Gripper Covers Removal and Replacement, 4-20
Purpose, 4-20
Removal, 4-20
Replacement, 4-20
Verification, 4-24
xiii
Contents
Multichannel Pod Cover Removal and Replacement, 4-24

Preparation, 4-24
Removal, 4-24
Replacement, 4-24
Verification, 4-25
4.100.4 LED Status Light Segment Removal and Replacement on Open
Enclosure, 4-27
Purpose, 4-27
Removal, 4-27
Replacement, 4-27
Verification, 4-28
4.100.5 LED Light Segment Removal and Replacement on Closed
Enclosure, 4-29
Purpose, 4-29
Removal, 4-29
Removal, 4-29
Replacement, 4-30
Verification, 4-33
4.200.1 Magnet Top Cover Removal and Replacement Procedure, 4-35
Purpose, 4-35
Removal, 4-35
Replacement, 4-35
Verification, 4-36
4.200.2 MC Pod Removal and Replacement , 4-37
Purpose, 4-37
Removal, 4-37
Replacement, 4-40
Verification, 4-40
4.200.3 D-Axis Ball Screw Assembly and Motor Removal/Replacement, 4-41
Purpose, 4-41
Removal, 4-41
Replacement, 4-46
Verification, 4-52
4.200.4 MC Pod Rotation Adjustment Procedure , 4-53
Purpose, 4-53
Rotation Adjustment, 4-53
Verification, 4-55
4.300.1 MC Head Removal and Replacement, 4-57
Purpose, 4-57
xiv
Contents
Removal, 4-57
Replacement, 4-57
Verification, 4-57
4.400.1 Span-8 Pod Probe Alignment, 4-59
Purpose, 4-59
Preparation, 4-61
Perpendicularity Check and Adjustment, 4-61
Probe Alignment, 4-61
Verification, 4-65
4.400.2 Probe Guide Assembly Removal and Replacement Procedure, 4-67
Purpose, 4-67
Preparation, 4-67
Removal, 4-67
Replacement, 4-69
Verification, 4-69
4.400.3 Span-8 Probe Correlate Axes Procedure, 4-71
Purpose, 4-71
Preparation, 4-71
Correlate Axes, 4-71
Verification, 4-76
4.500.1 Gripper Assembly Removal and Replacement, 4-77
Purpose, 4-77
Tools/Supplies Needed , 4-77
Removal, 4-77
Replacement, 4-79
Verification, 4-79
4.500.2 Gripper Grip Motor Removal and Replacement, 4-81
Purpose, 4-81
Removal, 4-81
Replacement, 4-86
Verification, 4-86
4.500.3 Gripper Finger Assembly Removal and Replacement, 4-87
Purpose, 4-87
Finger Removal, 4-87
Replacement, 4-88
Verification, 4-88
Gripper Pad Removal, 4-88
Gripper Pad Replacement, 4-88
4.500.4 Gripper Motion Board(s) Removal and Replacement for
Multichannel Arm, 4-91
Purpose, 4-91
xv
Contents

Removal, 4-91
Replacement, 4-93
Verification, 4-93
Span-8 Arm, 4-95
Purpose, 4-95
Removal, 4-95
Replacement, 4-97
Verification, 4-97
4.500.6 Gripper Rotate Motor Removal and Replacement, 4-99
Purpose, 4-99
Removal, 4-99
Replacement, 4-100
Verification, 4-101
4.500.7 Gripper Rotate Belt Removal and Replacement, 4-103
Purpose, 4-103
Removal, 4-103
Replacement, 4-104
Verification, 4-105
4.500.8 Gripper Z-Rail and Bearings Removal and Replacement, 4-107
Purpose, 4-107
Removal, 4-107
Replacement, 4-109
Verification, 4-110
4.500.9 Gripper Grip Axis Finger Rails and Linear Rail Removal and
Replacement, 4-111
Purpose, 4-111
Removal, 4-111
Replacement, 4-117
Verification, 4-118
4.500.10 Gripper Y-Axis Motor Removal and Replacement, 4-119
Purpose, 4-119
Removal, 4-119
Replacement, 4-120
Verification, 4-120
4.500.11 Y-Axis Belt Removal and Replacement, 4-121
Purpose, 4-121
Removal, 4-121
xvi
Contents
Replacement, 4-122
Verification, 4-122
4.500.12 Y-Axis Idler Pulley Removal and Replacement, 4-1
Purpose, 4-1
Removal, 4-1
Replacement, 4-1
Verification, 4-1
4.500.13 Y-Axis Linear Rail and Bearings Replacement, 4-3
Purpose, 4-3
Removal, 4-3
Replacement, 4-4
Verification, 4-5
4.500.14 Z-Motor Removal and Replacement, 4-7
Purpose, 4-7
Removal, 4-7
Replacement, 4-9
Verification, 4-10
4.500.15 Z-Axis E-chain Removal and Replacement, 4-1
Purpose, 4-1
Removal, 4-1
Replacement, 4-4
Verification, 4-4
Preventive Maintenance and Verification Procedures, 5-1

5.000.1 Preventive Maintenance Checklist, 5-1
5.100.1 Home All Axes, 5-5
Purpose, 5-5
Procedure, 5-5
Verification, 5-8
5.100.2 4 Post Framing Tool Procedure, 5-9
Purpose, 5-9
Instructions, 5-9
Results, 5-11
5.100.3 Service Check Out Method, 5-13
Purpose, 5-13
Instructions, 5-15
Verification, 5-24
5.100.4 Instrument Function Checklist Procedure, 5-27
xvii
Contents
Purpose, 5-27
Instructions, 5-27
Verification, 5-35
Schematics, 6-1
6.1 Engineering Documents, 6-1
7.1 Overview, 7-1
Error Message Overview, 7-1
Error Recovery Overview, 7-1
Error Prevention Overview, 7-2
7.2 Light Curtain Troubleshooting Procedure, 7-3
Generating Troubleshooting Information, 7-3
Check That All Relevant Mods Have Been Performed, 7-4
Initial Checks to Perform Prior to Troubleshooting, 7-7
Failure Mode – Light Curtain Stays Tripped, 7-11
Failure Mode – Light curtain fails to detect the 1.5” diameter test
rod (P/N 719724) , 7-12
Failure Mode – Light curtain fails to detect the .625” diameter test
rod (P/N B99815) , 7-13
7.3 Master Controller Log Collection, 7-15
Purpose, 7-15
Master Controller Log Collection, 7-15
Parts Lists, 8-1

8.1 Parts List, 8-1
Abbreviations
Glossary
Index
xviii
Illustrations
Illustrations
1.2-1 ESD strap attachment location for Span-8 Pod, 1-15

1.2-2 ESD strap attachment location for Multichannel Pod, 1-16
1.2-3 Fly-By Bar Code Reader Laser Warning Label location, 1-20
2.1-1 Biomek i7 Main Components, 2-2
2.1-2 Biomek i7 Additional Main Components on Enclosed
Version, 2-3
2.3-1 System Architecture, 2-12
2.3-2 Board Block Diagram - i7 Hybrid, 2-13
2.3-3 Chassis Board block diagram, 2-14
2.3-4 System view of chassis board, 2-15
2.3-5 System view of chassis board - view 2, 2-15
2.3-6 Chassis Board Mounting location, 2-16
2.3-7 Transport Supervisor Board Block Diagram, 2-19
2.3-8 Motion Board Layout, 2-20
2.3-9 Motion Board Fuse Locations, 2-21
2.3-10 Motion Board LEDs, 2-21
2.3-11 Tower Board connections, 2-23
2.3-12 Syringe Pump Controller board, 2-24
2.3-13 Light Curtain Connection Overview, 2-25
2.4-1 Fluidics System, 2-27
3.3-1 i-Series Table Packaging (1m x 1m table shown), 3-6
3.3-2 1m x 1m table and .7m x 1m table side panels, 3-7
3.4-1 i5 Mobile Workstation, 3-9
3.4-2 i7 Mobile Workstation, 3-9
3.5-1 Packing materials (i5 shown), 3-12
3.5-2 Turn the thumb wheel to raise the levelers, 3-13
3.5-3 Access Thumb wheel from inside via the trap door, 3-13
3.5-4 Insert U-Bolts into the crate base and ramp, 3-14
3.6-1 Install Side Tray, 3-16
3.6-2 Adjustable shelf brackets and shelves, 3-16
3.6-3 Install cart doors, 3-17
3.6-4 Pull out, then up off the lower tabs, 3-18
3.6-5 Drawer, casing and brackets, 3-19
3.6-6 Remove work surface, 3-19
xix
Illustrations
3.7-1 Install Large “L” bracket, 3-22

3.7-2 Attach mount column to L bracket, 3-22
3.7-3 Place monitor arm into the mount column, 3-23
3.7-4 Adjust counterbalance strength adjustment screw, 3-26
3.7-5 Instant height counterbalance adjustment, 3-26
3.7-6 Mounting Arm Bracket, 3-27
3.7-7 Mounting arm wall bracket, 3-27
3.8-1 Cut the Wire Straps, 3-30
3.8-2 Fold Down the Ramp, 3-31
3.8-3 Position the Ramp In Front of the Shipping Crate, 3-31
3.8-4 Removing the Top Cover, 3-32
3.8-5 Remove the Front and Back Side Wall Covers, 3-32
3.8-6 Insert U-Bolts Into the Crate Base and Ramp, 3-33
3.8-7 Removing the Brace Screws, 3-33
3.8-8 Remove the Shrink Wrap From the Side of the Instrument, 3-34
3.8-9 Remove the Remaining Shrink Wrap, 3-34
3.8-10 Remove the Door Shipping Restraints (Enclosed Model), 3-35
3.8-11 Remove the Door Shipping Restraint Screws (Enclosed
Model), 3-35
3.8-12 Cut and Remove the Wire Straps From the Shipping Cart, 3-36
3.8-13 Cut and Remove the Wire Straps From the Cart, 3-36
3.8-14 Remove the Locking Bolts from the Instrument Y Beams on the
i-7, 3-37
3.8-15 Loose release lever screw in the provided cart, 3-37
3.8-16 Rotate lever 90 degrees, 3-38
3.8-17 Arm in service position, 3-38
3.8-18 Align the instrument casters with
the C-channels on the shipping cart, 3-39
3.8-19 Align the instrument casters to the C-Channels On the Shipping
Cart, 3-39
3.8-20 Install the Anchor Bolts to lock the Instrument to the cart, 3-40
3.8-21 Lock the cart wheels, 3-40
3.8-22 Removing the locking bolts and washers from shipping post
braces (i7 only), 3-41
3.8-23 Raise the cart and wheel the Instrument out of the shipping
crate and down the ramp, 3-41
3.9-1 Light curtain sash on front logo panel, 3-44
3.9-2 Light curtain sash on front door assembly, 3-45
3.9-3 Raise workstation to just above bench height, 3-46
xx
Illustrations
3.9-4 Align cart and bench, 3-46

3.9-5 Roll the Instrument Onto the Lab Bench, 3-47
3.9-6 Lower the feet to raise the casters off the C-channel and the
bench surface, 3-47
3.9-7 Lock Feet with Locking Nut, 3-48
3.9-8 MC Arm Board Bracket Cover, 3-49
3.9-9 MC Pod Encoder Cable Clips, 3-49
3.9-10 MC Pod Connections, 3-50
3.17-1 PROService Connectivity, 3-67
3.19-1 SAMI Hardware Key Install, 3-73
3.19-2 Select Dongle Type and Installation Type, and note, 3-74
3.19-3 Device driver Installation Wizard, 3-74
3.19-4 Device Driver Installation Wizard Complete, 3-75
3.19-5 Installation success message, 3-75
3.19-6 Device driver software installed successfully message, 3-75
3.21-1 Biomek Height Measurement, 3-79
3.21-2 Install Side Shielding with Conveyor Location Hole Adjustment
Sliders, 3-80
3.21-3 Cytomat Attachment Bracket Mounted to Biomek Deck, 3-80
3.21-4 Attach Cytomat Attachment Bracket to the Biomek U-
Channel, 3-81
3.21-5 Attach Conveyor to Riser Block, 3-81
3.21-6 Place Cytomat 2C Mounting Strip Under Attachment
Bracket, 3-82
3.21-7 Place Cytomat 2C on Mounting Strip and Align with
Conveyor, 3-82
3.22-1 Install Side Shielding with Cytomat Metal Guard, 3-83
Channel, 3-84
3.22-4 Place Cytomat2C Mounting Strip Under Attachment
Bracket, 3-85
3.22-5 Side View of Cytomat 2C Attached to the Left Side of the Biomek
Deck, 3-85
3.22-6 Cytomat 2C Mounted to Left Side of Biomek Deck, 3-86
3.23-1 Barrel Sensor on Conveyor ALP, 3-87
3.24-1 Barcode Reader adjustments, 3-89
3.24-2 Barcode Reader installation, 3-90
3.25-1 Connection panels on the Cytomat 2C, 3-91
3.26-1 Cytomat Hotel Interlock without Hotel, 3-93
xxi
Illustrations
3.26-2 Cytomat Hotel Interlock with Hotel, 3-93

3.27-1 Conveyor Installation Program, 3-96
3.27-2 Conveyor Installation Type Selection, 3-96
3.27-3 Cytomat Installation Program, 3-97
3.27-4 Cytomat SILAS Module Configuration, 3-97
3.28-1 New Cytomat Device in Biomek Hardware Setup, 3-99
3.28-2 Biomek Software Showing Random Access Steps, 3-100
3.28-3 Standard Length Conveyor ALP, 3-100
3.28-4 Conveyor ALP inner Position Properties, 3-101
3.28-5 Cytomat Device using Cytomat for Direct Access in Biomek
Hardware Setup, 3-102
3.28-6 Biomek Software Showing Random Access Steps in Various
Tabs, 3-102
3.28-7 Cytomat2CLeft ALP Added to Biomek Deck, 3-103
3.28-8 Position Properties, 3-103
3.28-9 Disable Initialization of the Cytomat Device, 3-104
3.28-10 Cytomat ALP Position Properties, 3-105
3.28-11 Manual Framing Wizard, 3-105
3.28-12 Enable Initialization of Cytomat Device, 3-106
3.30-1 SAMI EX Installer Tool with a Cytomat 2C and Conveyor
Linked, 3-109
3.32-1 Cytomat Mounting Platform, 3-113
3.32-2 Biomek Height Measurement, 3-114
3.32-3 Install Side Shielding with Conveyor Location Hole Adjustment
Sliders, 3-114
3.32-4 Conveyor Attachment Bracket Mounted to Biomek Deck, 3-115
3.32-5 Attach Conveyor to Attachment Bracket, 3-115
3.32-6 Place Cytomat Mounting Platform on Table, 3-116
3.32-7 Place Cytomat on Mounting Platform and Align with
Conveyor, 3-116
3.32-8 Secure the Cytomat MPH Mounting Platform to Table Top, 3-117
3.33-1 Install Side Shielding with Cytomat Metal Guard, 3-119
Channel, 3-120
3.33-4 Attach Cytomat Mounting Platform to Attachment
Bracket, 3-121
3.33-5 Side View of Cytomat MPH Attached to the Left Side of the
Biomek Deck, 3-121
3.33-6 Cytomat MPH Mounted to Left Side of Biomek Deck, 3-122
xxii
Illustrations
3.34-1 Plate Holder and Barrel Sensor, 3-123

3.34-2 Transfer Prior to Attaching Bracket, 3-123
3.34-3 Barrel Sensor, 3-124
3.34-4 Barrel Sensor Mounting, 3-124
3.36-1 Cytomat Hotel Interlock without Hotel, 3-127
3.36-2 Cytomat Hotel Interlock with Hotel, 3-127
3.37-1 Configure Adjustment Transfer Station Screen, 3-130
3.37-2 Friction tape on Plate Shovel, 3-132
3.38-1 Conveyor Install “Welcome” Screen, 3-135
3.38-2 Conveyor Installation Type Selection, 3-136
3.38-3 Module Installation Dialog, 3-136
3.38-4 Module Configuration, 3-137
3.38-5 Installation Program, 3-137
3.38-6 Installation Completed, 3-138
3.39-1 Cytomat Device using Cytomat and Conveyor in Biomek
Tabs, 3-140
3.39-3 Conveyor ALP Added to Biomek Deck, 3-140
3.39-4 Conveyor ALP inner Position Properties, 3-141
3.39-5 Cytomat Device using Cytomat for Direct Access in Biomek
Tabs, 3-142
3.39-7 Cytomat ALP Added to Biomek Deck, 3-143
3.39-8 Disable Initialization of the Cytomat Device, 3-144
3.39-9 Cytomat ALP Position Properties, 3-145
3.39-10 Manual Framing Wizard, 3-145
3.39-11 Enable Initialization of Cytomat Device, 3-146
3.40-1 Cytomat MPH Options Configuration Dialog, 3-147
3.41-1 SAMI EX Installer Tool with a Cytomat and Conveyor
Linked, 3-149
3.42-1 Action Configuration Dialog, 3-151
3.43-1 Remove button-head screws and panels, 3-154
3.43-2 Remove M5 socket-head screws and panel supports, 3-154
3.43-3 Install HEPA fan supports, 3-154
3.43-4 Install additional panel support, 3-155
3.43-5 Fan Unit installed on halo, 3-155
3.43-6 Install power supply holder, 3-156
xxiii
Illustrations
3.43-7 Remove black mounting brackets on power strip bracket, 3-156

3.43-8 Reattach power strip to black mounting brackets, 3-157
3.43-9 Pre-filter replacement, 3-159
3.43-10 Remove screws and catches (i7 HEPA Kit shown), 3-160
4.100.2-1 Windows Search- Backup and Restore, 4-6
4.100.2-2 Create a System Image link, 4-6
4.100.2-3 Click on Start backup, 4-7
4.100.2-4 Windows creating backup, 4-8
4.100.3-1 Biomek i-Series Front, Top, and Side covers, 4-11
4.100.3-2 Biomek i-Series Rear Covers, 4-12
4.100.3-3 Side Panel Retainer Bolts., 4-13
4.100.3-4 Side panel thumbscrews, 4-13
4.100.3-5 Door Frame Stopper Screw, 4-15
4.100.3-6 Door Cover Removal, 4-15
4.100.3-7 Door panel and frame, top, 4-16
4.100.3-8 Door panel and frame bottom, 4-16
4.100.3-9 Top and Bottom Back Panels Removal and Installation, 4-17
4.100.3-10 Rear cover screws, 4-18
4.100.3-11 Remove bumper pad, 4-18
4.100.3-12 Gripper Covers Securing Screws, 4-20
4.100.3-13 Rotate motor cable connected to the e-chain cable, 4-21
4.100.3-14 Gripper flat cable connector in left gripper cover, 4-21
4.100.3-17 Gripper Y/Z assembly cable in circular cut-out and Z-axis linear
rail cable in slot., 4-23
4.100.3-18 Verify cables are clear of rotating components, 4-23
4.100.3-19 Installed Covers, 4-24
4.100.5-1 Corner cap and screws, 4-30
4.100.5-2 Remove diffuser lenses, 4-30
4.100.5-3 , 4-31
4.100.5-4 , 4-31
4.100.5-5 , 4-32
4.100.5-6 , 4-32
4.100.5-7 Reinstall corner caps, 4-33
4.200.1-1 Magnet top cover set screw, 4-35
4.200.2-1 MC Arm Board Bracket Cover, 4-38
4.200.2-2 MC Pod Connections, 4-38
xxiv
Illustrations
4.200.2-3 MC Pod Encoder Cable Clips, 4-39

4.200.2-4 MC Pod Mounting Screws, 4-39
4.200.2-5 MC Pod Encoder Cable Clips, 4-40
4.200.3-1 D-Axis Ball Screw Assembly, 4-41
4.200.3-2 Top Magnet cover set screw, 4-42
4.200.3-3 Z pulley cover with brake assembly, 4-42
4.200.3-4 Nut and washer at bottom of D-axis ball screw assembly, 4-43
4.200.3-5 Screws on front linear rail and linear bearings, 4-43
4.200.3-6 Top and bottom motion board bracket screws, 4-44
4.200.3-7 D-axis nut screws, 4-45
4.200.3-8 D-Axis ball screw assembly, 4-45
4.200.3-9 D-axis motor pulley set screw, 4-46
4.200.3-10 Putting belt on pulley and D-axis gear, 4-46
4.200.3-11 Add D-axis stroke plate & insert nut and washer on D-axis ball
screw, 4-47
4.200.3-12 Move D-axis stroke plate to max position, 4-47
4.200.3-13 Tighten D-axis nut flange, 4-48
4.200.3-14 Route E-Chain cable ends, 4-48
4.200.3-15 Motor Connectors, 4-49
4.200.3-16 Left and front view, 4-49
4.200.3-17 Datum edge of bearing, 4-49
4.200.3-18 Top plate, yoke plate, interface plate, 4-50
4.200.3-19 Tighten bottom screws, move yoke, tighten upper screws., 4-50
4.200.3-20 Move yoke all the way up and tighten top screws, 4-51
4.200.3-21 Move yoke plate down and tighten bottom screws at top of
rail, 4-51
4.200.3-22 Reconnect the brake assembly to the E-chain cable, 4-52
4.200.4-1 MC Pod underside and alignment brackets, 4-53
4.200.4-2 Pod alignment bracket screws, 4-54
4.200.4-3 Pod alignment bracket screws, 4-54
4.400.1-1 Span-8 Y-Axis Adjustment Screws, 4-59
4.400.1-2 Span-8 X-Axis Adjustment and Lock Screws, 4-60
4.400.1-3 Uncheck Finish step., 4-62
4.400.1-4 Probe 1 aligned with cross hairs of a well, 4-62
4.400.1-5 Probes aligned with cross hairs of a well, 4-63
4.400.1-6 Inspect alignment of all eight probes, 4-64
4.400.2-1 Remove Alignment bracket & screws, 4-68
4.400.2-2 Remove the locking nut from the aluminum bracket, 4-68
xxv
Illustrations
4.400.2-3 Loosen X adjustment screw and washers. Do not remove., 4-69

4.500.1-1 Bulkhead Connections, 4-78
4.500.1-2 Remove the Gripper Assembly Back Plate From the Bridge
Assembly, 4-78
4.500.1-3 Loosen the Alignment Screws Securing the Gripper Assembly To
the Bridge, 4-79
4.500.2-1 Rotate the Gripper Housing., 4-82
4.500.2-2 Remove the Gripper Grip Motor From the Upper Gripper
Housing, 4-82
4.500.2-3 Twist the Lower Gripper Housing 90°, 4-83
4.500.2-4 Remove the Gripper Belt From the Rotate Motor Pinion, 4-83
4.500.2-5 Remove the Lower Gripper Assembly From the Upper Gripper
Assembly., 4-84
4.500.2-6 Remove the Bearing Stopper Screw From the Right Gripper
Finger Rack Assembly., 4-84
4.500.2-7 Slide the Gripper Finger Rack Assemblies Away From the Grip
Motor Pinion, 4-85
4.500.2-8 Remove the Grip Motor Mounting Screws, 4-85
4.500.3-1 Remove the Gripper Finger Screws, 4-87
4.500.3-2 Gripper fingers, 4-88
4.500.3-3 Gripper Pad Correct Orientation, 4-89
4.500.4-1 Locate the Motion Control Board, 4-92
4.500.4-2 Disconnect the Cables from the Motion Control Board, 4-92
4.500.4-3 Remove the Screws Securing the Motion Control Board, 4-93
4.500.5-1 Locate the Motion Control Board, 4-96
4.500.5-2 Disconnect the Cables from the Motion Control Board, 4-96
4.500.5-3 Remove the Screws Securing the Motion Control Board, 4-97
4.500.6-1 Lower the Gripper Assembly., 4-99
4.500.6-2 Disconnect the Gripper Rotate Motor, 4-100
4.500.6-3 Remove the Gripper Rotate Motor From the Upper Housing
Assembly, 4-100
4.500.6-4 Gripper rotate motor and pinion oriented with motor ribbon to
the left, 4-101
4.500.7-1 Disconnect grip motor gripper adapter board, 4-103
4.500.7-2 Rotate lower gripper housing to be parallel to upper gripper
housing, 4-104
4.500.7-3 Motor Pinion and Belt, 4-104
4.500.8-1 Bulkhead Connections, 4-108
4.500.8-2 Remove the Gripper Assembly Back Plate From the Bridge
Assembly, 4-108
xxvi
Illustrations
4.500.8-3 Loosen the Alignment Screws Securing the Gripper Assembly To

the Bridge, 4-109
4.500.9-1 Disconnect the Grip Motor, 4-112
4.500.9-2 Bearing Retaining Screws, 4-112
4.500.9-3 Twist the Lower Gripper Housing 90°, 4-113
4.500.9-4 Remove the Gripper Belt From the Rotate Motor Pinion, 4-113
4.500.9-5 Remove the Lower Gripper Assembly From the Upper Gripper
Assembly, 4-114
4.500.9-6 Remove Gripper Finger Spring, 4-114
4.500.9-7 Remove the Bearing Stopper Screw From the Right Gripper
Finger Rack Assembly, 4-115
4.500.9-8 Slide the Gripper Finger Rack Assembly Away From the Grip
Motor Pinion, 4-115
4.500.9-9 Remove the Grip Motor, 4-116
4.500.9-10 Remove screws holding rotate motor pulley to lower housing
assembly, 4-116
4.500.9-11 Remove Grip Finger Linear Bearings from Lower Housing
Assembly, 4-117
4.500.10-1 Disconnect the Y-Axis Motor Cable, 4-119
4.500.10-2 Y-Axis Motor, 4-120
4.500.11-1 Remove the Idler Pulley and Loosen the Y-Axis Belt., 4-121
4.500.11-2 Loosen screw securing Y-axis belt to the vertical housing
assembly, 4-122
4.500.12-1 Remove the Y-Axis Idler Pulley., 4-1
4.500.13-1 Loosen the Set Screws to Remove the Vertical Housing
Assembly, 4-4
4.500.14-1 Lower the Gripper Assembly, 4-8
4.500.14-2 Loosen the Z-Motor Coupler From the Z-Axis Motor., 4-8
4.500.14-3 Remove the Z-Axis Motor Bracket From the Gripper Plate., 4-9
4.500.14-4 Disconnect the Z-Axis Motor Power and Encoder Cable
Assembly, 4-9
4.500.15-1 Disconnect Rotate Motor, 4-1
4.500.15-2 , 4-2
4.500.15-3 , 4-2
4.500.15-4 Clip cable tie, 4-3
4.500.15-5 , 4-3
5.100.1-1 Home All Axes, 5-5
5.100.1-2 Homing confirmation dialog, 5-6
5.100.2-1 Select Deck and Pod, 5-9
5.100.2-2 Selecting Accuframe Position, 5-10
xxvii
Illustrations
5.100.2-3 Attach 4-post Framing Tool, 5-10

5.100.2-4 4 Post Warning, 5-10
5.100.2-5 MC Pod Alignment Values, 5-11
5.100.4-1 Large Rod Test, 5-32
5.100.4-2 Extend one inch into instrument space, 5-34
5.100.4-3 Camera bracket mouniting screw, 5-34
5.100.4-4 Small Rod DetectionTest, 5-35
7.2-1 Light Curtain Indicator LED, 7-3
7.2-2 Onboard Potentiometer, 7-3
7.2-3 Potentiometer resistance measurement points, 7-4
7.2-4 White Plastic Card Guides, 7-4
7.2-5 Black Plastic Spring Clips, 7-5
7.2-6 Bottom Edge of Door, 7-5
7.2-7 Black Masking Piece, 7-7
7.2-8 Light Curtain Boards Seated Between Dowel Pins, 7-7
7.2-9 Pink Wires Connected to GND, 7-8
7.2-10 Chassis Board Connection, 7-8
7.2-11 Pink Cables Connect to GND, 7-9
7.2-12 Jumper on OUTPUT 8 pin header, 7-9
7.2-13 Right Side Emitter Board Jumper set in F position, 7-10
7.2-14 Left Side Emitter Board Jumper set in G position, 7-10
7.2-15 DIP switch, 7-11
7.3-1 Services Window, 7-15
xxviii
Tables
Tables
1.1-1 Additional Reference Material, 1-1

1.1-2 Customer Documents Available, 1-1
2.3-1 Electrical Components and Requirements, 2-11
2.3-2 Integrated Devices Electrical Requirements, 2-11
2.3-3 Chassis Board Power Distribution Table, 2-17
2.3-4 Chassis Board LED Status Lights, 2-18
2.3-5 Transport Supervisor Board LED Status Lights, 2-19
2.3-6 Motion Board LED Descriptions, 2-22
2.3-7 Syringe Pump Controller Board, 2-24
3.29-1 Transfer Station Parameters, 3-108
3.37-1 Transfer Station Parameters, 3-131
3.42-1 Cytomat MPH SILAS Module Commands, 3-152
4.100.1-1 Instrument Connection Troubleshooting, 4-3
5.000.1-1 Preventive Maintenance Checklist- General, 5-1
5.000.1-2 Preventive Maintenance Checklist- Modules, 5-2
5.000.1-3 Verification Procedures, 5-3
5.100.3-1 Single Service Checkout Methods, 5-13
5.100.4-1 Instrument Function Checklist Procedures, 5-27
xxix
Tables
xxx
CHAPTER 1
Introduction
1.1 Manual Description
Scope
This manual provides the reference information and procedures needed for installing, repairing,
and maintaining the Biomek i-Series Laboratory Automated Workstation. It is available in AirWatch
in PDF format.
Table 1.1-1 Additional Reference Material
For information on... See... PN

Installing the Shaking Peltier Shaking Peltier ALP Integration Manual A93393
Installing the Static Peltier Static Peltier ALP Integration Manual A93392
Customer Documents
This manual is to be used in conjunction with any customer documents for the instrument and does
not contain information and procedures already covered in them. Table 1.1-2 lists the customer
documents that are available now or will be available.
Table 1.1-2 Customer Documents Available
Document Language PN
Biomek i-Series Automated Workstations Instructions for Use English B54473
French B54527
Italian B54529
German B54528
Spanish B54535
Portuguese B54532
Russian B54533
Japanese B54530
Chinese B54534
Korean B54531
B54476AB 1-1
IntroductionManual Description
Table 1.1-2 Customer Documents Available
Document Language PN
Biomek i-Series Automated Workstations Safety Manual English B79871
Chinese
French
German
Spanish
Italian
Biomek i-Series Automated Workstations Pre-installation Manual English only B54472
Biomek i-SeriesAutomated Workstation Hardware Reference English only B54474
Manual
Biomek Software for Biomek i-Series Automated Workstations English only B56358
Reference Manual
Biomek i-Series Automated Workstations Tutorials English only B54475
Biomek i-Series Automated Labware Positioners, Accessories & English only B54477
Devices Instructions for Use
Automated Labware Positioners (ALPs) Instructions For Use English only 987836
Cytomat Device and Conveyor ALP Instructions for Use English only B91265
Static Peltier ALP Integration Manual for Biomek FX/FXP, NX/NXP, English only 93392, Rev. AC and
and i-Series Instruments up
Shaking Peltier ALP Integration Manual for Biomek FX/FXP, English only 93393, Rev AC and
NX/NXP, and i-Series Instruments up
SAMI EX Software for Biomek i-Series Automated Workstations English B58997
Instructions For Use
Chinese B58998
French B58999
SAMI EX Software for Biomek i-Series Automated Workstations English Only B59001
Reference Manual
Service Manual Updates

Any Service Mod that affects the information in this manual will include a Notice of Information
Update form for this manual. A Notice of Information Update form will summarize the changes and
will list the specific headings, figures, and tables affected.
1-2 B54476AB
1.1 Manual Description 11
Intended Audience
To use this manual effectively, you need the following:
• An operator’s knowledge of the Biomek i-Series Laboratory Automated Workstation and
Biomek Software v5.0 or later.
• Beckman Coulter authorized service training on the Biomek i-Series Laboratory Automated
Workstation.
• A thorough understanding of
— Basic electronic principles and devices
— Liquid handling terms and concepts
— Microsoft Windows 10 Operating System
— Troubleshooting concepts and techniques
• The ability to –
— Read electronic schematics and understand related terminology.
— Use a digital multimeter (DMM), torque drivers, a Breco-Flex meter, and an oscilloscope.
— Use basic mechanical tools and understand related terminology.
Organization
The material in this manual is organized into eight chapters, appendices, a list of abbreviations, and
a glossary.
To make it easier to access the information:

• In the HTML version, each screen has -
— A Contents button linked to a master table of contents. The master table of contents
includes links to:
· A list of illustrations.
· A list of tables.
• In the PDF version -

— Bookmarks linked to the main headings are listed on the left side of the screen.
— A master table of contents (including master lists of the illustrations and the tables) is
included at the beginning of the manual and an alphabetic index at the end.
CHAPTER 1, Introduction, includes a brief description of this manual, a list of supporting
documents, and essential safety information.
CHAPTER 2, Instrument Description, includes an introduction to the instrument with the function
and location of each major component, an explanation of the instrument’s operation by system, and
available options.
CHAPTER 3, Installation Procedures, contains the procedures used to install the Biomek i-Series
Laboratory Workstation and Windows 10 Automation Controller.
B54476AB 1-3
CHAPTER 4, Service and Repair Procedures, contains the procedures used to service and repair the
instrument. Each procedure includes a purpose, a list of needed tools and supplies, instructions, and
a verification procedure.
CHAPTER 5, Preventive Maintenance and Verification Procedures, contains the procedures used to
maintain the Biomek i-Series Automated Workstation and to verify the system is operating
correctly.
CHAPTER 6, Schematics, provides document part numbers for the engineering schematics,
diagrams, and layouts needed for servicing the Biomek i-Series Laboratory Workstation; if you
choose to print this manual, you can insert the schematics here.
CHAPTER 7, Troubleshooting, contains problem descriptions, including a comprehensive list of

error messages, with troubleshooting actions and tips. Use the information in this chapter in
conjunction with the procedures in Chapter 4 to locate and correct instrument problems.
CHAPTER 8, Parts Lists, contains a pointer to the location of the list of part numbers of the field
replaceable components (FRC) and field replaceable units (FRU) available for the Biomek i-Series
Automated Workstation.
Abbreviations contains a list of abbreviations, acronyms, and reference designators either used in
this manual or related to the information in this manual.
Glossary contains a collection of specialized terms, with their meanings, either used in this manual
or related to the information in this manual.
Numbering Format
Each chapter of this manual is further divided into topics that are numbered sequentially, beginning
at one. The numbering format for the topic heading, which is called the primary heading, is chapter
number, decimal point, topic number. For example, the primary heading number for the fifth topic
covered in Chapter 2 is 2.5.
The service procedures in Chapter 4 follow the same pattern, but they are grouped by general
procedures and serviceable modules, adding one more level to the numbering format. For example,
the primary heading number of the first topic in the third group of procedures covered in Chapter 4
is 4.300.1.
The figure and table numbers are tied directly to the primary heading number. For example, the
first figure under Heading 2.5 is Figure 2.5-1 and the first table under Heading 2.5 is Table 2.5-1. In
Chapter 4, the first figure under Heading 4.3000.1 is Figure 4.300.1-1.
NOTE In the PDF version, primary headings always begin on the top of a right-hand page.
Signal Words and Special Headings

Throughout this manual DANGER, WARNING, CAUTION, IMPORTANT, and NOTE headings are used
to indicate potentially hazardous situations and important or helpful information.
1-4 B54476AB
1.1 Manual Description 11
DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could
CAUTION
CAUTION indicates a potentially hazardous situation, which, if not avoided, may
result in minor or moderate injury. It may also be used to alert against unsafe
practices.
IMPORTANT
The signal word IMPORTANT is in bold-face and the associated text (in this example the definition
of IMPORTANT) is indented if the text wraps to one or more lines following the first line.
IMPORTANT IMPORTANT is used for comments that add value to the step or procedure being performed.
Following the advice in the IMPORTANT adds benefit to the performance of a piece of equipment or to
a process.
NOTE
The signal word NOTE is in bold-face and associated text (in this example the definition of NOTE) is
indented if it wraps to one or more lines following the first line.
NOTE NOTE is used to call attention to notable information that should be followed during installation, use,
or servicing of this equipment.
Conventions
This manual uses the following conventions to make the material clearer and more concise. An
example is given below each explanation.
• Selections that appear on a screen are in bold face.
• Information that is to be typed (entered) is in bold face and italics font.
• Keys on the Windows 10 Automation Controller or on a laptop computer are boxed, like
this: (F4) .
• The software path to a specific function or screen appears with the greater than (>) symbol
between succeeding screen options, like this: Select Control Panel > Network and Sharing.
B54476AB 1-5
• When the word “select” is used in conjunction with a screen and the associated buttons on the
screen, you are to press the buttons on the touch screen or click on the buttons with the mouse,
as necessary, to display the desired screen or to initiate the desired function.
NOTE The verb “press” is reserved for mechanical switches such as keys on a keyboard and buttons on
an instrument.
• Links that display a “fly-over” on the screen in the HTML version of the document are green and
are underlined.
• Links to information in another part of the document for additional information are in blue and
are underlined. To access the linked information, select the blue underlined text.
• For quicker access, the material is divided into many small sections (electronic files).
— Every primary heading is a separate file and whenever possible the amount of material
contained within one primary heading is limited to four to ten pages.
— If a primary heading must be large, invisible breaks are added to the HTML version to
further divide it.
NOTE These breaks are only apparent if you are scrolling through a section. Use the Previous and Next
options on the navigation bar to move from one section (electronic file) to the next in the HTML
version of the manual.
• Unless otherwise noted, left/right orientation to components is presented as if you are looking
at the front of the instrument.
Contact Us Information
The tables of error messages and software messages in this manual include, when applicable,
corrective actions for both the customer (operator) and for service. Not infrequently the last
corrective action for the customer is to contact us for help. In a customer document, “contact
us” is a link to the following information on that document’s copyright page.
Contact Us
If you have any questions, contact our Customer Support Center.
• Worldwide, find us via our website at

www.beckmancoulter.com/customersupport/support.
• In the USA and Canada, call us at 1-800-369-0333.
• Outside of the USA and Canada, contact your local Beckman Coulter Representative.
1-6 B54476AB
Introduction
1.2 Safety Precautions 1
1.2 Safety Precautions
Special
This group of warnings concerns conditions that can affect both your immediate personal safety
and the future safety of the instrument’s operators.
WARNING
Risk of personal or operator injury. Covers and interlocks are installed on Beckman
Coulter instruments to prevent injury from operating components. If you must
remove covers or disable interlocks to service an instrument:
1. Be alert and use extreme care when working around exposed components to
avoid personal injury.
2. At the end of the service call, always reinstall ALL instrument covers and
ensure interlocks are enabled to prevent operator injury.
WARNING
Risk of personal or operator injury. Broken or cut components with sharp edges
could puncture your gloves and skin, causing possible injury or biohazardous
contamination. Handle fragile components carefully to avoid breakage. Replace
any broken or cut components with sharp edges, even if they are still functioning.
Use mechanical means, such as hemostats, to handle a broken component,
whenever feasible. Dispose of broken components in accordance with the local
regulations and acceptable laboratory practice.
WARNING
Risk of personal or operator injury. Instrument doors, covers, and panels that are
mishandled can fail, leading to personal injury. Handle the doors, covers, and
panels with care and always follow the written instructions for opening and
closing or removing and reinstalling them.
WARNING
Risk of personal injury, operator injury, or damage to instrument components.
When performing a service call, always follow all applicable service manual or
Service Mod instructions. When questions arise, consult with Technical Support
for guidance.
B54476AB 1-7
Introduction
General Safety
WARNING
Risk of personal injury. To reduce the risk of personal injury, the safety shields
must be in place before operating.
WARNING
Risk of injury. Do not attempt to enter the workspace while the Biomek i-Series
instrument is operating. The instrument operates with a force that could cause
injury if a hand is in the way during the loading of tips or other movement of the
pipetting head. Always ensure the instrument is at a full stop before entering the
work area.
WARNING
Dark non-reflective material affects the sensitivity of the light curtain and
adversely impacts its effectiveness. Typical light colored lab dress, such as lab
coats and latex gloves, do not degrade light curtain operation; however, it is
advisable to test the impact of all lab dress on light curtain sensitivity before
operating the instrument. Verify lab dress impact on light curtain sensitivity as
follows:
Use Manual Control in the software and insert the large test rod no more than 2.54
cm (1.0 in.) past and approximately 53.34 cm (21.0 in.) above the light curtain
panel at the center of the instrument. Make sure the scrolling green indicator light
changes to solid flashing red.
Additionally, the small test rod may be inserted into the top left and top right
corner of the front instrument opening so that it extends approximately 2.54 cm
(1 inch) past the light curtain. Ensure that the scrolling green indicator light
changes to solid flashing red.
CAUTION
Risk of equipment damage. The head weighs between 2.54 - 3.85 kg
(5.6 - 8.4 pounds), and is connected to the multichannel pod by four screws.
Before removing the fourth screw, take hold of the head firmly to make sure it
does not fall once all of the screws are removed.
WARNING
Risk of equipment damage. The gripper fingers could bend if not correlated
properly. Position the AccuFrame on a framed ALP in a position near the center of
the deck, and use gripper framing tools to properly correlate the grippers.
1-8 B54476AB
Introduction
CAUTION
Risk of equipment damage. Moving Span-8 probes by hand could affect alignment
and the ability to access labware. Use Manual Control to move the probes in the
Y-axis.
WARNING
Risk of personal injury. Use care when handling septa fluted tips; they are
extremely sharp.
CAUTION
Risk of equipment damage. Use care when handling septa fluted tips; they are
extremely fragile.
WARNING
Risk of personal injury or contamination. When working with blood samples or
other bodily fluids, observe the cautionary procedures as defined by your safety
officer.
CAUTION
Septa Fluted Fixed tips can pull samples into the tubing, but the maximum sample
volume is limited to syringe and tubing capacity.
CAUTION
Risk of cross-contamination. Liquid drawn into the tubes can contaminate later
fluid transfers. Use appropriate air gaps when pipetting on the Span-8 pod. Follow
the appropriate decontamination procedures outlined by the laboratory safety
officer.
CAUTION
Risk of contamination. Use labware and tip combinations labeled as ‘Limited’ with
caution. Tips could become wedged inside labware, picking the labware up with
the probe when the probe is raised.
CAUTION
To prevent damage due to electrical static discharge (ESD), wear a wrist ground
strap when working with tips on the Span-8 Pod.
B54476AB 1-9
Introduction
CAUTION
Risk of equipment damage. Operating the system without the mandrels installed
and the tubing attached to tips may cause corrosion in the tip interface. Do not
perform aspirate or dispense operations without mandrels installed and tubing
attached to fixed tips.
WARNING
Risk of contamination. Removing fixed tips poses a potential spill hazard. Wipe up
any spills immediately according to the procedures outlined by your laboratory
safety officer.
WARNING
Risk of personal injury or contamination. Use an appropriately contained
environment when using hazardous materials.
WARNING
Risk of personal injury or contamination. Do not spill liquids on or around the
instrument. Wipe up any spills immediately according to the procedures outlined
by your laboratory safety officer.
WARNING
Risk of personal injury or property damage. Always observe appropriate
cautionary procedures as defined by your safety officer when using flammable
solvents or toxic, pathological, or radioactive materials.
WARNING
Risk of personal injury or contamination. Do not touch disposable tips with bare
hands. Always wear protective gloves when removing the tips.
CAUTION
Risk of method failure. Do not overtighten the Span-8 tip shuck tube. Problems
with unloading tips may result.
WARNING
Risk of contamination. Removing the disposable tips option poses a potential spill
hazard. Wipe up any spills immediately according to the procedures outlined by
your laboratory safety officer.
1-10 B54476AB
Introduction
CAUTION
Risk of method failure. Independent pump calibration for the Span-8 will cause
validated methods to become invalidated. Previously validated methods will
require revalidation before running them.
CAUTION
Risk of pipetting errors. Air bubbles in the system fluid could inhibit pipetting and
cause errors. De-gas the system fluid by letting it rest in the supply container for
24 to 48 hours prior to attaching it to the instrument.
CAUTION
Risk of method failure or leaks. Tap water is not recommended due to high mineral
content, which could cause blockages in the tubing and increase the possibility of
leaks at tubing connections.
WARNING
Risk of contamination. The supply container poses a potential spill hazard. Wipe
up any spills immediately according to the procedures outlined by your laboratory
safety officer.
CAUTION
Risk of method failure. Kinked tubing could cause blockage, causing an
insufficient amount of fluid to be available for a method. Always inspect all hoses
thoroughly before proceeding with a method run.
WARNING
Risk of contamination. The waste container poses a potential spill hazard. Wipe up
any spills immediately according to the procedures outlined by your laboratory
safety officer.
WARNING
Risk of contamination. Kinked tubing between the waste container, the Span-8 Tip
Wash ALP, and drip tray can cause insufficiently cleaned labware or leaks. Always
inspect all hoses thoroughly before proceeding with using biological or chemical
agents. Clean up any leaks immediately according to the procedures defined by
your laboratory safety officer.
B54476AB 1-11
Introduction
CAUTION
Risk of equipment damage. Purging the system without mandrels installed and
tubing attached to disposable or fixed tips could cause corrosion in the tip
interface. Always make sure the mandrels are installed and the tubing is attached
to tips prior to purging the system.
WARNING
Risk of personal injury or contamination. Follow the appropriate decontamination
procedures outlined by the laboratory safety officer.
CAUTION
Risk of equipment damage or inaccurate results. If the hardware configuration is
not updated using Hardware Setup, hardware crashes or inaccurate liquid
transfer could occur. Always use Hardware Setup to make changes to hardware
settings.
CAUTION
Risk of equipment damage or contamination. Changing Correlate Pods can lead to
the pods physically contacting each other.
CAUTION
Risk of inaccurate pipetting. Do not choose Cancel while Test Sensitivities is in
progress; if testing is stopped before the probe sensitivities have been
completed, liquid level sensing will not function and Find Sensitivities must be
repeated.
CAUTION
Risk of affecting pipetting performance. Changing the purge settings may change
the behavior of the Span-8 pod during pipetting.
CAUTION
Risk of equipment damage. Offset gripper fingers could physically contact the
instrument or pods. Always ensure the gripper fingers are away from the front,
sides, and back of the instrument. Also ensure the gripper fingers are not rotated
towards the pod.
1-12 B54476AB
Introduction
WARNING
Risk of equipment damage. Turn off power to the instrument before attaching or
removing devices from the CAN port. Failure to do so can cause electrical shock or
equipment damage.
WARNING
Risk of equipment damage. The AccuFrame cable positioning could violate the
light curtain, which would immediately halt the framing process. Make sure that
the AccuFrame cable does not violate the light curtain.
WARNING
Risk of equipment damage. The AccuFrame cable positioning could interfere with
pod movement. Make sure the AccuFrame cable is in a location that does not
obstruct pod movement.
CAUTION
Risk of equipment damage. If the Deck layout in the software does not match the
physical layout of the deck, crashes may occur. The software deck layout must
match the actual layout of hardware on the deck. Confirm that the physical deck
configuration matches the software deck layout.
CAUTION
Risk of equipment damage. Use Shift deck only before other ALPs or positions are
taught. Shift deck shifts all ALPs and positions, resulting in incorrect coordinates
if applied to previously framed ALPs and positions.
CAUTION
Risk of equipment damage or contamination. In Biomek Software, before clicking
“OK” to home all axes, the following conditions must be met:
• Make sure no disposable tips are loaded.
• Make sure there is no liquid in fixed tips.
• Make sure the gripper is not holding any labware.
• Make sure none of the pods are near the front, back, or side of the instrument.
• Make sure that the two pods are not near each other at either end of the
instrument.
• Make sure the grippers are not rotated underneath the pods
• Gripper fingers are free to rotate when the Gripper is at Z Max
• Make sure no framing fixtures are installed on the pods.
B54476AB 1-13
Introduction
• Make sure either disposable tip mandrels or fixed tips ARE installed on the
Span-8 Pod.
Failure to do so can cause the pod to crash into other items on the
workstation, causing equipment damage and/or hazardous waste spills.
Lifting the Instrument

When preparing to move the instrument, use the supplied scissor lift cart and installation
procedure (see 3.8, Unpacking and Inspecting the Biomek i-Series Instrument).
Electrical
Equipment Ratings
• 100-240Vac
• 50/60 Hz
• 10 A
DANGER
To reduce the risk of electrical shock, the instrument uses a three-wire electrical
cord and plug to connect it to earth-ground. Make sure that the matching wall
outlet receptacle is properly wired and earth-grounded.
NOTE The power plug serves as the disconnecting device and must remain easily accessible.
Warning and Cautions
WARNING
Risk of equipment damage. Do not connect or disconnect any cables while the
instrument is on. Turn off the main power before connecting or disconnecting
cables.
WARNING
Risk of personal injury. Rings or jewelry can contact exposed electronic
components, causing personal injury from electric shock. Remove rings and other
metallic jewelry before performing maintenance or service on the electronic
components of the instrument.
1-14 B54476AB
Introduction
CAUTION
Risk of damage to electronic components. If you remove or replace a circuit board
or other electronic component while the power is ON, damage to the component
can occur. To prevent damage to circuit boards and other electronic components,
always turn OFF the power before removing or replacing the component.
Electrostatic Discharge (ESD) Protection
CAUTION
Risk of damage to electronic components. Electrostatic discharge (ESD) can
damage electronic components. Perform any procedure where there is a
possibility of ESD damage at an ESD workstation or wear an antistatic wrist strap
attached to a metallic part of the chassis connected to an earth ground.
A wrist ground strap must be attached to the instrument prior to installing or removing Span-8
pipettors or MC head.
To attach a wrist ground strap:
1. Position the strap portion of the wrist ground strap snugly around the wrist.
2. Clamp the “alligator” clip of the wrist ground strap to the instrument (see Figure 1.2-1 and
Figure 1.2-2).
3. Power up the instrument, if needed.
Figure 1.2-1 ESD strap attachment location for Span-8 Pod
1. Side Cover PEM Nuts
B54476AB 1-15
Introduction
Figure 1.2-2 ESD strap attachment location for Multichannel Pod
1. Y-Axis Interior Cover Plate
Disposal of Electronic Instrumentation
It is very important that customers understand and follow all laws regarding the safe and proper
disposal of electrical instrumentation.
The symbol of a crossed-out wheeled bin on the product is required in accordance with the Waste
Electrical and Electronic Equipment (WEEE) Directive of the European Union. The presence of this
marking on the product indicates:
1. That the device was put on the European Market after August 13, 2005 and
2. That the device is not to be disposed of via the municipal waste collection system of any
member state of the European Union.
For products under the requirement of WEEE directive, please contact your dealer or local Beckman
Coulter office for the proper decontamination information and take-back program which will
facilitate the proper collection, treatment, recovery, recycling, and safe disposal of device.
1-16 B54476AB
Introduction
Chemical and Biological
WARNING
Risk of personal injury or contamination. If you do not properly shield yourself
before servicing the instrument, you can be injured or contaminated. To prevent
possible injury or contamination, always wear personal protection equipment
(PPE), such as gloves, lab coat, and eye protection when servicing the instrument.
WARNING
Risk of contamination. Biohazardous contamination can occur from contact with
the waste container and its associated tubing if not handled with care. Wear
personal protection equipment (PPE), such as gloves, lab coat, and eye
protection. Avoid skin contact. Clean up spills immediately. Dispose of the
contents of the waste container in accordance with the local regulations and
acceptable laboratory practices.
Use universal precautions when working with pathogenic materials. Means must be available to
decontaminate the instrument and to dispose of biohazardous waste.
WARNING
Risk of chemical injury from bleach. To avoid contact with the bleach, use barrier
protection, including protective eyewear, gloves, and suitable laboratory attire.
Refer to the Material Safety Data Sheet for details about chemical exposure
before using the chemical.
If a hazardous substance such as blood is spilled onto the instrument, ALPs, or accessories, clean up
the spill and follow the laboratory’s procedure for disposal of hazardous materials.
B54476AB 1-17
Introduction
WARNING
Before running with chemical or biological samples, test new labware types to
determine if labware offsets are necessary to access the labware during pipetting
operations. If you do not do the required testing, the labware could crash and the
contents could spill if the offset is incorrect. Normal operation of the instrument
may involve the use of materials that are toxic, flammable, or otherwise
biologically harmful. When using such materials, observe the following
precautions:
• Handle infectious samples according to good laboratory procedures and
methods to prevent the spread of disease.
• Observe all cautionary information printed on the original solutions’
containers prior to their use.
• Dispose of all waste solutions according to your facility’s waste disposal
procedures.
• Operate the instrument in accordance with the instructions outlined in this
manual and take all the necessary precautions when using pathological, toxic,
or radioactive materials.
• Splashing of liquids may occur; therefore, take appropriate safety
precautions, such as using safety glasses and wearing protective clothing,
when working with potentially hazardous liquids.
• Use an appropriately-contained environment when using hazardous
materials.
• Observe the appropriate cautionary procedures as defined by your safety
officer when using flammable solvents in or near a powered-up instrument.
• Always observe appropriate cautionary procedures as defined by your safety
officer when using flammable solvents or toxic, pathological, or radioactive
materials.
WARNING
Risk of personal injury or contamination. Do not spill liquids on or around the
instrument. Wipe up any spills immediately according to the procedures outlined
by your laboratory safety officer. Always use the appropriate Personal Protective
Equipment (PPE), such as gloves, lab coat, and eye protection when handling
hazardous materials.
1-18 B54476AB
Introduction
Moving Parts
WARNING
Risk of personal injury. To avoid injury due to moving parts, observe the following:
• Never attempt to exchange labware or reagents while the instrument is
operating.
• Never attempt to physically restrict any of the moving components of the
Biomek i-Series.
• Keep the Biomek i-Series work area clear to prevent obstruction of the
movement.
Laser
Laser Beam Hazard

This symbol indicates that a potential hazard to personal safety exists from a laser source. When this
symbol is displayed in this manual, pay special attention to the specific safety information
associated with the symbol.
The laser is a unique light source that shows characteristics different from conventional light
sources. The safe use of the laser depends upon familiarity with the instrument and the properties
of coherent, intense beams of light.
Laser Specifications
• Laser Type: Class II Laser Diode
• Maximum Output: 11 mW
• Wavelength: 670 nm
WARNING
Risk of personal injury. The laser beam can cause eye damage if viewed either
directly or indirectly from reflective surfaces (such as a mirror or shiny metallic
surface). To prevent eye damage, avoid direct exposure to the laser beam. Do not
view it directly or with optical instruments except from special service tools as
directed in this manual.
Indirect contact with the laser beam from reflective surfaces (such as jewelry or a screwdriver) is
called specular reflection and might also cause damage.
For these reasons, use the following precautions when working near an exposed laser:
B54476AB 1-19
Introduction
• Never look directly into the laser light source or at scattered laser light from any reflective
surface. Never look down the beam into the source.
• As a precaution against accidental exposure to the output beam or its reflection, wear proper
laser safety glasses (as required by the wavelength being used) when performing service or
maintenance procedures on the system.
• Ensure lasers are off in the presence of flammable material or explosives; these include volatile
substances such as acetone, methanol, alcohol, solvents, and ether.
• Avoid direct exposure and indirect reflection of the laser beam to your skin. The intensity of the
beam can cause flesh burns.
• Assure that any spectators are not potentially exposed to a hazardous condition.
• Do not leave the laser unattended if there is a chance that an unauthorized person may try to
use it.
• Make the following recommendations to the laboratory:
— Limit access to the instrument. Keep the instrument out of the hands of inexperienced and
untrained personnel.
— Never remove a warning label from the instrument.
— Post warning signs at the site to alert personnel that lasers are being used.
— Advise all those using the laser of these precautions.
Laser Warning Labels

Laser Warning labels are placed near or on those covers that when removed might expose laser
radiation. Only remove these covers when performing service and maintenance on the system as
instructed in this service manual or in the Instructions for Use manual for operators.
• See Figure 1.2-3 for the label and its location on the Fly-By Bar Code Reader.
Figure 1.2-3 Fly-By Bar Code Reader Laser Warning Label location
Troubleshooting
Bring the following warning to the customer’s attention before advising that customer to perform
any service, maintenance, or troubleshooting procedures on the instrument.
1-20 B54476AB
Introduction
WARNING
Risk of personal injury or contamination. If you do not properly shield yourself
while performing service, maintenance, and troubleshooting procedures, residual
fluids in the instrument could injure or contaminate you. Beckman Coulter
recommends barrier protection, such as appropriate safety glasses, lab coat, and
gloves, be worn throughout the performance of service, maintenance, and
troubleshooting procedures to avoid contact with cleaners and/or residual fluids
in the instrument.
IMPORTANT It is the customer’s responsibility to decontaminate components of the instrument before

requesting service by a Beckman Coulter Representative or returning parts to Beckman Coulter for repair.
Beckman Coulter will NOT accept any items which have not been decontaminated where it is appropriate
to do so. If any parts are returned, they must be enclosed in a sealed plastic bag stating that the contents
are safe to handle and are not contaminated.
Also, make sure customers are aware of the warning and information labels shown in Figure 1.2-3.
B54476AB 1-21
Introduction
1-22 B54476AB
CHAPTER 2
Instrument Description
2.1 Introduction to the Biomek i-Series Automated Laboratory

Workstation
Summary
This section on the general description of the system includes:
• Instrument Overview
• System Components
• Configurations for the Biomek i-Series
• Software
Instrument Overview
The Biomek i-Series Automated Laboratory Workstation is a multi-axis liquid-handling instrument
used in life sciences or biomedical laboratory. The open-architecture design, along with extensible
software, provides a foundation for integrating current and future specific-use components. The
design of the Biomek i-Series instrument provides the foundation for continual evolution and
expansion of liquid-handling systems.
A variety of labware and hardware adapt the deck of the Biomek i-Series instrument to accomplish
multiple tasks, ranging from performing simple labware positioning and liquid transfers to
completing complex activities that typically require additional devices in the laboratory.
The capabilities of the Biomek i-Series instrument depend on the components installed, including
the arm(s), pod(s), head(s), ALPs, and third party devices.
System Components
The standard components and optional devices for the workstation are divided into three groups:
• Main Components
• Labware
• Optional Devices
B54476AB 2-1
Instrument DescriptionIntroduction to the Biomek i-Series Automated Laboratory Workstation
2.1 Introduction to the Biomek i-Series Automated Laboratory Workstation
Main Components
Refer to Figure 2.1-1 and Figure 2.1-2 for the Biomek i-Series main components. For more
information on the Biomek i-Series components refer to the Biomek i-Series Hardware Reference
Manual (B54474).
Figure 2.1-1 Biomek i7 Main Components
1. Status Light Bar 8. Deck

2. Multichannel Arm 9. Span-8 Arm (on Hybrid Instrument) or
3. Deck Observation Cameras Multichannel Arm (on dual MC arm instrument)
4. Side Panels (left and right) 10. Span-8 Pump Assembly
5. Light Curtain (Span-8 arm equipped instruments only)
6. ALPs 11. Chassis
7. Back Panels (2) 12. Deck Illumination Switch
2-2 B54476AB
2.1 Introduction to the Biomek i-Series Automated Laboratory Workstation 22
Figure 2.1-2 Biomek i7 Additional Main Components on Enclosed Version
1. Halo with 360° status light display

2. Door
Configurations for the Biomek i-Series

The Biomek i-Series instrument is available in two sizes, the Biomek i5 and the Biomek i7
instruments. Both models are available in non-enclosed and enclosed configurations.
The non-enclosed configuration includes a:
• Left side panel

• Right side panel
• Top and Bottom rear panels
• Front light curtain
• Front tower cameras
• Front status light display
The enclosed configuration includes a:
• Left side panel

• Right side panel
• Top and bottom rear panels
• Front tower cameras
• Door
B54476AB 2-3
• Halo with integrated 360° status light display
Biomek i5 Instrument
The Biomek i5 instrument includes 5 deck plates with up to 25 microplate positions, and is available
as a single arm instrument only. Different operating components can be installed on the arm, to
perform a variety of functions, depending upon desired tasks and configurations. The
configurations available for a Biomek i5 single-arm instrument are:
• One Multichannel arm with gripper

• One Span-8 arm with gripper
NOTE For detailed information on the Multichannel Pod and interchangeable heads, refer to the Biomek
i-Series Automated Workstation Hardware Reference Manual (B54474) Multichannel Pod. For
detailed information on the Span-8 Pod and probes, refer to Biomek i-Series Automated Workstation
Hardware Reference Manual (B54474) Span-8 Pod.
Biomek i7 Instrument
The Biomek i7 instrument includes 9 deck plates with up to 45 microplate positions. It is available
as a single- or dual-arm instrument. Different operating components can be installed on each arm,
providing options for performing a variety of functions sequentially or simultaneously, depending
upon desired tasks and configurations. Configurations available for the Biomek i7 instrument are:
• One Multichannel arm with gripper

• One Span-8 arm with gripper
• One Multichannel arm with gripper and one Span-8 arm with gripper (hybrid)
• Two Multichannel arms (both with grippers)
NOTE For detailed information on the Multichannel Pod and interchangeable heads, refer to the Biomek
i-Series Automated Workstation Hardware Reference Manual (B54474) Multichannel Pod. For
detailed information on the Span-8 Pod and probes, refer to Biomek i-Series Automated Workstation
Hardware Reference Manual (B54474) Span-8 Pod.
Software
Biomek Software
The workstation is controlled through the Biomek Controller using Biomek Software. Biomek
Software is a linear step-based method building application used to construct automated methods
to perform an assay.
2-4 B54476AB
2.1 Introduction to the Biomek i-Series Automated Laboratory Workstation 22
Biomek Software Requirements

To run Biomek Software 5.0, a workstation with the following system specifications is required:
• Biomek i-Series Automation Controller

• SQL Server 2014 SP2
• Beckman Coulter Accounts and Permissions, version 3.2.0.
• SILAS, version 4.1.2.2 or higher
Refer to the Biomek i-Series Automated Workstations Instructions for Use Manual (B54473) for more
information.
SAMI EX Software
SAMI EX Software is a flexible software package designed to provide complete automation and
process control for Integrated Workstations. SAMI EX Integrated Workstations are operated from
the host computer using SAMI EX Software. SAMI EX Software is tightly integrated with Biomek
Software.
SAMI EX Editor Software is used to write methods. Methods are configured using graphical
representations of labware, desired actions, and scientific constraints. The software then
automatically plans the actions in an appropriate sequence, manages the resources to complete the
actions a specified number of times, and creates a schedule to effectively complete the actions.
SAMI EX Software Requirements

To Run SAMI EX Software, a workstation with the following system specifications is required:
• Biomek i-Series Automation Controller

• Biomek Software v5.0 or later
• USB Keylock Hardware Key programmed for SAMI EX v5.0 or later compatible with the Biomek
Software version.
B54476AB 2-5
2-6 B54476AB
2.2 Standard Components 2
2.2 Standard Components
For detailed information of the Biomek i-Series components, refer to the Biomek i-Series Hardware
Reference Manual (B54474).
Chassis
The Biomek i-Series instrument chassis is the structural frame of the instrument. It provides mount
points for the Deck, Enclosure, X -Axis, and Syringe Pump Bank, if installed. The X-Axis supports the
width of the back and front of the instrument. Arms are attached to the X-Axis support.
The Chassis has leveling feet that allow it to sit on a variety of lab benches and carts. The base has
multiple openings to allow for integration from below the instrument to the Deck, when deck plates
are removed.
All power and communication interfaces are mounted to the chassis. External power and USB
connectors are on the outside of the right back tower. Internal USB and CAN ports are available on
the inside of both back towers.
The chassis contains these main components and connections:
• Front and rear towers

• X-axis linear rail travel plate
• Power supply
• Chassis Board (power and communication distribution)
• Deck observation system
• Interior deck lighting
Arms
The Biomek i-Series arms are self contained structures mounted on the front and back X-axis
supports. An arm holds a Multichannel or Span-8 pod, and enables movement of the pod in the X-
and Y-axes.
There are two types of arms available for the Biomek i-Series instruments:
• Multichannel arm
• Span-8 arm
The operation of the arms, grippers, heads, pods and probes are controlled by Biomek Software
from the Biomek i-Series controller.
B54476AB 2-7
Gripper
Each arm includes a 360° rotating gripper with offset fingers that grasps and moves labware onto,
off of, and within the Biomek i-Series instrument. The grippers can travel in the Y- and Z-axes
independent of the pod or probes.
Deck
The deck is the work surface of the Biomek i-Series instrument. It attaches to the chassis and
provides a mounting surface for accessories such as Labware Positioners, Process Elements,
Mounting Plates, and Trash and Wash ALPs. The deck consists of easily attachable and removable
deck plates that mount to the chassis via dowel pins and can be secured by screws. The i7 deck
includes 9 full deck plates. The i5 includes 5 full deck plates. The full deck plates have holes
(mounting points) predrilled in a grid pattern of seven columns and 30 rows which are used to
specify the location of accessories on the deck, and within the software deck editor user interface.
The i5 and i7 also have two extension plates. The extension plates are predrilled with five columns
of 30 rows each.
ALPs
Automated Labware Positioners (ALPs) are removable and interchangeable platform structures that
are installed on the i-Series deck to allow automated assays to be performed. There are two types of
ALPs available for the Biomek i-Series instruments:
• Passive ALPs
• Active ALPs
All ALPs mount to the deck using dowel pins for positioning, and a captive thumbscrew to fasten the
ALP to the deck. Biomek i-Series-designed ALPs mount directly to the deck. Legacy Biomek FXP/NXP
ALPs require a mounting plate adapter to mount them to the deck. Mounting plates will attach to
the deck using dowels pins for positioning and screws for attaching the plate to the deck. Legacy
Biomek FXP/NXP ALPs will attach to the mounting plates, either with pins for locating and thumb
screws for fastening, or in the case of the Orbital Shaker ALP, just pins to locate and position on the
mounting plate.
Refer to:
• Biomek i-Series Cytomat ALP and Devices User Manual (PN B91265)
• Biomek i-Series Automated Labware Positioners, Accessories, & Devices Instructions for Use
(PN B54477)
• Automated Labware Positioners (ALPs) Instructions For Use (PN 987836)
• Static Peltier ALP Integration Manual for Biomek FX/FXP, NX/NXP, and i-Series Instruments
(PN A93392, Rev. AC and up)
• Shaking Peltier ALP Integration Manual for Biomek FX/FXP, NX/NXP, and i-Series Instruments
(PN A93393, Rev. AC and up)
2-8 B54476AB
2.2 Standard Components 2
Deck Observation System

The Deck Observation System consists of two wide angle cameras installed on the front towers, that
allow remote viewing of the deck as the instrument operates.
IMPORTANT The cameras may capture images of individuals in the lab if they are in range. The instrument
owner is responsible for compliance with any applicable laws, rules, or regulations, including privacy and
data protection laws, regarding the use of these features.
Protective Barriers
A perimeter protective safety system that is standard in all Biomek i-Series instruments. It helps
protect against operator injury, damage to the equipment, and interruptions during the liquid-
handling process.
This safety system includes transparent safety shields along the left, right, and back sides of the
instrument. It also includes a Light Curtain Protection System, a diffuse-reflective light curtain that
runs along the front of the instrument. When a part of the human body, or an object larger than
approximately 2.54 cm (1.0 in.) in diameter (such as labware and large cables), penetrates this
protective zone, the instrument immediately stops operating, stopping all arm, pod, and head
movements. Some ALP operations, such as shaking, may continue.
On a configuration with enclosure, a vertically sliding front door allows access to the instrument.
Opening or closing the door does not affect the light curtain operation. A halo encloses the top of
Biomek i-Series instrument and protects the instrument from particulates. A status indicator light
bar is installed on the halo and is visible on all sides of the instrument.
Status Indicator Light Bar

On an open system a status indicator bar with green, blue, yellow, and red indicator lights, is built
into the top front X-axis support, and indicates the current operational status of the Biomek i-Series
instrument and light curtain.
Interior Deck Lighting

Integral LED deck lighting is installed along the rear X axis of the instrument to improve visibility
in the workspace. It is controlled by an on/off switch on the right side of the instrument.
Enclosures
There are two enclosure types: Open Enclosure and Closed Enclosure. The Open Enclosure consists
of back and side panels. The Closed Enclosure adds a door and a top panel, or halo. Safety is provided
by a light curtain at the front of the instrument of all models.
The side and back panels allow interface points for external integrations. The top panel can support
a top-mounted HEPA filter.
A display light at the top edge of the Closed Enclosure instrument provides a status display that is
easily visible 10 feet away all around the instrument. A display light at the top front of the Open
B54476AB 2-9
Enclosure instrument provides a status display that is easily visible from 10 feet away from the front
of the instrument.
2-10 B54476AB
2.3 Electronics and Wiring 2
2.3 Electronics and Wiring
The Biomek i-Series Laboratory Automated Workstation is equipped with a Power Supply that
distributes regulated power to the system.
Command, Control, and Communication

The Automation Controller supplied with the instrument communicates with the Biomek i-Series
instrument through USB 2.0 communication. Commands from the Biomek Software pass through a
Chassis board that provides both CAN and USB. CAN communication is used to communicate with
the AccuFrame and to Legacy Biomek FXP/NXP Active ALPs. USB communication is used to
communicate with the rest of the instrument including instrument arms, tower cameras, and future
expansion to USB-operated devices.
Electrical Requirements
Verify that the proper electrical supply to the Biomek i-Series Laboratory Automated Workstation
and any accessories requiring power is available. Table 2.3-1 defines the electrical requirements for
the instrument.
TIP Connecting the instrument to an uninterruptible power source (UPS) is recommended for preventing
unexpected power failures.
Table 2.3-1 Electrical Components and Requirements
Electrical Component Electrical Requirements

Base Unit 100-240 VAC @ 9 amps max
Automation Controller 100-240 VAC @ 2.5 amps min.
Monitor 100-240 VAC @ 1 amp min
I/O Box 100-240 VAC @ 6.3 amps max
Table 2.3-2 Integrated Devices Electrical Requirements
Electrical Component Electrical Requirements

Cytomat Microplate Hotel (MPH) 100-230 VAC @ 0.7 amps
Cytomat 2C 100-120 VAC @ 6 amps
230 VAC @ 6 amp
Conveyor ALP 100-240 VAC @ 1.2 amps
Circulating Reservoir/Tip Box ALP 115 VAC @ 1.5 amps
220 VAC @ 0.8 amps
Fly-By-Bar Code Reader (FBBCR) US: 100-240 VAC @ 6 amps max
Europe: 200-240 VAC, 50 Hz
NOTE All AC devices are at 50/60 Hz
B54476AB 2-11
System Architecture
Figure 2.3-1 System Architecture
2-12 B54476AB
Figure 2.3-2 Board Block Diagram - i7 Hybrid
Power is distributed from the power supply to the chassis board at 36V (17.89A max),
24V (6.25A max), and 5V (22A max).
USB type B connector will be used to connect the chassis board to the master controller (host
connection).
Each arm is connected to the chassis board with an E-chain and 2 USB type A connectors. The USB
type A connectors will connect to the transport supervisor board located on each arm and will
deliver power for CAN to the Span-8, AccuFrame ALP, arm ID, and safety system. The power lines on
the connector include 36V, 36V interlocked, and 5V. Each power line shall route through an
appropriately rated slow-blow fuse. Each E-chain is capable of providing a unique arm ID for the
chassis board.
There are two tower boards connected to the chassis board. Cables run across the top of the X-Axis
and down through the chassis towers. Each tower connector shall provide 36V switched, 36V
interlock STATUS signal, and the CAN for ALPs.
AccuFrame will be connected to the chassis board through a cable that runs across the top of the
X-Axis and down through the left back tower. The connector shall be provided 36V switched and 5V
power along with CAN messages from the transport supervisor board to the AccuFrame.
The syringe pump bank connector shall be connected to the chassis board through a cable that runs
across the top of the X-Axis and down through the right back tower. The connector shall be provided
24V switched power and CAN messages from the transport supervisor board to control the syringe
pump bank for operating the Span-8 pod.
The light curtain connector shall be connected to the chassis board through a cable that runs across
the top of the X-Axis and down through the right front tower. The light curtain segments are
connected to each other and terminated on the light curtain emitter board located on the front left
tower. The connector shall route 22V power and logic signals from the chassis board to the safety
light curtain.
The status bar strip will connect to the chassis board through (a quadrant connector(s) located in
the front right (and left) tower(s) through a cable connected to the back right (and left) tower(s) to
B54476AB 2-13
the chassis board). The chassis board will supply 5V fused power to and will carry logic signals for
the LED strip(s).
There are four quadrant connectors located on the chassis board that may lead to the top four
corners of the instrument. Each quadrant connector contains 3.3V and pins for possible
connections for environmental sensors or other devices. Interlock signals, option device
communication, and 24V pins and return paths are all provided through these connectors.
Chassis Board
The key functions of the chassis board include:
• power switching and distribution

• communication distribution
• safety system
• status bar control
• deck light control
• deck light switch
Figure 2.3-3 Chassis Board block diagram
2-14 B54476AB
Figure 2.3-4 System view of chassis board
Figure 2.3-5 System view of chassis board - view 2
The chassis board is located in the top, back of the instrument (Figure 2.3-6). The board is mounted
to a chassis board mounting plate assembly. The mounting plate assembly uses guide pins to locate
the assembly to the rear span plate on the chassis, and then captive thumb screws are used to secure
the span plate to the chassis board mounting plate assembly. The chassis board takes power voltage
from the power supply and data from the host controller and routes them to boards on the
instrument (Table 2.3-3). The chassis board is also responsible for containing the main safety
systems for the instrument. The chassis board acts as the controller for the deck and status lights,
and the board monitors voltage rail status and environmental sensors.
B54476AB 2-15
Figure 2.3-6 Chassis Board Mounting location
2-16 B54476AB
The chassis board takes in 36V, 24V, and 5.2V from the power supply. These main voltages are
branched off and routed through on-board relays and switches. There are 9 power rails on the board
(see Table 2.3-3)
Table 2.3-3 Chassis Board Power Distribution Table
Current Usage and/or Output

Power Limit Function Connector
36V 25A May be used by the legacy Span E-chain Connectors (J5, J7)
Pod (16 Axis Board and LLS
Board).
Also routed through relays for
36V Interlocked and 36V
Switched
36V Interlocked 15A The interlock physically cuts 36 V E-chain Connectors (J5, J7),
power when either the light Tower Connectors (J6, J8)
curtain breaks or software tells it
to cut power.
Physically cutting power is
important because it ensures the
system is incapable of moving
any motors, even if a
communication break or defect
causes a motion board to attempt
movement.
Primarily used to drive all motors
on the Biomek instrument.
May also b e used for power on
certain ALPs
36V Switched 10A May be used for power on the Tower Connectors (J6, J8),
AccuFrame and other ALPs AccuFrame connector (J12)
24V 10A Regulated down to a digital 5V
power source for the on-board
barometric sensor
Also routed through mosfets for
24V Switched
24V Switched 10A Power for i-Series instrument Quadrant Connectors
status lights and the Syringe (J3, J4, J9, J10)
Pumps. Syringe Pump Connector
Also regulated down to 22V. (J11)
22V 1.5A Power and data for the Safety Light Curtain Connector
Light Curtain. (J14)
B54476AB 2-17
Table 2.3-3 Chassis Board Power Distribution Table (Continued)
Current Usage and/or Output

Power Limit Function Connector
5V 20A General logic power supply for General logic power supply
the chassis board, as well as other Echain Connectors (J5 & J7),
downstream boards connected
through the chassis board. Tower connectors (J6 & J8),
AccuFrame Connector (J12),
Status Bar Connector (J17),
UART Connector (J25)
3.3V 1.5A General logic supply for the General logic power supply,
chassis board. Quadrant Connectors
(J3, J4, J9, J10)
There are 13 status LEDs located on the Chassis board.
Table 2.3-4 Chassis Board LED Status Lights
Status LED Type Description

Interlock Signal System-wide interlock signal status. When the interlock is
tripped, the LED will turn ON.
36V Power When the 36V is present, the LED will turn ON.
36V_INLK Power When the interlocked 36V is present, the LED will turn ON.
36V_SW Power When the switched 36V is present, the LED will turn ON.
24V_SW Power When the switched 24V is present, the LED will turn ON.
3V3 Power When the 3.3V is present, the LED will turn ON.
LC_VREG Power When the LC_VREG, the 22V power supply to the light
curtain is present, the LED will turn ON.
CAN1_DEBUG1_LEDR Debug Debug signal for CAN, programmable as a GPIO on the
microcontroller.
CAN1_DEBUG2_LEDG Debug Debug signal for CAN, programmable as a GPIO on the
microcontroller.
CAN0_DEBUG3_LEDR Debug Debug signal for CAN, programmable as a GPIO on the
microcontroller.
CAN0_DEBUG4_LEDG Debug Debug signal for CAN, programmable as a GPIO on the
microcontroller.
2-18 B54476AB
Transport Supervisor Board

The transport supervisor board is a service breakout board that supplies power and communication
to each arm from the chassis board. The chassis board provides 5V, 36V, and 36V interlocked power
lines that is distributed by the transport supervisor board to downstream motion boards. The
transport supervisor board also provides an interlock signal that indicates whether or not a safety
fault has occurred.
The transport supervisor board also provide CAN communication to low-speed CAN and high-speed
CAN nodes.
The transport supervisor board provides a USB 2.0-compliant interface to at least three downstream
USB devices (currently not in use).
Figure 2.3-7 Transport Supervisor Board Block Diagram
There are nine status LEDs present on the transport supervisor board.
Table 2.3-5 Transport Supervisor Board LED Status Lights
LED Monitor Signal Logic Description

Interlock Active Low When the interlock is tripped, the LED will turn ON.
Interlocked 36V Active High When the interlocked 36V is present, the LED will turn ON. If
the voltage level drops below 30V, the LED will turn OFF.
36V Active High When the 36V is present, the LED will turn ON. If the voltage
level drops below 30V, the LED will turn OFF.
B54476AB 2-19
Table 2.3-5 Transport Supervisor Board LED Status Lights
LED Monitor Signal Logic Description

5V Active High When the 5V is present, the LED will turn ON.
3.3V Active High When the 3.3V is present, the LED will turn ON.
CAN1 Debug 1 Active High Firmware-defined functionality
The Transport Supervisor board is uniquely addressed through an in-harness addressing scheme.
This means that the board is assigned its address based on the physical location. No jumpers or
switches are required.
Upon replacing a Transport Supervisor Board and powering on the system, the board will be
initialized and checked for firmware. If no firmware or outdated firmware is found for the replaced
board, the system (through master controller embedded in software) will update the board with
firmware and will recognize the unique address of the board.
Motion Board
Figure 2.3-8 Motion Board Layout
The motion board supplies power and communication to each motor and receives feedback from
each motor encoder. The motion board supports one to two 2-phased stepper motors, one to two
brushed motors, or 1 three-phase brushless motor. The motion board supplies 5V for logic power
and supplies 5V to encoders. The motion board supports 36V and 36V interlock for motors. The
board is fused (Figure 2.3-9) and contains LEDs for quick diagnostics (Figure 2.3-10).
2-20 B54476AB
Figure 2.3-9 Motion Board Fuse Locations
Figure 2.3-10 Motion Board LEDs
B54476AB 2-21
Table 2.3-6 Motion Board LED Descriptions
LED Purpose Color Off On

2 Interlock Blue Interlock is not engaged; power Interlock is engaged; power
on the 36V rail may or may not should be absent from the 36 V
be present rail
1 36V Power Rail for Green 36V power is low, removed, or a 36V power is present
Motors fuse is blown
3 12V Power Rail Green 12V power is low, removed, or a 12 V power is present
fuse is blown
6 5V Power Rail Green 5V power is low, removed, or a 5 V power is present
fuse is blown
9 3.3 V Power Rail Green 3.3 V power is low, removed, or 3.3 V power is present
a fuse is blown
4 CAN0 Status Red [Controlled by firmware] [Controlled by firmware]
5 CAN0 Status Green [Controlled by firmware] [Controlled by firmware]
7 CAN1 Status Red [Controlled by firmware] [Controlled by firmware]
8 CAN1 Status Green [Controlled by firmware] [Controlled by firmware]
Because multiple motion boards are used within a single system, separate addresses for each board
are needed. Unique addressing is done through the use of an in-harness addressing scheme. This
means that the board is assigned its address based on the physical location, since each connector on
the harness can be uniquely configured. No jumpers or switches are required.
Upon replacing a motion board and powering on the system, the board will be initialized and
checked for firmware. If no firmware or outdated firmware is found, the system (through master
controller embedded in software) will update the board with firmware and will recognize the
unique address of the board.
Tower Board
The chassis contains two circuit boards called tower boards which provide internal device
connections to the system. The front of the tower boards provide access to 4 CAN ports and 7
USB+POWER ports on each side of the instrument. These ports are placed symmetrically so that the
same board can be used across both sides of the instrument. The back side of the board contains a
12 pin header to transfer CAN and power from the chassis board and a micro-B connector to pass
host communication from the chassis board.
NOTE There is an AccuFrame port on the rear left tower, near two of the CAN ports on the tower board. This
AccuFrame port does not connect to the Tower Boards. Instead it connects directly to the Chassis Board.
2-22 B54476AB
Figure 2.3-11 Tower Board connections
Each CAN and USB connector has a dedicated self-resetting fuse to prevent damage from external
devices. The fuses are not replaceable.
WARNING
equipment damage.
If a specific port needs to be re-enabled:
1. Unplug the device.

2. Wait a minute for the self-resetting fuse to cool down.
3. Plug the device back in.
If a power interruption occurs again, check the device being plugged in for damage.
Indicator Lights
The status light LED strip is used to provide visual indication of the instrument state. The LED strip
is sized for each instrument and receives power and communication from the chassis board. A
spring steel strip is secured to the backside of the LED strip and serves to reinforce the LED strip and
protect it from damage when handling. The LED strip is easily installed and removed from the
system by snapping it onto a set of magnets. Refer to the Biomek i-Series Automated Workstation
Hardware Reference Manual (PN B54474) Status Indicator Light Bar -Configuration with Closed Enclosure
for a chart describing the colors and operational statuses.
B54476AB 2-23
Syringe Pump Bank Controller Board

i-Series instruments with a Span-8 pod have two Syringe Pump Bank Controller Boards. These
boards provide power and communication to the 8 individual syringe pumps. The boards are located
directly behind the syringe pumps, and each syringe pump connects directly into the controller
board.
Figure 2.3-12 Syringe Pump Controller board
Table 2.3-7 Syringe Pump Controller Board
Connector Description
J1 Syringe Pump controller RS-232 Connector
J2 Syringe Pump CAN Bus Access Connector
J3 Master Power /CAN Bus Connector
J4 Slave Power / Can BUS connector
J5 Output Slave Power Can BUS Connector
2-24 B54476AB
Light Curtain and Light Curtain Emitter Board

Figure 2.3-13 Light Curtain Connection Overview
The light curtain contains two primary components - the Light Curtain Boards (segments along the
bottom front of the instrument) and the Emitter Boards (located near the top of the front two
towers).
The light curtain is a diffuse reflective system. Each light curtain segment contains a series of high
power infrared emitter LEDs and light modulation photo IC’s (detectors) that are alternately placed
in adjacent wells. The LEDs shine light up from the wells to form a curtain of light above the boards.
If an object comes into contact with the light emitted from the LEDs the light is reflected back to
toward the detectors which trips the safety interlock system.
The i-Series light curtain board uses 12” segments to reduce the number of boards required to
populate an instrument.
The i-Series light curtain board includes a laser etched aperture lens that is installed over the
emitter / detector channels. The aperture lens effectively narrows the detectors field of view,
allowing the light curtain to operate within the taller and narrower opening of the i-Series platform.
The i-Series light curtain board uses plastic card guides to reinforce the PCB and provide a stable
mounting surface.
The platform contains one light curtain board part number.
• B73202 (LIGHT CURTAIN BOARD ASSY, 12 IN) – The aperture width over all of the detectors
is .050”.
The emitter board is comprised of the same high power infrared emitter LEDs that are used on the
light curtain boards. The emitter boards are mounted inside of chassis front towers and connected
in series with the light curtain board chain. The emitter boards are oriented perpendicular to the
B54476AB 2-25
light curtain chain and are used to provide an area of intense IR light in the corners of the
instrument where the pinch points occur. Objects that breach this area will reflect the light down to
the light curtain boards and trip the safety interlock. The added light from the emitter boards allows
the gain setting of the light curtain chain to be reduced which in turn reduces the possibility for
false trips.
The emitter boards contain a DIP switch that is set to S1 to set the gain of the LEDs. The emitter
boards also contain a 3 pin header with a mating 2 pin jumper. The jumper is used to designate
which board is first in the light curtain chain. The first board provides a pulse signal which
synchronizes the LEDs and detectors at a common frequency so that the detectors do not get
tripped by exterior light sources.
2-26 B54476AB
2.4 Fluidics System 2
2.4 Fluidics System
The Span-8 arm uses syringe pump based positive liquid displacement to aspirate and dispense from
8 pipetting probes. Customers may select different syringe, mandrel, and tubing types depending
on their application.
Low volume tubing is standard on Biomek i-Series instruments. Large volume tubing (for large
volume pipetting applications) may be upgraded in the field.
Customers may choose to use fixed tips (Fixed 100s) or disposable tips with a set of several syringe
size options ranging from 100 μL to 5 mL. A Span-8 system requires a Span-8 Wash Station on deck
to drain system fluid to a waste bottle during purge operations, washing operations, and for
resetting system trailing air gaps.
The fluidics system connections are briefly described below. Refer to Figure 2.4-1.
Figure 2.4-1 Fluidics System
Source Fluid
Deionized water that is allowed to de-gas in source carboy bottles for 24 - 48 hours is used as system
fluid. Source tubing (bundle of 8 separate tubing lines) is connected through the source bottle cap
into deionized water.
B54476AB 2-27
2.4 Fluidics System
Mandrels
Install fixed or disposable mandrels to probe tubing. Make sure to install posts of mandrels straight
into tubing. Use an emery cloth to hold low volume tubing while installing mandrels. Use large
volume tubing tools to install large volume mandrels into large volume tubing. See Hardware
Manual for additional information.
IMPORTANT Make sure source bottle is full. Use properly de-gassed deionized water.
IMPORTANT Make sure tubing and mandrel connections are tight and seated all the way on the mandrel
post. This is necessary for making a proper seal.
Wash Station Tubing/Waste Bottle

1. Install Span-8 Wash Station on deck. Connect waste tubing to ALP. Route other end of waste
tubing through/behind deck to a waste bottle. Make sure tubing connections are tight.
2. Use Biomek Software to manually frame the Span-8 Wash Station.

3. Replace syringe pump covers.
4. Power on instrument.
5. Home all axes. Make sure to purge system tubing and syringes with water until there are no air
bubbles in the lines and syringes. Small micro-bubbles may remain in tubing and syringes.
These bubbles are common and generally do not affect pipetting results.
2-28 B54476AB
2.5 Software 2
2.5 Software
Biomek Software v5.0 and later is used to operate the Biomek i-Series instruments. Compatible SAMI
EX Software v5.0 or later is available to operate the Biomek i-Series instrument with accessories and
peripherals for complex workflow planning and scheduling.
Refer to Biomek i-Series Automated Workstations Instructions For Use (PN B54473), and SAMI EX
Software for Biomek i-Series Automated Workstations Instructions For Use (PN B58997) for additional
information.
B54476AB 2-29
2.5 Software
2-30 B54476AB
2.6 Labware and Accessories 3
2.6 Labware and Accessories
Purpose
Refer to the Biomek i-Series Automated Labware Positioners, Accessories, & Devices User Manual
(B54477).
Labware
New Biomek i-Series disposable tips are available for a range of pipetting volumes and applications.
Options include conductive tips and wide bore tips; non-sterile and sterile with/without filters.
Pipette tips are available in two labware configurations including 96 pipette tips and 384 pipette
tips. The 96 pipette tips are compatible with 300 μL Multichannel Head, 1200 μL Multichannel Head,
and Span-8 pod. 384 pipette tips are compatible with 60 μL Multichannel Head.
Fixed 100 mm and Septum Piercing Tips are available for the Span-8 pod.
Below is the list of new tips where maximum pipetting range is included in the name:
BC1070 BC230 BC90 BC40F

BC1070_LLS BC230_LLS BC90_LLS BC40F_LLS
BC1070_WB BC230_WB BC50F BC50_384
BC1025F BC190F BC50F_LLS BC40F_384
BC1025F_LLS BC190F_LLS BC80 BC30_384
BC1025F_WB BC190F_WB BC80_LLS BC25F_384
For product information, please visit www.beckman.com.
Optional Devices
Optional devices can be added to the workstation to accommodate specific operations, such as tip
and labware disposal, plate heating and cooling, and microplate filtration. Refer to the following
manuals for more information about these devices:
• Biomek i-Series ALPs, Accessories, and Devices Reference Manual (B54477)
• Static Peltier ALP Integration Manual for Biomek FX/FXP, NX/NXP, and i-Series Instruments (A93392)
• Shaking Peltier ALP Integration Manual for Biomek FX/FXP, NX/NXP and i-Series Instruments
(A93393)
B54476AB 2-31
Installation Procedures
2.6 Labware and Accessories
2-32 B54476AB
CHAPTER 3
Part A Instrument Installation
3.1 Pre-Site Inspection
IMPORTANT Before beginning the installation procedure, ensure the installation site meets the
requirements for the Biomek i-Series Automated Workstation outlined in the Biomek i-Series Automated
Workstation Preinstallation Manual (B54472).
Appropriate site preparation includes making sure that:
• Adequate work space is set up for the instrument and controller PC. Refer to Biomek i-Series
Automated Workstation Preinstallation Manual (B54472).
• The bench holding the Biomek i-Series system can support the total installed weight of the
instrument and any peripheral equipment (refer to Biomek i-Series Automated Workstation
Preinstallation Manual (B54472) Component Weights). The bench must also be level and stable so
that normal operations of the Biomek i-Series instrument do not cause the bench to shift, jerk,
or sway.
• Adequate electrical supply and power quality are available for operation. Refer to
Biomek i-Series Automated Workstation Preinstallation Manual (PN B54472) Electrical Requirements.
• Appropriate degassed system fluid is available for a Biomek i-Series instrument equipped with
a Span-8 Pod. Refer to Biomek i-Series Automated Workstation Preinstallation Manual (PN B54472),
System Fluid Requirements (Span-8 only).
B54476AB 3-1
Installation ProceduresInstallation Procedures
3.1 Pre-Site Inspection
3-2 B54476AB
3.2 Preinstallation Checks 3
3.2 Preinstallation Checks
Before beginning the installation procedure, ensure the installation site meets the requirements for
the Biomek i-Series Laboratory Automated Workstation outlined in the Biomek i-Series Automated
Workstation Preinstallation Manual (B54472).
The customer is to provide the minimum requirements set forth by the Biomek i-Series Automated
Workstation Preinstallation Manual (B54472) sent prior to your arrival. Follow the checklist below to
ensure all requirements have been met and verify there are no missing or damaged items necessary
to complete the installation.
Biomek i-Series Instrument Preinstallation Requirements
 Did the end user receive the site preparation document?

 Check packages for visible damage. Do not unpack if damage is present on the shipping
container and have the customer file a freight damage claim.
 Verify that all ordered items are present.
 Verify sufficient workspace is available for the installation of the instrument controller and all
other instrument peripherals.
 Verify the proper electrical supplies are available at the workspace where the instrument(s) will
be positioned. The power requirements are 100-240VAC @ 10 AMPS max.
 Verify that proper water supplies are available. (De-ionized Type II or Distilled min.)
 Discuss Operator Training requirements with the customer. Train up to 2 people, requires 4 hours
uninterrupted time to review basic operation, maintenance, and safety.
 Verify the customer has completed registration through the Learning Management System.
 Verify the customer has completed e-Learning modules prior to Basic Operator Training.
B54476AB 3-3
3.2 Preinstallation Checks
3-4 B54476AB
3.3 i-Series Table Installation 3
3.3 i-Series Table Installation
The i-Series tables are available in two sizes: .7m x 1m and 1m x 1m. The tables are designed to be
used as support structures for integrated devices when a Biomek i-Series instrument is installed on
a mobile workstation, as well as support structures on BRT II and SCARA robotic systems.
Tools/ Supplies Needed

 Eye protection
 Leather gloves or suitable equivalent
 Steel strapping cutter, or two pliers (for removing metal strapping)
 Adjustable wrench
 Level
Moving the Shipping Crate

The shipping crate for the i-Series table may be lifted from either end and moved using a long bladed
pallet jack; or, the crate may be lifted from either end or either side using a fork lift.
B54476AB 3-5
Unpacking the i-Series Table
CAUTION
Risk of personal injury. The cut edges of the banding are sharp and will cut. Ensure
no one else is standing near the box, and use eye and hand protection when
cutting the banding on the boxes.
Figure 3.3-1 i-Series Table Packaging (1m x 1m table shown)
The shipping crate for the i-Series Table may be too large to fit through a standard doorway, so
remove the instrument from the shipping crate in the receiving area. Clear the area around the
crate to allow plenty of space for table removal. Once the i-Series table is removed from the crate, it
may be moved with a standard or long bladed pallet jack.
1. Note any damage to the shipping crate.

a. Take pictures of damage to share with customer’s receiving department for making a
shipping claim.
b. Send the pictures to Beckman Coulter Tech Support when reporting shipping damage to
determine if installation should continue.
2. Using a steel strapping cutter or two pliers, remove the metal strapping. Collect all steel
strapping and carefully discard.
3. Remove the crate packing material.
3-6 B54476AB
3.3 i-Series Table Installation 3
4. Note any shipping damage to the i-Series Table.

shipping claim.
5. Remove the side panels from both sides of the table.
Figure 3.3-2 1m x 1m table and .7m x 1m table side panels
CAUTION
Risk of personal injury. The 1m x .7m table weighs over 45 Kg (100 lbs). The
1m x 1m table weighs over 68 Kg (150 lbs). Do not attempt to lift the i-Series
tables without the help of at least three other people.
6. Lift the table, grasping the upper part of the white frame that was exposed when the side panels
were removed.
7. Move the table off the pallet and place it on the floor.
8. The table can now be carried to the desired location, or transported using a pallet jack.
9. When the table has been placed in the desired location, replace the side panels.
10. Using an adjustable wrench and a level, adjust the four leveling feet as needed.
11. If a monitor arm will be installed on the i-Series table, refer to 3.7, Installing the Workstation
Monitor Arm.
B54476AB 3-7
3-8 B54476AB
3.4 Mobile Workstation Installation 3
3.4 Mobile Workstation Installation
The i5 and i7 Mobile Workstation units are shipped pre-assembled in a box on a pallet. The Start-up
Kit, Monitor Arm, and Bridge Plate (i5 only) are shipped with the Mobile Workstation and require
assembly.
The i5 Mobile Workstation is configured with a top cutout on the left, interior drawer on the right,
and interior adjustable shelf on the left. The Monitor Arm will be boxed and shipped inside the unit.
The Start-up Kit and Side Tray are shipped behind of the unit.
See Reversing the Biomek i5 Workstation Configuration to reverse the Biomek i5 Mobile
Workstation standard configuration to place the top cutout on the right.
Figure 3.4-1 i5 Mobile Workstation
The i7 Mobile Workstation is configured with top cutouts on the left and right. The Monitor Arm is
boxed and shipped inside the unit. The Start-up Kit and side tray are behind of the unit.
Figure 3.4-2 i7 Mobile Workstation
B54476AB 3-9
3.4 Mobile Workstation Installation
Preinstallation Checklist
Before unpacking the Mobile Workstation, verify the 3.1, Pre-Site Inspection and 3.2, Preinstallation
Checks have been completed.
3-10 B54476AB
3.5 Unpacking and Inspecting the Mobile Workstation 3
3.5 Unpacking and Inspecting the Mobile Workstation
CAUTION
CAUTION
Risk of personal injury. The i5 Mobile Workstation weighs over 102 Kg (225 lbs).
The i7 Workstation weighs over 136 Kg (300 lbs). Do not attempt to lift the mobile
workstation without mechanical assistance or the help of seven other people.
Tools/Supplies Needed
The following list is the most common and specialty tools suggested for instrument un-crating and
installation:

 Eye protection
 Steel strapping cutter, or two pliers to remove metal strapping
 Long-blade pallet jack
Preparation
Before unpacking the Mobile Workstation, verify the 3.1, Pre-Site Inspection and 3.2, Preinstallation
Checks have been completed.

The shipping pallet containing the Mobile Workstation may be lifted from either end and moved
using a long bladed pallet jack; or, the crate may be lifted from either end or either side using a fork
lift.
Location for Unpacking the Mobile Workstation

The shipping pallet for the Mobile Workstation may be too large to fit through a standard doorway,
so remove the Mobile Workstation from the shipping pallet in the receiving area.
Clear the area around the pallet to allow plenty of space for Mobile Workstation removal. Allow at
least three times the length of the shipping crate of space to remove the Workstation.
B54476AB 3-11
Unpacking the Mobile Workstation

Figure 3.5-1 Packing materials (i5 shown)
CAUTION
1. Note any damage to the shipping crate.

shipping claim.
2. Using steel strapping cutter or two pliers, remove the four steel straps from the exterior of the
packaging. Collect all steel strapping and carefully discard.
3. Remove Outer Box by lifting it up and off the Mobile Workstation.
4. Remove the 7/16” OSB board and cardboard sheet from the top of the cart.
5. Note any shipping damage to the Mobile Workstation.
shipping claim.
3-12 B54476AB
3.5 Unpacking and Inspecting the Mobile Workstation 3
6. Remove the carton with the Monitor Arm (Articulating Arm), Start Up Kit, doors, and Side Tray
and set aside.
7. Remove the bubble wrapped interior shelf and brackets from inside the unit.
NOTE Before attempting to move the Mobile Workstation, the levelers must be fully retracted.
8. Use the thumb wheel to fully raise the levelers so the Mobile Workstation is on the casters
(Figure 3.5-2). If access to the rear levelers is restricted, there is an alternate access point inside
the unit (Figure 3.5-3).
Figure 3.5-2 Turn the thumb wheel to raise the Figure 3.5-3 Access Thumb wheel from inside via
levelers the trap door
OPTIONAL: Use The Ramp From The Biomek i-series Instrument Packing to unload the
Mobile Workstation
IMPORTANT The Mobile Workstation packaging skids are designed to be used with the i-Series Instrument
packaging ramp. Measure the height of the mobile workstation skid to determine if it matches the height
of the ramp. Early versions of the Mobile Workstation packaging skid may not be the appropriate height
for use with the ramp. In those cases, skip to Manually Removing The Mobile Workstation From The Pallet.
1. Refer to Unpacking the Biomek i-Series Instrument to remove the ramp from the
Biomek i-Series packaging.
2. Position the ramp in front of the Mobile Workstation shipping crate.
3. Insert the U-Bolts into the crate base and ramp.
NOTE If the skid does not have a hole for the U-bolt, drill one if necessary.
B54476AB 3-13
Figure 3.5-4 Insert U-Bolts into the crate base and ramp
4. Remove the side panel from each side of the cart (refer to Removing the End Panels).
5. Grasping the Mobile Workstation from the top, on the short side (non-ramp end), carefully roll
the Mobile Workstation down the ramp until all four leveling casters sit on a flat surface.
Manually Removing The Mobile Workstation From The Pallet
CAUTION
Risk of personal injury. The i5 Mobile Workstation weighs over 102 Kg (225 lbs).
The i7 Workstation weighs over 136 Kg (300 lbs). Do not attempt to lift the mobile
workstation without mechanical assistance or the help of at least seven other
people.
1. When lifting, grasp the Mobile Workstation at the horizontal white frame on the side and front.
2. With mechanical assistance or the help of at least seven other people, lift the Mobile
Workstation to move it off of the pallet, and set it on the floor.
3. Replace side panels and roll the Mobile Workstation to the desired location.
3-14 B54476AB
3.6 Assembling the Mobile Workstation Accessories 3
3.6 Assembling the Mobile Workstation Accessories
• Side Tray
• Adjustable Shelves
• Sliding Doors
• Cable Routing
• Removing the End Panels
• Reversing the Biomek i5 Workstation Configuration
The Mobile Workstation includes one side tray. Additional side trays are available for purchase. Up
to two side trays can be mounted on each short side of the Mobile Workstation. The side tray may
be mounted on either the left or right side of the Mobile Workstation.
Mount the Monitor Arm using only the front facing holes on the frame.
installation:
 Hardware Kit #116

 3/16” Allen wrench
 Phillips head screwdriver
 11 mm socket wrench
 13 mm socket wrench
Side Tray
1. Using a 3/16” Allen wrench and 5/16-18 bolts and washers, mount the side tray to either the
upper or lower mounting positions located on the left and/or right sides of the Mobile
Workstation.
B54476AB 3-15
Figure 3.6-1 Install Side Tray
Adjustable Shelves
The i5 Mobile Workstation includes 1 small shelf and 1 large adjustable shelf. The i7 Mobile
Workstation includes 2 small shelves and 1 large adjustable shelf.
NOTE Doors may be shipped installed and must be removed in order to install the large adjustable shelf in
the Mobile Workstation.
1. Set brackets at the desired height by inserting bracket tabs at an angle into the pre-punched
locations. When the bracket tabs are fully engaged, rotate the bracket in towards the panel to
lock in place.
Figure 3.6-2 Adjustable shelf brackets and shelves
NOTE The longer shelf brackets are intended to mount at the side panels of the Mobile Workstation. The
shorter shelf brackets are intended to mount in the internal dividers of the Mobile Workstation.
2. Slide the shelves in to rest on the brackets. The shelves do not attach to the brackets with any
hardware.
3-16 B54476AB
Sliding Doors
On the i7 Mobile Workstation there are two right doors and two left doors. Install the far left and far
right doors in the rear track, then install the center left and right doors in the front track.
On the i5 Mobile Workstation, install the right door in the rear track, then install the left door in the
front track.
1. Place the upper rollers in the upper track. Ensure the rollers are hooked in the upper track, then
compress the lower rollers and swing the door into place, so the lower rollers are engaged in
the corresponding lower track and the door is vertical (Figure 3.6-3).
Figure 3.6-3 Install cart doors
2. Slide the door back and forth to verify the door has been properly installed. If not properly
installed, the top rollers on the door will disengage from the track when the door is moved.
Cable Routing
WARNING
Risk of personal injury or equipment damage. Exceeding the current rating of the
power strips or branch circuit could result in breaker trips and other damage. Do
not plug the i-Series instrument into a power strip. If a power strip is used for
accessories, do not exceed the rated limit of the power strip. Ensure the power
drawn from an outlet does not exceed 80% of the maximum power available from
the outlet’s circuit branch. Do not daisy-chain power strips.
A four position power 10 amp strip and extended SVGA, USB, and four power cables are provided for
the monitor, keyboard, mouse, and other miscellaneous devices mounted on the Mobile
Workstation.
• The PC and power strip should be located inside the center location on the i7 Mobile
Workstation.
• The PC and power strip should be located inside the drawer side on the i5 Mobile Workstation.
B54476AB 3-17
• Cabling for items located on the Monitor Arm should be routed through the upper hole in the
side panel of the Mobile Workstation nearest the monitor arm, then internally as required to
reach the PC and power strip.
• Cabling for items located on top of the Mobile Workstation should be routed through one of the
upper holes in the rear of Mobile Workstation, then internally as required to reach the PC and
power strip.
• The power cord for the power strip should be routed through one of the lower holes in the rear
of the Mobile Workstation to the nearest available electrical outlet.
Removing the End Panels

NOTE Remove the interior adjustable shelf and brackets before removing the end panel.
1. Use the upper cutout to pull the panel out, before pulling it off the lower tabs.
Figure 3.6-4 Pull out, then up off the lower tabs
Reversing the Biomek i5 Workstation Configuration

1. Remove the sliding doors. Remove the front-most door first by pulling the lower rollers forward
out of the lower track. Angle the door out, pushing up slightly to remove the door panel.
2. Repeat with remaining door(s).
3. Remove the adjustable shelves. Slide the shelf out and remove the brackets. To release the
brackets, tilt away from the panel and pull from notched location.
4. Remove the drawer and case. Pull the drawer out of the drawer case. Unscrew the 4x ½-20 screws
mounting the drawer case to the drawer mounting brackets.
3-18 B54476AB
Figure 3.6-5 Drawer, casing and brackets
5. Remove the drawer brackets by unscrewing the two ¼-20 screws from each bracket. Save the
hardware for reinstallation.
6. Unbolt the divider panel. Remove the ¼-20 hardware from the inner panel on the top and
bottom of the unit. Remove the inner panel. Save the hardware for reinstallation.
At this point the interior should be empty, as doors, shelves, inner panel and drawer case have
been removed.
7. Remove the work surface. Remove the screws and flat clips from the underside of the top in the
corners of the cart. Save the hardware to re-install the top once it has been rotated.
Figure 3.6-6 Remove work surface
B54476AB 3-19
8. Reinstall the work surface. Rotate the top 180°and place it back on the frame, with the cut-out
on the right side. Using the reserved hardware, fasten the top to the frame.
9. Using the hardware reserved when removing the drawer case, attach the hanging brackets and
drawer case to the frame on the left side. Insert the drawer case.
10. Reinstall the inner panel, lining up with the holes located in the top frame and the base shelf of
the unit towards the right.
11. Reinstall the adjustable shelves (see Adjustable Shelves) and sliding doors (see Sliding Doors).
3-20 B54476AB
3.7 Installing the Workstation Monitor Arm 3
3.7 Installing the Workstation Monitor Arm
See the specific installation instructions for the Monitor Arm provided below.
• Monitor Arm- Innovative Brand

• Monitor Arm- Ergortron StyleView Sit Stand Combo Arm
Mount the Monitor Arm using only the front facing holes on the Mobile Workstation frame.
installation:

 3/8” socket wrench
 11mm socket wrench
 13mm socket wrench
B54476AB 3-21
Monitor Arm- Innovative Brand

There are two brands of Monitor Arm used on the Mobile Workstation. For the Ergotron brand, skip
to Monitor Arm- Ergortron StyleView Sit Stand Combo Arm.
NOTE The Innovative Monitor Arm comes with hardware to allow multiple attachment options. The following
instructions will discuss only those that are required to attach the monitor arm to the Mobile Workstation.
1. Using a 3/16” Allen wrench and 5/16-18 bolts and washers, attach the Large “L” bracket to the
front vertical support structure on either the left or right side of the Mobile Workstation as
shown in figure Figure 3.7-1.
Figure 3.7-1 Install Large “L” bracket
2. Attach the mount column to the L Bracket using the 3/8-16 x 7/8” bolt, and 3/8-16 nylon nut
(see Figure 3.7-2).
Figure 3.7-2 Attach mount column to L bracket
1. 3/8-16 nylon nut

2. Mount column
3. 3/8-16 x 7/8” Button Socket Cap Screw
3-22 B54476AB
3. Place the Monitor Arm into the Mount Column.
Figure 3.7-3 Place monitor arm into the mount column
B54476AB 3-23
4. Follow steps 1 through 5 for the monitor and swing-up keyboard installation instructions.
A. Rotation Prevention Bracket C. M4 x 18mm Phillips Pan Head Screw (4)

B. 10-32 x 5/8” Phillips Flat Head Screw (4) D. 1/2” Standoff
3-24 B54476AB
E. Velcro
F. Mouse Holder with Velcro Strip
5. Counterbalance the arm.
NOTE The arm must be in the mount, and a monitor attached to the arm before adjusting the counter-
balance.
a. Press the arm down to approximately parallel with the Mobile Workstation top prior to
turning the strength adjustment screw (Figure 3.7-4).
B54476AB 3-25
Figure 3.7-4 Adjust counterbalance strength adjustment screw
b. If the arm drifts upward, use a 7/32” Allen wrench to turn the adjustment screw clockwise.
If the arm drifts downward, turn the adjustment screw counter-clockwise.
NOTE Depending on the weight of the monitor, adjustment may take 15 to 20 turns.
6. In some instances, further counterbalance adjustments are needed to allow the arm’s instant
height adjustment function to work properly. If the arm is not staying in position after
performing step 5:
a. With arm in raised position, using a 3/32” Allen wrench, tighten set screw A (Figure 3.7-5).
Figure 3.7-5 Instant height counterbalance adjustment
b. With arm in horizontal position, using a 3/32” Allen wrench, tighten set screw B
(Figure 3.7-5).
NOTE Do Not overtighten screws.
3-26 B54476AB
Monitor Arm- Ergortron StyleView Sit Stand Combo Arm

There are two brands of Monitor Arm used on the Mobile Workstation. For the Innovative brand, see
Monitor Arm- Innovative Brand.
1. Attach the monitor arm mounting bracket to the front left or right upright of the Mobile
Workstation with the two supplied (5/16-18 x 1.00 inch socket head cap screws as in
Figure 3.7-6. the flat side of the bracket should always face towards the Mobile Workstation.
Figure 3.7-6 Mounting Arm Bracket
2. Attach the Ergotron monitor arm wall bracket to the monitor arm mounting bracket attached
in step 1 with four M10x 18mm flat socket head screws (Figure 3.7-7).
Figure 3.7-7 Mounting arm wall bracket
3. Refer to the Ergotron StyleView Sit Stand Combo arm User’s Guide to mount and adjust the arm.
B54476AB 3-27
3-28 B54476AB
3.8 Unpacking and Inspecting the Biomek i-Series Instrument 3
3.8 Unpacking and Inspecting the Biomek i-Series Instrument
CAUTION
CAUTION
The instrument weighs over 500 lbs with accessories. The installation scissor lift
cart that ships with the instrument is required to install the Biomek i-Series
Laboratory Automated Workstation. Failure to do so could result in bodily injury
and/or damage to the workstation.
The following list is the most common and specialty tools suggested for instrument un-crating:
 Eye protection
 Steel strapping cutter or two pliers (for removing metal strapping)
 Cordless drill or cordless socket wrench with 3/8” bit for sockets (optional)
 7/16” socket and box wrench
 9/16” socket and box wrench
 Socket wrench set with metric bits and adapters, including 10 mm and 19 mm
 Metric Allen wrenches (2 mm to 6 mm set)
 Phillips screw driver
Preparation

The shipping crate containing the Biomek i-Series instrument may be lifted from either end and
moved using a long bladed pallet jack; or, the crate may be lifted from either end or either side using
a fork lift.
Location for Unpacking the Biomek i-Series instrument

The shipping crate for the Biomek i-Series instrument crate is too large to fit through a standard
doorway, so the instrument should be removed from the shipping crate in the receiving area.
B54476AB 3-29
Wear leather gloves and eye protection. Do not stand in front of steel banding while cutting it. Clear
the area around the crate to allow plenty of space for instrument removal. Allow at least three times
the length of the shipping crate of space to remove the instrument.
Unpacking the Biomek i-Series Instrument
CAUTION
Risk of injury. The shipping ramp is heavy. Removing the metal strapping holding
the ramp releases the ramp restraints, which could cause it to fall. Use safety eye
wear and leather gloves or suitable equivalent, and use appropriate precautions
when removing the metal strapping.
1. Using steel strapping cutters, carefully cut the wire straps (refer to Figure 3.8-1). Alternatively,
use two pliers to twist the banding open.
Figure 3.8-1 Cut the Wire Straps
2. Remove the wire straps. Collect all steel strapping and carefully discard.
3. Fold down the ramp and position it in front of the shipping crate (refer to Figure 3.8-2 and
Figure 3.8-3).
3-30 B54476AB
Figure 3.8-2 Fold Down the Ramp
Figure 3.8-3 Position the Ramp In Front of the Shipping Crate
CAUTION
Risk of injury. The instrument top cover is large and awkward to handle. Acquire
assistance to remove the top cover.
4. Remove the plywood top board from the top of the instrument crate and set aside.
5. Remove the top cover off of the instrument crate and set it aside (refer to Figure 3.8-4).
NOTE Move the box top up, alternating from side to side so the top slides off evenly.
B54476AB 3-31
Figure 3.8-4 Removing the Top Cover
6. Remove the front and back side wall covers, lifting them up and out away from the wood braces
on the sides (refer to Figure 3.8-4 and Figure 3.8-5).
Figure 3.8-5 Remove the Front and Back Side Wall Covers
3-32 B54476AB
7. Insert two U-bolts into the crate base and ramp (refer to Figure 3.8-6).
Figure 3.8-6 Insert U-Bolts Into the Crate Base and Ramp
8. Using a phillips head screwdriver or bit with a drill, remove the wooden support closest to the
ramp (refer to Figure 3.8-7).
Figure 3.8-7 Removing the Brace Screws
9. Remove the shrink wrap from the back of the instrument holding the box of rear panels
(Figure 3.8-8).
B54476AB 3-33
Figure 3.8-8 Remove the Shrink Wrap From the Side of the Instrument
10. Set the box of rear panels to the side.

11. Remove the remaining shrink wrap from the instrument (Figure 3.8-9).
Figure 3.8-9 Remove the Remaining Shrink Wrap
12. For open models, skip to step 14.

For enclosed models, use a 4 mm straight hex driver and remove the enclosure front door
shipping restraint screw from the inside of the top part of the door frame. Raise door
(Figure 3.8-10).
3-34 B54476AB
Figure 3.8-10 Remove the Door Shipping Restraints (Enclosed Model)
13. Use a 3 mm metric driver and remove the L-shaped shipping restraint and screws from each end
of the door (Figure 3.8-11).
Figure 3.8-11 Remove the Door Shipping Restraint Screws (Enclosed Model)
CAUTION
14. Remove the strapping holding the accessory boxes. Remove the accessory boxes and set aside.
15. Cut and remove the wire straps from the cart and set them aside (Figure 3.8-12).
B54476AB 3-35
Figure 3.8-12 Cut and Remove the Wire Straps From the Shipping Cart
NOTE If you do not have wire cutters handy, you can use a pair of pliers and a wrench to cut the wire
straps (Figure 3.8-13).
Figure 3.8-13 Cut and Remove the Wire Straps From the Cart
NOTE Carefully bend and dispose of the metal banding.
16. Inspect the accessories inside the instrument for shipping damage.
NOTE Inspect the pump tubing to make sure it is not kinked or damaged. Be careful not to damage the
pump tubing when removing the accessory boxes.
17. Remove deck plates to get access to the Y-Beams and the casters.
• On the i5 these are the two left and two right plates.
• On the i7 these are the two left-most and two right-most full sized plates.
18. Use a 7/16” socket wrench and a 7/16” box wrench to remove locking bolts and washers from
the instrument and shipping blocks Refer to Figure 3.8-14.
• On the i7 instrument- three bolts and washers tied through each Y beam.
• On the i5 instrument- two bolts and washers through each foot hole.
3-36 B54476AB
Figure 3.8-14 Remove the Locking Bolts from the Instrument Y Beams on the i-7
19. Change the foot pump and hydraulic release pedal from the shipping configuration to the
service configuration in the provided cart.
a. Use an m5 driver to loosen the release lever screw.
Figure 3.8-15 Loose release lever screw in the provided cart
B54476AB 3-37
b. Rotate the lever 90 degrees so it can engage the release valve. Re-tighten the screw.
Figure 3.8-16 Rotate lever 90 degrees
c. Remove the pin from the foot pump. Move the foot pump arm up into the service position
and replace the pin.
Figure 3.8-17 Arm in service position
3-38 B54476AB
20. Gently pump the shipping cart lift to raise the instrument.
21. Position the cart so the casters on the instrument are even with the C-channels on the cart
(Figure 3.8-18 and Figure 3.8-19).
Figure 3.8-18 Align the instrument casters with

the C-channels on the shipping cart
Figure 3.8-19 Align the instrument casters to the C-Channels On the Shipping Cart
22. After all instrument casters are aligned and positioned in the c-channels, use a 10 mm wrench
to install the four anchor bolts to secure the instrument to the cart, and align the holes on the
Biomek instrument with the holes on the c-channel (refer to Figure 3.8-20).
B54476AB 3-39
Figure 3.8-20 Install the Anchor Bolts to lock the Instrument to the cart
23. Lock the cart wheels (Figure 3.8-21).
Figure 3.8-21 Lock the cart wheels
24. Ensure the wheels on the cart are locked, then raise scissor cart to lift the instrument off the
shipping post braces.
25. If an i-7, use a 7/16” socket wrench and remove three locking bolts and washers from each of
the shipping post braces. Set braces and filler pieces aside.
3-40 B54476AB
Figure 3.8-22 Removing the locking bolts and washers from shipping post braces (i7 only)
26. If an i5, use a 9/16” socket and cordless ratchet or drill and box end wrench to remove two of
the four shipping posts. The cart wheels are wider than the posts and will need to be removed
before wheeling the instrument off the crate.
27. Release the scissor lift cart brake. Wheel the instrument out of the shipping crate and down the
ramp (Figure 3.8-23).
Figure 3.8-23 Raise the cart and wheel the Instrument out of the shipping crate and down the ramp
28. Use a separate cart (not provided) to transport the accessories from the shipping dock to the
instrument lab.
B54476AB 3-41
Inspecting the Biomek i-Series Instrument

After unpacking, carefully inspect the instrument and all additional contents of package to make
sure nothing is damaged. Inspection should include, but not be limited to, checking for the
following:
• Damage to covers
• Damage to cables
• Missing, broken, or loose parts
NOTE Use the packing list(s) included with the Biomek i-Series instrument to ensure that all parts have
been included with the instrument.
If any damaged or missing parts are detected, contact the nearest Beckman Coulter Service
Representative immediately.
Moving the Biomek i-Series Instrument to the Installation Site

Using the supplied scissor cart, move the instrument and parts to the installation site.
1. Place the rear panels and other accessories onto a second roll-around cart.
2. Roll both carts to the installation site.
3-42 B54476AB
3.9 Preparing and Placing the Biomek i-Series Instrument 3
3.9 Preparing and Placing the Biomek i-Series Instrument
installation:
 Socket wrench set with metric bits and adapters, including 10 mm and 19 mm
 Metric Allen wrenches
 4-Post Framing tool and service method (for Multichannel arms)
 384 Square Well Plate for probe alignment for Span-8 arms (optional)
 Emery cloth
 Service check-out method
 Phillips #1, #2, and flat blade screw drivers
 Bubble or digital level
 LLS Cable alignment tool (for Span-8 arms) (optional)
Preparing the Biomek i-Series Instrument and Placing It on the Bench

While the instrument is lowered on the cart, remove all pod shipping restraints:
1. Use M4 driver to remove the front pod shipping bracket (MC and Span-8).
2. Use M2.5 hex driver to remove shipping bracket from gripper.
3. Use M4 hex driver to remove rear pod shipping brackets.
a. For Span-8 systems, snip cable ties from Span-8 probe shipping bracket before removing
rear pod shipping bracket.
4. Remove camera lens caps and interior light shipping restraints.

5. If MC system, mount the MC Pod on the instrument. Do not make electrical connections yet
(refer to 4.200.2, MC Pod Removal and Replacement).
a. Install four mounting screws on the Multichannel pod.
b. Install Multichannel Pod onto bridge by aligning pins from the Multichannel arm with the
alignment holes on the Multichannel pod. Make sure the Multichannel Pod is installed with
the E-chain facing the right side (towards the right side of the Multichannel arm).
c. Use a long 3 mm straight handled driver and tighten mounting screws.
6. If a Span-8 system:
a. Remove the white shipping collars located between the tip interfaces and the Z probe
guides.
b. Check that all LLS cables are not kinked or damaged from shipment. the LLS cables should
be freely hanging and properly connected.
c. Snip free the Span-8 tubing bundle and inspect for damage.
B54476AB 3-43
7. Remove nut from leveling feet. Using fingers or M6 tool, thread leveling feet all the way through
base support. Reinstall the nut on the top side of the leveling feet after threading them into the
base support.
8. Remove plastic film from rear panels and install. Mount the rear panels. Refer to 4.100.3, Rear
Panels Removal and Replacement.
9. Install the light curtain sash.
• If the system does not include a front door: Use an M4 hex driver and loosen the M5 screws
from the standoffs on the back of the front logo panel. Hook the light curtain sash over the
screws. Ensure that the light curtain sash is even with the bottom edge of the logo panel.
Tighten the M5 screws.
Figure 3.9-1 Light curtain sash on front logo panel
• If the system does include a front door: Use an M4 driver and loosen the M5 screws installed
into the clinch nuts on the angled face of the front door light curtain bracket. Hook the light
3-44 B54476AB
curtain sash over these screws. Ensure that the light curtain sash is even with the bottom
of the door panel. Tighten the M5 screws.
Figure 3.9-2 Light curtain sash on front door assembly
10. If closed enclosure, remove the top panels, remove the plastic film from the panels, clean them
and reinstall (refer to Rear Panels Removal and Replacement).
11. Remove paper-backed film from the side panels.
12. If closed enclosure, remove the plastic film from the front door.
13. Ensure the bench, cart, or table is level and can support the cumulative weight of the system,
accessories and labware.
14. If the workstation is mobile, secure it.
CAUTION
The lowering mechanism of the cart is not precise. It can lower very quickly when
released. Do not attempt to lower the cart while the C-channel is over the top of
the bench.
15. Raise the cart so the C-channels are at or just above workstation height. The C-channels should
align very closely with the top of the bench or table. (Figure 3.9-3).
NOTE The end of the cart c-channels may scrape the customers' bench, table, or workstation. Use tape
or other protective material to prevent damage.
B54476AB 3-45
Figure 3.9-3 Raise workstation to just above bench height
16. Align instrument cart up against the workbench (Figure 3.9-4). Secure the cart.
Figure 3.9-4 Align cart and bench
17. Measure the distance between the instrument feet (back and front), and measure the same
distance on the workstation surface, allowing room around the back and front of instrument.
18. Use 10 mm nut driver to remove anchoring bolts from back cart c-channels.
3-46 B54476AB
IMPORTANT Be extremely careful to not roll the instrument off the back of the workbench!
19. Roll the instrument onto the bench.
Figure 3.9-5 Roll the Instrument Onto the Lab Bench
20. Adjust the location of the instrument on the bench.

21. Lower the feet of the instrument to raise the casters off the cart C-channel and the bench
surface (Figure 3.9-6)
Figure 3.9-6 Lower the feet to raise the casters off the C-channel and the bench surface
22. When the casters are no longer supporting the instrument, remove the cart.
23. Use M6 hex driver to level the instrument.
NOTE The bottom of the y-beams should be 32 mm (1-1/4 in.) above the bench surface for some
integrations.
24. Lock the feet with locking nut (see Figure 3.9-7). Use adjustable wrench or nut driver to tighten
locking nut.
B54476AB 3-47
Figure 3.9-7 Lock Feet with Locking Nut
25. Replace and tighten deck plates.

26. Install gripper finger assemblies (refer to 4.500.3, Gripper Finger Assembly Removal and
Replacement).
27. Connect the AccuFrame tool to the instrument AccuFrame port.
28. Attach the instrument power cable.
WARNING
Risk of personal injury or equipment damage. Exceeding the current rating of the
power strips or branch circuit could result in breaker trips and other damage. Do
not plug the i-Series instrument into a power strip. If a power strip is used for
accessories, do not exceed the rated limit of the power strip. Ensure the power
drawn from an outlet does not exceed 80% of the maximum power available from
the outlet’s circuit branch. Do not daisy-chain power strips.
29. Make the electrical connections for the Multichannel pod.

a. Put on an wrist ground strap and connect the clip to the instrument (for location, see
1.2, Safety Precautions, Electrostatic Discharge (ESD) Protection)
b. Remove Multichannel Arm covers (front, left side, and right side covers). Refer to MC Arm
Covers Removal and Replacement. Set covers aside.
c. Use #1 Phillips screwdriver to loosen screws holding the Multichannel Arm board bracket
cover (Figure 3.9-8). Remove cover and set aside.
3-48 B54476AB
Figure 3.9-8 MC Arm Board Bracket Cover
d. Install the pod E-chain to the E-chain bracket (If the pod is being installed on the
instrument for the first time, E-chain screws will be installed in the E-chain bracket for
shipment. Remove E-chain screws before installing E-chain.).
e. Route Z encoder cables through cable clips. Ensure cable clips are fully pressed into the
bracket.
Figure 3.9-9 MC Pod Encoder Cable Clips
B54476AB 3-49
f. Open cable holder clip for E-chain bundle. Reconnect the C156, C266, C271, C273, C275,
C277, and C278 cables to the numbered connnectors on the MC board (see Figure 3.9-10).
Close the E-chain bundle cable clip.
Figure 3.9-10 MC Pod Connections
g. Replace the Multichannel arm board bracket cover. Tighten the screws.
h. Replace the arm covers. Refer to the MC Arm Covers Removal and Replacement procedure.
i. Disconnect the wrist ground strap.
30. Attach the instrument communication cable (host USB cable).

31. Setup the instrument controller, monitor, keyboard, and mouse (refer to 3.11, Windows 10
Automation Controller Installation).
NOTE The scissor cart is no longer needed for installation. If the customer would like to continue to use the
cart, install the handle.
1. Cut the zip ties off the handle.
2. Use a 19 mm socket wrench and install bolts and washers through cart to secure the handle.
3. Provide the customer some simple training on the cart operation.
Optional: C-Channels and anchor bolts can be removed and stored with the instrument for later
service use.
3-50 B54476AB
3.10 Making Connections and Powering On 3
3.10 Making Connections and Powering On
WARNING
The instrument power MUST be turned off before connecting or disconnecting any
CAN communications. Damage will occur if proper precautions are not taken. Use
717781 or other CAN cable for these connections.
WARNING
equipment damage.
WARNING
Risk of equipment damage. The AccuFrame cable positioning could violate the
light curtain, which would immediately halt the framing process. Make sure that
the AccuFrame cable does not violate the light curtain.
WARNING
Risk of equipment damage. The AccuFrame cable positioning could interfere with
pod movement. Make sure the AccuFrame cable is in a location that does not
obstruct pod movement.
Making Connections and Powering On

1. Unpack and install the Windows 10 Automation Controller and Monitor (refer to 3.11, Windows
10 Automation Controller Installation)
2. Connect instrument controller and monitor power cables to wall outlet, or the power strip
provided with the Workstation.
3. If a table or cart was purchased from Beckman Coulter, mount the monitor, keyboard, and
mouse on the table or cart.
4. Turn on system using the System Power Up Procedure.
5. Log in, using the Automation Controller default password: AdvancingScience123.

6. Once logged in, reset the controller password. Press Ctrl+Alt+Del to change a password.
7. Create a password hint and record the password for the customer.
OPTIONAL: If the customer chooses to network the controller:
a. Attach the network cable and plug into the customer’s network. There are two network
ports on the instrument controller. One is located on the controller motherboard, and one
is located on a network card. Connect the cable to the port on the motherboard.
B54476AB 3-51
3.10 Making Connections and Powering On
b. Update settings, including computer name, windows updates, etc.
CAUTION
Risk of data loss or system failure. The Automation Controller is configured to
automatically obtain updates when connected to the internet. Upon notification
of these updates, perform a system reboot as soon as possible. The system is
configured to avoid automatic restart to avoid loss of data and/or samples;
however, this leaves the system vulnerable to cybersecurity threats. Ensure
updates are addressed in a timely manner.
NOTE Beckman Coulter is not responsible for viruses introduced into your system through third
party devices. Ensure the flash drive used for this operation does not contain malware.
c. Change automatic updates, based on customer requirements (refer to Biomek i-Series

Instructions for Use (PN B54473)).
d. Follow instructions to update the User Manuals from the Beckman Coulter website:
1) Go to www.beckmancoulter.com > Support > Technical Documents on a computer
connected to the internet.
2) Search for Biomek i-Series Safety Messages and System Help Download Instructions
PN B96939, and select the link for this file.
3) In the pop-up, select the Save down arrow, and then select Save As.
4) Browse to the location where you wish to save the file, and then select Save. If installing
the files on the current system, go to step 6.
5) If installing on another system that is not connected to the internet:
a) Save the files on a portable memory device, such as a flash drive.
b) Insert the memory device into the Biomek i-Series Automation Controller.
c) Browse to the downloaded file on the portable memory device and copy the files to
the Biomek i-Series Automation Controller.
6) Double click on the file to initiate the installer, and follow the instructions on the
installer window to complete the process.
7) If the PC is to be connected to the network:
a) Go to Start. Right-click on File Explorer > Properties.
b) Next to Computer name, click Change settings.

c) Click Change... next to To rename this computer...
d) Enter a unique computer name as desired by the customer. The name must be
different from other PCs on their network.
e) Click OK.
f) Click OK on the restart dialog.
g) Close System Properties and the System menu.
h) Reboot the computer.
3-52 B54476AB
3.11 Windows 10 Automation Controller Installation 3
3.11 Windows 10 Automation Controller Installation
Windows 10 Automation Controller Installation

1. Unpack and set up the controller.
2. Unpack and set up the keyboard and mouse. Connect both to the black USB ports on the back of
the controller.
3. Connect USB host cable from the instrument ship kit to a USB 3.0 port on the back of the
Windows 10 Automation Controller. Ports are designated with SS.
4. Store the recovery media DVDs in a safe place. For example, some people tape the recovery
media to the inside cover of the Automation Controller.
Monitor Installation
1. Open the box containing the monitor and remove the monitor and stand.
2. Attach the monitor base to the monitor using the instructions included in the packaging.
3. Attach the power cord and communication cable to the monitor and instrument controller.
4. Attach the monitor cable to the back of the computer to the monitor port.
IMPORTANT Ensure that the instrument, Automation Controller, and monitor cables are securely connected
and power cords are plugged in.
B54476AB 3-53
3.11 Windows 10 Automation Controller Installation
3-54 B54476AB
3.12 Software Configuration and Accessory Installation 3
3.12 Software Configuration and Accessory Installation
The Biomek i-Series Instrument is shipped with a factory-configured Windows 10 Automation

Controller.
Biomek Software is installed. Hardware Settings are configured in the software for the following
options:
• Instrument Added to Master Controller

• Pod Options
— Serial Number completed
— Pod Correlation
• If Multichannel, a head will be configured.

— Seek Limits completed
• If Span-8, disposable mandrels and syringes will be configured.

— Correlate axes completed
— Find LLS Sensitivities completed
— Find CD Sensitivities completed
— Span-8 Pump Calibration completed for 10 μL
• Gripper
— Correlate axes completed
• Manufacturing test decks are in Deck Editor and framed for specific manufacturing test uses.
• A manufacturing project is included with manufacturing test methods
Purpose
Use these procedures to:
• configure the system using customer accessories.

• complete remaining software configurations and save files
 De-gassed de-ionized water
B54476AB 3-55
Configure Customer Accessories

NOTE Make sure that gripper fingers are straight and gripper pads are tightened properly and are in good
condition.
NOTE Ensure that the Multichannel head screws are tightened properly on installation.
1. If your customer has purchased different options, including:

• Multichannel Head option,
• Span-8 syringe size,
• Span-8 mandrels,
install accessories. Refer to the Biomek i-Series Hardware Manual (B54474).

2. Install Span-8 system fluid and waste bottles. Refer to 3.15, Span-8 Bottles and Tubing Setup.
3. Select Utilities > Deck Editor and select a manufacturing test deck that has a framed position for
each pod located in the middle of the deck. Install an ALP.
4. Power on the instrument. Home all axes (refer to Biomek i-Series Hardware Automated
Workstation Reference Manual, B54474, Home All Axes of the Pods).
CAUTION
Risk of accessories damage. Make sure MC head configuration in Utilities >
Hardware Setup matches the installed head before Homing All Axes. Failure to do
so may result in Multichannel Head damage.
5. Gripper correlation must be repeated on installation. Refer to the Biomek i-Series Automated
Workstation Hardware Reference Manual (B54474,) for instructions.
6. Rename the manufacturing test deck to Deck1. Clear the deck.
7. Install ALPs, frame positions, and associate any devices purchased by your customer using the
instructions provided in the Biomek i-Series ALPs, Accessories, and Devices Reference Manual
(B54477)
8. Save the deck.
9. Delete all other decks except the standard deck, which cannot be deleted.
Finish Software Setup

1. Go to File > Open > Project and open the default project.
2. Save this project as Service.
3. Select File > Import > Method and import the following service methods and project items: Four
Post Framing Tool Method and the Service Checkout Method. These methods can be downloaded
from Airwatch.
4. Close methods.
5. Select Utilities > Hardware Setup.
6. Select Pod. Validate Pod Settings. Save Pod Settings.
7. Select File > Save > Instrument and save the instrument file.
3-56 B54476AB
3.12 Software Configuration and Accessory Installation 3
8. Close Biomek Software to create daily, weekly, and monthly backup files.
B54476AB 3-57
3-58 B54476AB
3.13 Biomek i-Series Installation Flow Chart
B54476AB
Biomek i-Series Installation Flow Chart

3-59
3
3-60 B54476AB
3.14 Multi-Channel Wash Station 3
3.14 Multi-Channel Wash Station
Refer to Biomek i-Series Automated Labware Positioners, Accessories & Devices (PN B54477), Installing
Multichannel Wash Station ALPs for installation and setup instructions.
B54476AB 3-61
3.14 Multi-Channel Wash Station
3-62 B54476AB
3.15 Span-8 Bottles and Tubing Setup 3
3.15 Span-8 Bottles and Tubing Setup
Purpose
The Span-8 system requires degassed, deionized water in a source bottle for system fluid. This is
connected to the source tubing that supplies the syringe valves, syringes, and syringe pump to
Span-8 mandrels tubing lines.
System fluid is periodically purged at a Span-8 wash station. The Span-8 wash station is connected
to tubing and a waste bottle.
This procedure should be used to setup source and waste tubing and bottles.
Tools and Supplies Needed

 Supply and Waste Assembly, PN 989852
 Span-8 Tip Wash Kit, PN B87476
Tubing and Bottle Setup Preparation

Span-8 mandrels and Span-8 Passive Wash Station accessories should be installed prior to Tubing
and Bottle Setup.
Tubing and Bottle Setup Procedure

1. Fill the system fluid container with Deionized Water.
2. Install source tubing bundle (8 lines) through bottle cap of source bottle.
3. Add 1 -2 sets of line weights to keep the source tubing straight and immersed in system fluid.
4. Securely close bottle cap on source bottle.
B54476AB 3-63
3.15 Span-8 Bottles and Tubing Setup
5. Install the Span-8 wash alp tubing through the waste bottle and cap.
NOTE The water and waste lines must not have any kinks or sharp bends. The waste lines should have
no sags in them to allow for proper waste drainage.
6. Select Method > Manual Control > Advanced Controls, then select the Span-8 Pod and Purge
Syringes until bubbles are removed from tubing and syringes.
3-64 B54476AB
3.16 Instrument Operation 3
3.16 Instrument Operation
Purpose
Use this procedure to complete the instrument installation.
Procedure
Refer to Chapter 5 Operational Checks.
1. Run the Four Post Framing Tool Method (see 5.100.2, 4 Post Framing Tool Procedure).
2. Run the Single Service Checkout Method (see 5.100.3, Service Check Out Method).
3. Complete Instrument Function Checklist (5.100.4, Instrument Function Checklist Procedure).
Basic Instrument Installation is complete.
B54476AB 3-65
3.16 Instrument Operation
3-66 B54476AB
3.17 PROService RMS 3
3.17 PROService RMS
Figure 3.17-1 PROService Connectivity
PROService is a remote management system that connects the instrument to Beckman Coulter.
Biomek i-Series instruments may connect to a RAP box, which is the hardware that enables
PROService. The RAP box is a small computer located within close proximity to the instrument to
which it's connected.
The RAP box isolates its connected instruments from the customer network and external security
threats. Connected instruments send data to the RAP box, and the RAP box transmits instrument
data to Beckman Coulter. Data is transmitted through the internet via a secure messaging protocol.
For more information on PROService and how to install the equipment, enroll a Biomek i-Series
instrument, and use the Biomek i-Series Basic Dashboard, refer to AirWatch for the PROService
Service Manual.
B54476AB 3-67
3.17 PROService RMS
3-68 B54476AB
3.18 SAMI EX Software Installation 3
3.18 SAMI EX Software Installation
Purpose
Use this procedure to install SAMI EX v5.0 or later Software.
Prerequisites
• Windows 10 Automation Controller, PN B87685.
Procedure
1. Install:
• Biomek Software 5.0 or later
2. Open and save the deck.

3. Add ALP devices through Utilities > Hardware Setup. Refer to ALPs and Accessories Manual.
4. Close the Biomek Software.
5. Add active devices and install SILAS Modules:
a. Instantiate Peltier SILAS modules. Refer to Static Peltier ALP Integration Manual for Biomek
FX/FXP, NX/NXP, and i-Series Instruments PN 93392 (Rev. AC and up); and Shaking Peltier
ALP Integration Manual for Biomek FX/FXP, NX/NXP, and i-Series Instruments PN 93393 (Rev.
AC and up).
b. Install Cytomat and Conveyor modules. Refer to 3.30, Cytomat 2C Setup and Configuration
the SAMI EX Installer Tool (Optional) or 3.41, Cytomat MPH SAMI EX Software Setup and
Configuration (Optional).
c. Install Virtual Modules & Consumer Modules from Start > Beckman Coulter Service Tools >
SILAS Module Installs:
1) Barcode Assign Installation
2) Logger Installation
3) MDAssign Installation
4) Pooling Installation
5) ReadFile Installation
6) Reschedule Installation
7) RunProgram Installation
8) VerifyDiskSpace Installation
6. Open Biomek Software > Utilities > Deck Editor.
a. Associate active ALPs and Devices
b. Frame devices
7. Install Hardware Key (refer to 3.19, zSAMI EX Hardware Key Installation)
B54476AB 3-69
8. Configure SAMI EX:

a. Open the Biomek module from Start > Beckman Coulter Service Tools > SILAS Module
Installs. Validate the workspace, then install.
b. Go to Start > Beckman Coulter Service Tools > SAMI EX Installer Tool
c. Configure module options.
d. Link positions.
1) For each device with shared positions that should be linked with a position on another
device, drag-and drop the device until the linked positions are overlapping. They will
both turn purple.
2) Click on each pair of purple positions so that they turn green. The positions are now
linked.
e. Check workspace.
9. Configure SAMI EX:
a. T he Capability Editor is used to modify the allowed operations at each Biomek i-Series
position for each Biomek i-Series pod and gripper. To use the Capability Editor:
1) Open the SAMI EX Capability Editor from Start > Beckman Coulter Service Tools >
SAMI EX Capability Editor.
2) Select the Biomek i-Series pod that you wish to modify the settings for. This will also
select the corresponding gripper.
3) Click on an operation in the list view on the left to select that operation.
4) Click on one or more positions to toggle the selection between Allowed (green) and
Not Allowed (red).
5) Press Save Changes, then close the SAMI EX Capability Editor.
6) Restart the SAMI EX Editor and SAMI EX Runtime applications, if they are running.
Positions that appear in gray will not be selectable. These are positions that are either
not compatible with the chosen operation, or are beyond the reach of the chosen pod
or gripper.
Positions whose capabilities are overridden will be shown in dark red or dark green.
Positions that are currently set to the default setting will be light red or light green.
b. Modify Gripper Settings

1) Select Start > Beckman Coulter Service Tools > SAMI EX Grip Editor.
2) Select the Biomek i-Series gripper that you wish to modify the settings for.
3) If you wish to enable or disable positions for an existing grip, select that grip and click
on the position(s) you wish to toggle.
4) If you wish to delete an existing grip, select that grip and press Remove.
5) If you wish to add a new grip, press Add.
a) Type the name of the new grip, then press OK.
b) Select the new grip in the list.
3-70 B54476AB
3.18 SAMI EX Software Installation 3
c) Enter the grip offsets (X/Y/Z/Squeeze/Unsqueeze) for the new grip, if any. You
may leave these boxes blank to use the offsets for the labware type from Biomek
Software instead.
d) Specify the grip side using the Side drop down, choosing either A1Near or
A1AwayFrom.
e) Click on the positions you wish to enable for this grip.
6) Press Save Changes, then close the SAMI EX Grip Editor.
7) Restart the SAMI EX Editor and SAMI EX Runtime applications, if they are running.
Be aware that grips for Biomek i-Series devices in SAMI EX will be prioritized
alphabetically, if there are two or more grips that can be used for a given move.
c. Configure consumer modules. Launch the SAMI EX Editor and select Project > Consumer
Modules menu item.
NOTE Consumer Modules menu item is only available if one or more consumer modules are
installed.
d. Configure Alarm Module and create Alarm Module profiles and settings in SAMI EX
Runtime.Configure consumers modules.
10. Configure BCAP:

a. Set administrator password.
b. Configure support options.
NOTE SAMI EX and Biomek must match.
c. Set up accounts.
11. Customer Training

a. SAMI EX Customer Startup Guide Training
1) Explain Accounts & Permissions user levels
2) Security
3) Create backup files:
a) Utilize A&P Archive to create a backup SQL repository
b) Create a spack file
c) Start Tutorials
B54476AB 3-71
3-72 B54476AB
3.19 zSAMI EX Hardware Key Installation 3
3.19 zSAMI EX Hardware Key Installation
NOTE SAMI EX Hardware Key must be installed before running any SAMI EX method through SAMI EX
Runtime on a live system.
Purpose
Use this procedure to install SAMI EX 5.0 or later Hardware Key.
Prerequisites
• SAMI EX Software must be installed prior to installing the SAMI EX Hardware Key.
Procedure
1. Verify that the contents of the packaged USB SAMI EX Hardware key (B96856) are complete and
without damage.
2. Insert the SAMI Workstation EX Software Disc to a disk drive.
3. Select the SAMIHardwarekeyInstall.exe (Figure 3.19-1).
Figure 3.19-1 SAMI Hardware Key Install
4. Select Dongle Type KEYLOK 2 (USB w/Driver) option (Figure 3.19-2). A warning appears.
NOTE Do not attach USB Dongle until the installation is completed.
B54476AB 3-73
Figure 3.19-2 Select Dongle Type and Installation Type, and note
5. Select OK to acknowledge the warning.

6. Select installation type of Standalone (Figure 3.19-2).
7. Select Begin Install.
8. The Device Driver Installation Wizard appears (Figure 3.19-3). Select Next to begin drive
installation.
Figure 3.19-3 Device driver Installation Wizard
9. When installation is complete, select Finish (Figure 3.19-4).
3-74 B54476AB
3.19 zSAMI EX Hardware Key Installation 3
Figure 3.19-4 Device Driver Installation Wizard Complete
10. If the driver installation is successful, the following message appears:
Figure 3.19-5 Installation success message
11. Attach the USB hardware key to a USB port on the front or back of the Automation Controller.
12. When the USB Dongle has successfully completed driver installation, the following message
appears (Figure 3.19-6):
Figure 3.19-6 Device driver software installed successfully message
13. The SAMI EX Hardware Key has been installed. Restart the computer before using the SAMI EX
Hardware Key.
NOTE Before running a method through SAMI EX Runtime, the hardware key must be inserted into a USB
port and the drivers recognized. This may take 40 seconds or more.
If you receive a hardware key error through SAMI EX Runtime, wait a minute and retry.
B54476AB 3-75
3-76 B54476AB
3.20 Cytomat 2C Incubator Integration for Biomek i-Series 3
Part B Cytomat 2C Installation
3.20 Cytomat 2C Incubator Integration for Biomek i-Series
Purpose
This custom integration provides the necessary hardware and software modifications for using a
Thermo Scientific Cytomat 2C on a custom system running Biomek or SAMI EX Software.
The Cytomat 2C contains 2 hotel locations and provides uniform temperature, humidity and CO2
conditions.
This integration allows for use of a free standing Cytomat 2C on the system accessed directly by a
Biomek Gripper or by a Conveyor transporter. A Cytomat SILAS Module interface is provided for
automated control of the device in a Biomek Method or SAMI EX Method. The SILAS Module will
also provide manual control capabilities through Biomek Software or SAMI EX Software.
NOTE The device configuration must be specified at the time of purchase. Changes to the device
configuration after device shipment may require the purchase of additional hardware or software.
Items Provided
The following items are supplied as part of this custom integration:
• Mounting hardware for supporting and positioning the Cytomat 2C device
• Conveyor or Servo Shuttle SILAS Module Software for the use in Biomek or SAMI EX Software
(necessary if conveyor or Servo Shuttle transporter is used)
• Cytomat SILAS Module Software for the use of the Cytomat 2C device in Biomek or SAMI EX
Software
• Random Access Storage Steps Software for the use of the Cytomat 2C directly, or accessed by a
Conveyor (necessary if the Cytomat 2C will be used in Biomek Software)
• A Serial communications cable for communication with the Cytomat 2C device’s labware
transportation mechanism
• An Installation Guide for installing the Cytomat 2C as a custom integration on various Biomek
and SAMI EX Platforms (this document)
• A User’s Guide for using the Cytomat SILAS Module in Biomek and SAMI EX Software
NOTE The Cytomat 2C may be separately provided or may be provided with this custom integration, if
ordered as part of this custom integration. It must be ordered with a Transfer Station.
NOTE The short or standard length Conveyor may be separately provided, or it may be provided with
this custom integration, if it was ordered as part of this custom integration.
B54476AB 3-77
3.20 Cytomat 2C Incubator Integration for Biomek i-Series
Prerequisites
It is assumed that prior to the installation of this custom integration the customer has a working
system installed with the following items:
• Standard BCI Controller PC with Windows 10
• A Conveyor for labware transportation to and from the Cytomat 2C device unless it will be
accessed directly by a Biomek Gripper
• Biomek Instrument with appropriate ALP types and peripherals
• Biomek Software, version 5.x or greater
• SILAS Software, version 4.1.22 or greater, for using the newest SILAS Modules
• SAMI EX Software, version 5.x or greater, for the system (optional)
WARNING
Risk of personal injury or equipment damage. The device is heavy and requires
precautions to be observed before lifting the device. Please use two or more
people to lift the device, or use appropriate lifting equipment to lift the device, to
place it into position on the system.
3-78 B54476AB
3.21 Cytomat 2C with Conveyor Installation 3
3.21 Cytomat 2C with Conveyor Installation
Multiple hardware options are available for the Cytomat 2C. The Cytomat 2C can be supported on a
custom table, at the same height as the Biomek table, where it can be accessed by a Conveyor.
Purpose
The Cytomat 2C is installed onto the standard mounting platform for all Biomek integrations. The
standard mounting platform shown here, or a mounting strip, may be used for robotic integrations.
The Cytomat with Conveyor can also be installed on the left side or right side of the Biomek deck.
Mirror these installation instructions for the right side of the Biomek deck.
 Left side shield with conveyor cutouts and blanking plates
Procedure
To install the Cytomat 2C accessible by a Conveyor on the Biomek deck:
1. Before starting the installation of the Cytomat hardware, make sure that the Biomek is at the
appropriate height. The height of the Biomek must be adjusted so that the bottom of the beams
under the Biomek deck plates that run from the front to the back of the Biomek on each side of
the Biomek are 1.2 inches from the top of the table. This sets the Biomek at the correct height
for the conveyors to align properly to the Cytomat devices. Use the Biomek leveling feet to
make this adjustment. Make sure that the Biomek is level and that the bottom of the beams are
1.2 inches off of the table top before proceeding (see Figure 3.21-1).
Figure 3.21-1 Biomek Height Measurement
B54476AB 3-79
2. Install the left full side shield with Conveyor cutouts for rows 1, 3, and 5 (see Side Panel Removal
and Replacement). Attach the blanking plates to the cutouts not to be used. The middle cutout is
used for a Cytomat2C/Conveyor on either side of the Biomek deck. Attach the hole adjustment
sliding plates over the hole so they are fully open to allow for mounting the Conveyor.
NOTE The other cutout locations are for when using a Cytomat MPH.
Figure 3.21-2 Install Side Shielding with Conveyor Location Hole Adjustment Sliders
3. Attach the Cytomat 2C attachment bracket to the left side of the Biomek deck. It mounts to the
Biomek U-Channel under the deck plates. See the next step for hole mounting locations on the
U-Channel.
Figure 3.21-3 Cytomat Attachment Bracket Mounted to Biomek Deck
4. The Cytomat2C attachment bracket is attached to front holes on middle row (row 3) of the
Biomek deck. Mount the bracket with the four M6 machine screws provided to the U-Channel
in this location. Leave the hardware loose until the Cytomat 2C alignment is completed.
3-80 B54476AB
3.21 Cytomat 2C with Conveyor Installation 3
Figure 3.21-4 Attach Cytomat Attachment Bracket to the Biomek U-Channel
5. Attach a Conveyor Riser Block to the deck where the Conveyor will be mounted. This should
raise the Conveyor about ½ inch. Attach the Conveyor to the bracket to pass through the cutout
in the side shield.
Figure 3.21-5 Attach Conveyor to Riser Block
6. Place the Cytomat 2C mounting strip under the Cytomat 2C attachment bracket near where the
Cytomat 2C device will be placed (see Figure 3.21-6). The holes for the mounting strip should be
located away from the Biomek. Loosely attach the mounting strip to the bracket to allow for
Cytomat 2C alignment.
B54476AB 3-81
Figure 3.21-6 Place Cytomat 2C Mounting Strip Under Attachment Bracket
7. Remove the Transfer Station (Plate Holder) from the Cytomat 2C device. Save the plate sensor
for attachment to the Conveyor or Servo Shuttle. Place the Cytomat onto the mounting strip, in
the correct orientation, to locate the feet of the Cytomat 2C and align it physically with the end
of the Conveyor.
Figure 3.21-7 Place Cytomat 2C on Mounting Strip and Align with Conveyor
3-82 B54476AB
3.22 Cytomat 2C Directly Accessed by Biomek Gripper Installation 3
3.22 Cytomat 2C Directly Accessed by Biomek Gripper Installation
Purpose
The Cytomat 2C for direct access by the Biomek Gripper can only be installed on the left side of the
Biomek deck.
Procedure
To install the Cytomat 2C to be Accessible by the Biomek Gripper Directly:
1. Install the left full side shield with Cytomat cutouts for rows 1, 3, and 5. Attach the blanking
plates to the cutouts not to be used. The middle cutout is used for a Cytomat 2C on the left side.
Attach the metal guard around the hole for the Cytomat.
Figure 3.22-1 Install Side Shielding with Cytomat Metal Guard
B54476AB 3-83
2. Attach the Cytomat 2C attachment bracket to the left side of the Biomek deck. It mounts to the
U-Channel.
3. The Cytomat 2C attachment bracket is attached to front holes on middle row (row 3) of the
in this location. Leave the hardware loose until the Cytomat alignment is completed.
4. Place the Cytomat 2C mounting strip under the Cytomat 2C attachment bracket near where the
Cytomat MPH device will be placed (see Figure 3.22-4). The holes for the mounting strip should
3-84 B54476AB
3.22 Cytomat 2C Directly Accessed by Biomek Gripper Installation 3
be located away from the Biomek. Loosely attach the mounting strip to the bracket to allow for
Cytomat 2C alignment.
Figure 3.22-4 Place Cytomat2C Mounting Strip Under Attachment Bracket
5. Place the Cytomat 2C onto the mounting strip, in the correct orientation, and align it physically
so that the Transfer Station is centered in the hole cut out of the side shield. Slide the
Cytomat 2C toward the Biomek so that the gate cover on the Cytomat is within ¼ inch of
touching the side shield. Verify that the guard on the side shield covers the Cytomat transfer
station shuttle area. Secure the mounting hardware to lock it into place and replace the Biomek
deck plates.
Figure 3.22-5 Side View of Cytomat 2C Attached to the Left Side of the Biomek Deck
B54476AB 3-85
6. Verify that the Biomek Gripper can access the Cytomat Transfer Station.
Figure 3.22-6 Cytomat 2C Mounted to Left Side of Biomek Deck
See 3.25, Cytomat Electrical and Communications Connections for electrical connections.
3-86 B54476AB
3.23 Conveyor Installation 3
3.23 Conveyor Installation
Purpose
The Conveyor may be positioned at any of the two right-most or left-most rows of positions on the
deck of the Biomek, depending on the location of the Cytomat 2C. The inner (on-deck) position of
the Conveyor has to be accessible by the Biomek Gripper.
NOTE For detailed instructions on setting up, configuring and framing the Conveyor refer to the
Cytomat Device Integration Instructions For Use, PN B91265).
Procedure
1. Orient the Conveyor so the unsupported end of the conveyor extends beyond the deck of the
Biomek instrument.
2. Fasten the Conveyor to the deck using the thumbscrews on the base of the ALP.
3. Connect one end of the serial communication cable (Cable AF) to the serial communication port
on the Conveyor. Connect the other end of the serial communication cable to a serial
communication port on the host PC (note the port number).
4. Connect the power supply to the Conveyor.
NOTE After installing the Conveyor, the location and height of the custom Cytomat 2C table may need
to be adjusted to properly align the end of the Conveyor with the gate and shovel of the Cytomat 2C.
5. Remove the plate sensor from the Transfer Station of the Cytomat 2C by first disconnecting the
DB9 connector from the device.
6. Unscrew the barrel sensor from the Transfer Station and thread it through the mounting tab on
the conveyor or shuttle (Figure 3.23-1).
Figure 3.23-1 Barrel Sensor on Conveyor ALP
7. Adjust the height of the barrel sensor by turning it. The sensor should be close to, but not make
contact with, a microplate setting on the conveyor/shuttle.
8. Reattach the DB9 connector to the Cytomat 2C.
B54476AB 3-87
3.23 Conveyor Installation
3-88 B54476AB
3.24 Bar Code Reader Installation 3
3.24 Bar Code Reader Installation
Purpose
If installing the optional Barcode Reader on the Conveyor (Cytomat ALP), follow the additional steps
below.
NOTE The instructions given are for reading bar codes on the short end of the plate. If reading bar codes on
long end of plate, remove the top BCR mounting screws and rotate the BCR 90 degrees. Replace and
tighten the top mounting screws.
Procedure
1. Mount the Barcode Reader to the Barcode Reader Hardware.
2. Attach the Bar Code Reader to the bracket using the two supplied screws. Thread the cable
through the cable clamp on the side of the bracket. (Figure 3.24-1)
Figure 3.24-1 Barcode Reader adjustments
3. Remove one mounting screw and loosen the other. Rotate the clamping plate to allow the
bracket to fit between the rails on the Conveyor (Figure 3.24-1).
4. Attach the bracket on the Conveyor as shown in Figure 3.24-2. Replace the mounting screw
removed previously.
5. Position the bracket on the Conveyor approximately 3.5” from the end of the rails. Tighten the
mounting screws to secure the bracket.
6. Adjust the height using the lower two screws on the Barcode Reader Hardware (Figure 3.24-1).
7. Be sure the reader is high enough to allow tip boxes and deep-well labware to pass under it if
necessary.
8. Adjust the bracket until the laser beam is lined up on the bar code label of a plate.
B54476AB 3-89
3.24 Bar Code Reader Installation
Figure 3.24-2 Barcode Reader installation
3-90 B54476AB
3.25 Cytomat Electrical and Communications Connections 3
3.25 Cytomat Electrical and Communications Connections
Purpose
Use the following procedure to connect the Cytomat electrical and communications connections.
NOTE For technical specifications see

https://www.thermofisher.com/search/browse/category/us/en/602485/Laboratory+Automation+Freezer
s+%26+Incubators.
 Cytomat 2C Configuration Software CD
Procedure
1. Connect one end of the serial communication cable into the serial communication port on the
device (see Figure 3.25-1).
Figure 3.25-1 Connection panels on the Cytomat 2C
2. Connect the other end of the serial communication cable into a serial communication port on
the host PC (note the port number for later use).
3. Connect power and turn on the device.
4. Plug in the appropriate power and communication cables as shown in Figure 3.25-1, making
note of the specified COM Port for subsequent software configuration purposes.
5. Install the Cytomat Configuration Software onto the Host PC and configure the plate shovel to
properly transport plates to the transfer station.
B54476AB 3-91
3.25 Cytomat Electrical and Communications Connections
3-92 B54476AB
3.26 Loading Cytomat Hotels 3
3.26 Loading Cytomat Hotels
There are various sizes of hotels to be used with the Cytomat 2C. Regardless, they will all load into
the device in a similar orientation. On the base of the turntables, elongated interlocks are used to
receive and secure the hotels into place. An example is shown in Figure 3.26-1 and Figure 3.26-2.
Figure 3.26-1 Cytomat Hotel Interlock without Hotel
Figure 3.26-2 Cytomat Hotel Interlock with Hotel
B54476AB 3-93
3.26 Loading Cytomat Hotels
3-94 B54476AB
3.27 Cytomat 2C Configuration Software Installation 3
3.27 Cytomat 2C Configuration Software Installation
Purpose
This section includes:
• Cytomat Configuration Software Installation Procedure
• Conveyor SILAS Module Installation
• Cytomat SILAS Module Installation
• Random Access Storage Step Installation (Install only if using the device in Biomek Software)
 Cytomat 2C software CD
Cytomat Configuration Software Installation Procedure

1. Locate the CD with the Cytomat 2C vendor supplied software. Follow the instructions in the
software setup guide to install this software on the PC. This software will be used later to align
the transfer station plate handler with the end of the Conveyor.
B54476AB 3-95
Conveyor SILAS Module Installation

NOTE Use the Conveyor SILAS Module installation provided with this integration rather than the one
provided with the Conveyor (Cytomat ALP).
1. Locate the Conveyor Installation.msi on the integration CD supplied.

2. Launch the install and follow the on-screen instructions, selecting the options that correspond
to the Conveyor being installed.
3. Select the type of Conveyor to be installed on the system. It should match the hardware type of
the Conveyor provided.
Figure 3.27-1 Conveyor Installation Program
Figure 3.27-2 Conveyor Installation Type Selection
4. Continue with the installation of the SILAS Module. The installation should complete normally.
3-96 B54476AB
3.27 Cytomat 2C Configuration Software Installation 3
Cytomat SILAS Module Installation

1. Locate the CytomatInstall.n.n.n.msi on the integration CD supplied. Check Airwatch for the
latest installation.
to the Cytomat being installed. Give the module an appropriate Module Name (such as
Cytomat2C) in the configuration screen to differentiate it from other Cytomat devices on the
system.
NOTE If multiple Cytomat 2C devices are installed on the system, give each one a unique name. Each
device must have an associated SILAS Module.
Figure 3.27-3 Cytomat Installation Program
Figure 3.27-4 Cytomat SILAS Module Configuration
B54476AB 3-97
Random Access Storage Step Installation (Install only if using the device in Biomek
Software)
Purpose
This installation program installs the steps necessary to use the Cytomat 2C more easily in Biomek
Software.
1. On the installation disk, locate and run the file

RandomAccessStorageBiomekSupport Install – n.n.n.msi.
2. Follow the on-screen instructions to complete the installation.
3-98 B54476AB
3.28 Cytomat 2C Setup and Configuration in Biomek Software 3
3.28 Cytomat 2C Setup and Configuration in Biomek Software
Purpose
Setup of the Cytomat 2C in Biomek Software requires configuring the device in the Biomek Software
Hardware Configuration Tool, and using the Biomek Deck Editor.
NOTE This section is not necessary when using the device with a robotic transporter on a SAMI EX System.
Biomek Setup with Conveyor Procedure

Setup of the Cytomat 2C in Biomek requires creating a Cytomat Device in Biomek Software’s
Hardware Setup. This subsection is not necessary when using SAMI EX.
1. Open the Biomek Hardware Setup window by selecting Instrument > Hardware Setup from the
Biomek Software menu.
2. Click Add Device, and then select Cytomat Device to add a new Cytomat Device. A new Cytomat
Device will appear under the Random Access Storage Hotels > Cytomat Devices area within
Biomek Hardware Setup (see Figure 3.28-1).
Figure 3.28-1 New Cytomat Device in Biomek Hardware Setup
3. A Cytomat Device in Biomek Software references the SILAS Modules used to control a Cytomat
and a Conveyor. Highlight the newly created Cytomat Device and specify the Storage Module
and Conveyor Module to use to control the individual components of the Cytomat Device on the
system.
B54476AB 3-99
4. Make sure that the Random Access Storage steps are available in Biomek Software (see
Figure 3.28-2). These steps are used when creating a Biomek Method that utilizes the Cytomat
Device.
Figure 3.28-2 Biomek Software Showing Random Access Steps
5. Open the Deck Editor in Biomek Software. Add the appropriate Conveyor ALP to the Biomek
deck that matches the type of conveyor provided.
Figure 3.28-3 Standard Length Conveyor ALP
6. For Biomek systems, double-click on the inner position for the Conveyor ALP to open the
Position Properties window. Associate the Cytomat Device configured in Hardware Setup with
the inner position on the Conveyor ALP, or with the Cyto position of the Cytomat ALP (see
Figure 3.28-4).
3-100 B54476AB
Figure 3.28-4 Conveyor ALP inner Position Properties
NOTE Do not associate a device to the outer Conveyor ALP position.
7. Teach the Cytomat Device’s inner or Cyto position utilizing the Accu-frame tool and the Auto
Teach method. Teach the position using the normal Conveyor (Cytomat ALP) framing
techniques.
8. Configure and teach the remaining positions on the Biomek deck if they haven’t been taught
yet.
Biomek Setup for Biomek Gripper Direct Access Procedure

1. Open Biomek Hardware Setup by selecting Utilities > Hardware Setup from the Biomek Software
menu.
B54476AB 3-101
Figure 3.28-5 Cytomat Device using Cytomat for Direct Access in Biomek Hardware Setup
3. A Cytomat Device in Biomek Software references the SILAS Module used to control the Cytomat
and allowing device setup and labware data to be included with the labware. Highlight the
newly created Cytomat Device and specify the Cytomat2C for the Storage Device module.
4. Specify None for the Conveyor/Shuttle module to access the Cytomat directly.
5. Make sure that the Random Access Storage tool bar palette is installed in Biomek Software (see
Device.
Figure 3.28-6 Biomek Software Showing Random Access Steps in Various Tabs
3-102 B54476AB
6. Open the Deck Editor in Biomek Software. Add the Cytomat2CLeft ALP to the Biomek deck.
Figure 3.28-7 Cytomat2CLeft ALP Added to Biomek Deck
7. Select the Cytomat.

8. Select More >> to expand properties.
9. Select the Device dropdown box, then select the device added in HW setup to associate it
(Figure 3.28-8).
Figure 3.28-8 Position Properties
B54476AB 3-103
Framing the Cytomat ALP
CAUTION
Framing a Cytomat ALP sets the correct position for the current deck; it does not
change framing information for other decks. If a different deck is used, this ALP
must be re-framed for that deck before it is used in a method.
A Cytomat ALP is framed using the gripper framing technique instead of using the AccuFrame tool.
An error will occur if the Cytomat initializes while framing using the gripper. Perform the following
steps to frame the Cytomat Device using the gripper framing technique:
1. To prevent the Cytomat error from occurring, open Biomek Hardware Setup and uncheck
(disable) the check mark box to Initialize modules at the beginning of method for CytomatDevice1
(refer to Figure 3.28-9).
Figure 3.28-9 Disable Initialization of the Cytomat Device
2. Click the Accept button to save the hardware changes.
3-104 B54476AB
3. Open the Biomek Deck Editor. Double-click the Cytomat ALP position square to open the
Cytomat ALP Position Properties window.
Figure 3.28-10 Cytomat ALP Position Properties
4. Click Manual Teach to open the Manual Framing Wizard. Follow the instructions to frame the
position using the gripper framing technique (refer to Figure 3.28-11).
Figure 3.28-11 Manual Framing Wizard
B54476AB 3-105
5. Click OK to close the Cytomat ALP Position Properties window.

6. Click Save to save changes to the Biomek Deck and close the Biomek Deck Editor.
7. Open Biomek Hardware Setup and click (enable) the check mark box to Initialize modules at the
beginning of method for CytomatDevice1 (refer to Figure 3.28-12).
Figure 3.28-12 Enable Initialization of Cytomat Device
8. Click Accept to save the hardware changes.
3-106 B54476AB
3.29 Cytomat 2C Configuration Using Device Software 3
3.29 Cytomat 2C Configuration Using Device Software
Purpose
Setup consists of configuring the device for use in Biomek Software, configuring the device for use
in SAMI EX Software, and specifying the device’s SILAS Module Options.
 Cytomat 2C Configuration Software CD
Procedure
The device’s Cytomat Configuration Software is used to configure the height of the plate handler for
external loading and unloading of labware. Use this tool to aid in the alignment of the transfer
station to the Conveyor or Servo Shuttle transporter.
NOTE The following is a brief overview of the configuration procedure. For detailed instructions on
configuration and use of this software refer to the vendor supplied software documentation.
1. Start the software and select the COM-port that is associated with the Cytomat 2C.
2. In the Adjustment drop-down menu click the transfer station item to set up transfer station
parameters. While the window is opening, the Parameter fields will slowly fill in automatically
as the utility connects with the Cytomat 2C.
3. Start by entering a number in the Height of first transfer station [Step] text box corresponding
to the desired height of the shovel.
4. Click the Turn “out” button in the middle of the screen. This will turn the transfer station out to
allow for adjustment. Then click Shovel “out” button to extend the shovel.
5. Continue to fine-tune the parameters in Table 1 below by entering values in the Parameter fields
and clicking the corresponding buttons in the Run to field, until the shovel exits just above the
transfer station.
6. Place a microplate onto the transfer station and try picking it up with the shovel using the
height, height plus and height minus buttons.
The following table shows parameters for adjusting the plate handler position:
B54476AB 3-107
3.29 Cytomat 2C Configuration Using Device Software
Table 3.29-1 Transfer Station Parameters
Parameter Functional Description Button to Move to the

Value of Parameter
Height delta plus (Step) This is the height at which the shovel moves height plus
when carrying a plate. This setting is high
enough to allow the plate to clear the edges
(friendly’s) of the Transfer Station.
Height of first transfer This is the height at which the shovel and plate height
station (Step) are in contact with each other on the Transfer
Station.
Height delta minus (Step) This is the height at which the shovel is in height minus
between a plate that is on the Transfer Station
and the top of the Transfer Station. It is low
enough to pass under the plate without hitting
the Transfer Station.
7. After the alignment is done, click the Turn “in” and Shovel “in” buttons to retract the shovel and
then click the Write parameter button to write the values to the device’s memory.
8. Close the window and quit the software.
NOTE To avoid software complications, be sure to Initialize the device through the Cytomat SILAS
Module after exiting the device’s Configuration Software.
3-108 B54476AB
3.30 Cytomat 2C Setup and Configuration the SAMI EX Installer Tool (Optional) 3
3.30 Cytomat 2C Setup and Configuration the SAMI EX Installer Tool

(Optional)
Purpose
Setup of the Cytomat 2C in SAMI EX Software requires configuring the device in the SAMI EX
Installer Tool.
SAMI EX Installer Tool Configuration Procedure

Figure 3.30-1 SAMI EX Installer Tool with a Cytomat 2C and Conveyor Linked
1. Open the SAMI EX Installer Tool.

2. Drag the devices to their correct locations on the system, and link them. When the positions
overlap, they will turn to a green fill color to indicate that they can be linked.
3. When linked, the fill color for the position will turn from green to purple.
4. The SAMI EX Installer Tool images in Figure 3.30-1 above show a Cytomat linked with the
Conveyor.
When using a robotic transporter, linking is done through the Robotic Transporter’s Device
Configuration settings. Linked positions for a robotic transporter in the SAMI EX Installer Tool
will not show in a green or purple color.
B54476AB 3-109
3.30 Cytomat 2C Setup and Configuration the SAMI EX Installer Tool (Optional)
3-110 B54476AB
3.31 Cytomat MPH Integration for Biomek i-Series 3
Part C Cytomat MPH Installation
3.31 Cytomat MPH Integration for Biomek i-Series
Purpose
This custom integration provides the necessary hardware and software modifications for using a
Thermo Scientific Cytomat MPH on a custom system running Biomek Software or SAMI EX
Software.
The carousel of the Cytomat MPH can hold up to 9 hotels with up to 21 plates in each hotel
(depending on device configuration). The device is controlled through the RS 232 interface.
This integration allows for use of a Cytomat MPH on a system accessed directly by a Biomek Gripper,
by a Conveyor transporter, by a Servo Shuttle transporter, or by a robotic transporter. A Cytomat
SILAS Module interface is provided for automated control of the device in a SAMI EX Method. The
SILAS Module also provides manual control capabilities through SAMI EX Software.
Items Provided
The following items are supplied as part of this custom integration:
• Mounting hardware for the Cytomat MPH device
• Cytomat SILAS Module for configuring and controlling the Cytomat MPH
• Random Access Storage Steps for using the Cytomat MPH directly with a Biomek Gripper, or
with a Conveyor or Servo Shuttle (only applicable to Biomek Software integrations)
• Communication cables for the custom components of the system
• User Guide
Prerequisites
It is assumed that prior to the installation of this custom integration the customer has a working
system installed with the following items:
• Standard BCI Controller PC with Windows 10
• A Conveyor for labware transportation to and from the Cytomat MPH device, unless it will be
accessed directly by a Biomek Gripper
• Biomek Instrument with appropriate ALP types and peripherals
• Biomek Software, version 5.x or greater
• SILAS Software, version 5.x or greater, for using the newest SILAS Modules
• SAMI EX Software, version 5.x or greater, for the system (optional)
Refer to the manuals for the aforementioned items for installation and setup instructions.
B54476AB 3-111
3.31 Cytomat MPH Integration for Biomek i-Series
WARNING
Risk of personal injury or equipment damage. The device is heavy and requires
precautions to be observed before lifting the device. Please use two or more
people to lift the device, or use appropriate lifting equipment to lift the device, to
place it into position on the system.
WARNING
Risk of contamination. There is the potential for labware spillage when
transporting labware to and from the Cytomat MPH. Ensure the Cytomat MPH
transfer station is positioned accurately and that the transporter moving labware
moves at an appropriate speed. Do a dry run before running a method with
labware that contains liquids.
3-112 B54476AB
3.32 Cytomat MPH With Conveyor Installation 3
3.32 Cytomat MPH With Conveyor Installation
The Cytomat MPH is a plate storage unit that is accessible via the transporter appropriate to the
system.
Purpose
The Cytomat MPH is installed onto the standard mounting platform for all Biomek integrations. The
standard mounting platform shown here, or a mounting strip, may be used for robotic integrations.
Figure 3.32-1 Cytomat Mounting Platform
The Cytomat with Conveyor can also be installed on the left side or right side of the Biomek deck.
Mirror these installation instructions for the right side of the Biomek deck.
Procedure
To install the Cytomat MPH Accessible by a Conveyor on the Biomek deck:
1. Before starting the installation of the Cytomat hardware, make sure that the Biomek is at the
appropriate height. The height of the Biomek must be adjusted so that the bottom of the beams
under the Biomek deck plates that runs from the front to the back of the Biomek on each side
of the Biomek are 3 cm (1.2 in.) from the top of the table. This sets the Biomek at the correct
height for the conveyors to align properly to the Cytomat devices. Use the Biomek leveling feet
to make this adjustment. Make sure that the Biomek is level and that the bottom of the beams
are 1.2 inches off of the table top before proceeding (see Figure 3.32-2).
B54476AB 3-113
Figure 3.32-2 Biomek Height Measurement
2. Install the left full side shield with Conveyor/Servo Shuttle cutouts for rows 1, 3, and 5 (see Side
Panel Removal and Replacement). Attach the blanking plates to the cutouts not to be used. The
left front cutout is used for a Cytomat/Conveyor on the left side. The right rear cutout is used
for a Cytomat/Conveyor on the right side. Attach the hole adjustment sliding plates over the
hole so they are fully open to allow for mounting the Conveyor.
NOTE The other cutout locations are for when using a mirrored Cytomat MPH, or for using a Cytomat 2C
through the middle (row 3) cutout.
Figure 3.32-3 Install Side Shielding with Conveyor Location Hole Adjustment Sliders
3. Attach the Conveyor attachment bracket to the deck plate on the Biomek. The Cytomat will be
mounted to the table top, so the left to right location of the bracket is adjustable. Mount this
3-114 B54476AB
bracket further to the left to allow for more deck space. Do not place it further left than the left
partial deck plate. The bracket must rest fully on the deck plate(s).
Figure 3.32-4 Conveyor Attachment Bracket Mounted to Biomek Deck
4. Attach a Conveyor to the bracket to pass through the cutout in the side shield.
Figure 3.32-5 Attach Conveyor to Attachment Bracket
B54476AB 3-115
5. Place the Cytomat MPH mounting platform near where the Cytomat MPH device will be placed
(see Figure 3.32-6). The mounting slots at the bottom of the mounting platform
(see Figure 3.32-8) should face the Biomek and Conveyor.
Figure 3.32-6 Place Cytomat Mounting Platform on Table
6. Remove the Transfer Station (Plate Holder) from the Cytomat MPH device. Save the plate sensor
for attachment to the Conveyor or Servo Shuttle. Place the Cytomat onto the mounting
platform, in the correct orientation, and align it physically with the end of the Conveyor.
Figure 3.32-7 Place Cytomat on Mounting Platform and Align with Conveyor
3-116 B54476AB
7. After alignment has been verified through operation with the Conveyor under software control,
secure the mounting platform to the table top using the L-Shaped brackets and M6 machine
screws provided. It may be necessary to drill and tap the holes into the tabletop, if threaded
holes are not provided.
Figure 3.32-8 Secure the Cytomat MPH Mounting Platform to Table Top
B54476AB 3-117
3-118 B54476AB
3.33 Cytomat MPH Directly Accessed by Biomek Gripper Installation 3
3.33 Cytomat MPH Directly Accessed by Biomek Gripper Installation
Purpose
The Cytomat MPH for direct access can only be installed on the left side of the Biomek deck.
Procedure
To install the Cytomat 2C to be Accessible by the Biomek Gripper Directly:
1. Install the left full side shield with Cytomat cutouts for rows 1, 3, and 5. Attach the blanking
plates to the cutouts not to be used. The middle cutout is used for a Cytomat 2C on the left side.
Attach the metal guard around the hole for the Cytomat.
Figure 3.33-1 Install Side Shielding with Cytomat Metal Guard
B54476AB 3-119
2. Attach the Cytomat attachment bracket to the left side of the Biomek deck. It mounts to the
U-Channel.
3. The Cytomat 2C attachment bracket is attached to front holes on middle row (row 3) of the
in this location. Leave the hardware loose until the Cytomat alignment is completed.
3-120 B54476AB
3.33 Cytomat MPH Directly Accessed by Biomek Gripper Installation 3
4. Place the Cytomat MPH mounting platform near where the Cytomat MPH device will be placed.
The mounting slots at the bottom of the mounting platform should face the Cytomat
attachment bracket. Attach the Cytomat mounting platform to the threaded tabs of the Cytomat
attachment bracket.
Figure 3.33-4 Attach Cytomat Mounting Platform to Attachment Bracket
5. Place the Cytomat onto the mounting platform, in the correct orientation, and align it
physically so that the Transfer Station is centered in the hole cutout of the side shield. Verify
that the guard on the side shield covers the Cytomat transfer station shuttle area. Secure the
mounting hardware to lock it into place and replace the Biomek deck plates.
Figure 3.33-5 Side View of Cytomat MPH Attached to the Left Side of the Biomek Deck
B54476AB 3-121
6. Verify that the Biomek Gripper can access the Cytomat Transfer Station.
Figure 3.33-6 Cytomat MPH Mounted to Left Side of Biomek Deck
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3.34 MPH Transfer Station Configuration for a Conveyor 3
3.34 MPH Transfer Station Configuration for a Conveyor
Purpose
To use the Cytomat MPH with a Conveyor that extends from a Biomek deck, additional transfer
station configuration is required.
Procedure
1. Make sure the Cytomat transfer station assembly is correctly mounted directly to the Cytomat
MPH device. Refer to the documentation supplied by the manufacturer for detailed
instructions.
2. Remove the plate holder portion of the transfer station (Figure 3.34-1) if present so that the
transfer station appears as in Figure 3.34-2.
Figure 3.34-1 Plate Holder and Barrel Sensor
Figure 3.34-2 Transfer Prior to Attaching Bracket
B54476AB 3-123
3.34 MPH Transfer Station Configuration for a Conveyor
3. Remove the Barrel Sensor from the Transfer Station plate holder.
Figure 3.34-3 Barrel Sensor
4. From within the Cytomat Device Software (see 3.37, Cytomat MPH Configuration Using Device
Software), extend the shovel out over the transfer station.
5. Align the Cytomat MPH such that the shovel is centered in the end of the Conveyor.
6. Mount the barrel sensor to the Conveyor by screwing it into the threaded hole provided for it
in the outer end of the Conveyor (Figure 3.34-4).
Figure 3.34-4 Barrel Sensor Mounting
7. Connect the DB9 connector of the barrel sensor to the correct port on the Cytomat device.
3-124 B54476AB
3.35 MPH Installing Cabling 3
3.35 MPH Installing Cabling
Purpose
Use the procedure below to install Cytomat communication and power cables.
Procedure
1. Plug one end of the serial communication cable into the serial communication port on the
Cytomat.
2. Plug the other end of the serial communication cable into a serial communication port on the
host PC (note the port number).
3. Firmly attach the power cord to the device and plug it into the appropriate power outlet. Power
will not be supplied to the unit until the power switch is turned on.
NOTE When power is applied to the system, the device will automatically and immediately initiate the
home sequence. Care should be taken to remove obstacles that may interfere with movement of the
device before powering on the device.
B54476AB 3-125
3.35 MPH Installing Cabling
3-126 B54476AB
3.36 Loading Cytomat MPH Hotels 3
3.36 Loading Cytomat MPH Hotels
There are various sizes of hotels to be used with the Cytomat 2C. Regardless, they will all load into
the device in a similar orientation. On the base of the turntables, elongated interlocks are used to
receive and secure the hotels into place. An example is shown in Figure 3.36-1 and Figure 3.36-2.
Figure 3.36-1 Cytomat Hotel Interlock without Hotel
Figure 3.36-2 Cytomat Hotel Interlock with Hotel
B54476AB 3-127
3.36 Loading Cytomat MPH Hotels
3-128 B54476AB
3.37 Cytomat MPH Configuration Using Device Software 3
3.37 Cytomat MPH Configuration Using Device Software
Purpose
The Cytomat MPH device comes with an additional software utility supplied by the manufacturer
which is used to configure the device. Install this program on the controller PC and use it to
configure the device before continuing. Refer to documentation supplied by the manufacturer for
details on using device software. The following instructions are intended as guidelines for initial
setup and testing.
 Cytomat MPH software CD
Procedure
Setup Utility
1. Install the manufacturer-supplied software that came with the device.
2. Open the software and set the communications port that is associated with the device.
3. Click the Set Password in the Password menu.
4. The Password window will open. Type the password of ELEKTRONIK and press Enter. A dialog
should be displayed with “Password OK” in it. This will allow for full modification of any
parameters of the software.
B54476AB 3-129
Transfer Station Parameters

1. From the Adjustment menu, select Transfer Station. While the window is opening, the Parameter
fields will fill in automatically as the utility connects to the device and reads the values from the
device firmware.
Figure 3.37-1 Configure Adjustment Transfer Station Screen
2. Click the Turn “out” button to rotate the handler to face outward, ready to extend the shovel.
3. Click the Shovel “out” button to move the shovel out to the transfer station to allow for
adjustment.
The following parameters are what will be necessary for making adjustments for the transfer
station. The following reference table shows the parameter, function, and the button to press
once the adjustment has been made. Keep these parameters handy, because they will be needed
for this entire process.
4. Adjust parameters until the plate comes out and goes back in at the required position on the
transfer station. The Write parameter button does not need to be clicked each time a parameter
is changed. Changes can be tested within the software until the correct settings are found. Once
the final changes are made, Write parameter must be clicked so that they are written to the
device firmware and will subsequently work with the module.
3-130 B54476AB
Table 3.37-1 Transfer Station Parameters
Parameter Functional Description Button to Move to the

Value of Parameter
Height delta transfer This value is added to the Height transfer height plus
station plus station value to get the height at which the
shovel moves when carrying a plate. This
setting is high enough to allow the plate to
clear the edges of the Transfer Station, without
having tall labware hit the top of the plate
handler opening.
Height transfer station This is the height at which the shovel and plate height
are in contact with each other on the Transfer
Station. During automated operation, this
value is not used by itself, but rather in
conjunction with the Height delta transfer
station plus value or the Height transfer
station minus value.
Height delta transfer This value is subtracted from the Height height minus
station minus transfer station value to get the height at
which the shovel moves when it is between the
Transfer Station and a plate on it. It is low
enough to pass under a plate and high enough
to not hit the Transfer Station.
5. After parameters are fully tested and written to the device, click the Shovel “in” button to cause
the plate shovel to retract back into the device.
6. After the shovel is in, click the Turn “in” button to rotate the handler to face inward.
7. After the shovel is turned in, click the Close gate button to close the automated door.
8. An additional test should be done before closing the software to ensure the parameters are
written correctly. With a plate on the transfer station, use the following commands to test
automated retrieval of a plate from the transfer station, into the device, and then back to the
transfer station:
• height minus
• Turn “out”
• Shovel “out” {shovel should be aligned with transfer station and plate and should not hit
them}
• height plus {shovel should cleanly lift the plate above the transfer station}
• Shovel “in”
• Turn “in”
• height {at this point the plate should be on the handler shovel inside the device}
• height plus
• Turn “out”
• Shovel “out”
• height minus {the plate should be set cleanly onto the transfer station}
B54476AB 3-131
• Shovel “in”
• Turn “in”
9. If not already done, it is recommended that 3 inch by 0.75 inch self-adhesive friction tape be
added to the Cytomat MPH plate shovel (Figure 21). This helps to prevent some labware types
from slipping on the shovel during automated operation. This is most easily accomplished while
the plate shovel is extended during alignment.
Figure 3.37-2 Friction tape on Plate Shovel
Turning Off “Rotisserie Mode”

Many Cytomat MPH devices are preconfigured to automatically start rotating after 10 minutes. This
can cause trouble for automated operation of the device. To turn this off:
1. From the Parameter menu, select basic parameter to open the basic parameter screen.
2. Set both the Time to turn the turntable [s] and Time to turn the turntable [Min] values to 0 (zero).
3. Click the Close button to close this screen and return to the main menu.
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Final Testing
After closing the software, test labware motions using the SILAS Module to confirm proper
operation. This can be an iterative process. Make sure the SILAS Module is not in memory while
using the software provided by the manufacturer.
NOTE It is important that the transfer station and hotel configuration parameters are accurately configured.
Refer to the manufacturer-supplied documentation for additional information on how to use the software.
IMPORTANT Attention!!! To avoid software complications, be sure to initialize the device after exiting the
device’s configuration software.
B54476AB 3-133
3-134 B54476AB
3.38 Installation of Software Items 3
3.38 Installation of Software Items
Purpose
This section includes:
• Conveyor SILAS Module Installation
• Cytomat MPH SILAS Module Installation
• Random Access Storage Step Installation (Install only if using the device in Biomek Software)
 Cytomat MPH software CD
Conveyor SILAS Module Installation

1. Locate the Conveyor Installation.msi on the integration CD supplied.
to the Conveyor being installed.
3. Select the type of Conveyor to be installed on the system. It should match the hardware type of
the Conveyor provided.
Figure 3.38-1 Conveyor Install “Welcome” Screen
B54476AB 3-135
Figure 3.38-2 Conveyor Installation Type Selection
4. Continue with the installation of the SILAS Module. The installation should complete normally.
Cytomat MPH SILAS Module Installation

To install the Cytomat MPH SILAS Module:
1. On the installation disk, locate and run the CytomatInstall.x.x.x.msi installer and step through
the installation (Figure 3.38-3).
Figure 3.38-3 Module Installation Dialog
2. When the configuration screen appears (Figure 3.38-4), select the appropriate Cytomat Type to
install. Change the name of the module if desired. Make sure a unique identifier is chosen if
3-136 B54476AB
3.38 Installation of Software Items 3
more than one Cytomat device is installed on the same system. The Simulating? check box
should remain unchecked unless otherwise instructed by Tech Support. Click OK to continue.
Figure 3.38-4 Module Configuration
Random Access Storage Step Installation (Install only if using the device in Biomek
Software)
Purpose
This installation program installs the steps necessary to use the Cytomat MPH more easily in Biomek
Software.
1. On the installation disk, locate and run the file

RandomAccessStorageBiomekSupport Install – n.n.n.msi.
Figure 3.38-5 Installation Program
B54476AB 3-137
2. Follow the on-screen instructions to complete the installation.
Figure 3.38-6 Installation Completed
3-138 B54476AB
3.39 Cytomat MPH Setup and Operation 3
3.39 Cytomat MPH Setup and Operation
Purpose
Setup consists of configuring the device for use in Biomek Software, configuring the device for use
in SAMI EX Software, and specifying the device’s SILAS Module Options.
Biomek Setup with Conveyor Procedure

NOTE When accessing the Cytomat MPH with a robotic transporter on a SAMI EX system, the following steps
are not necessary. Skip to the next major section.
Biomek Hardware Setup with Conveyor

1. Open the Biomek Hardware Setup window by selecting Utilities > Hardware Setup from the
Biomek Software menu.
Figure 3.39-1 Cytomat Device using Cytomat and Conveyor in Biomek Hardware Setup
A Cytomat Device in Biomek Software references the SILAS Modules used to control a Cytomat
and a Conveyor or Servo Shuttle. Highlight the newly created Cytomat Device and specify the
B54476AB 3-139
Storage Device module and Conveyor/Shuttle module to use to control the individual
components of the Cytomat Device on the system.
NOTE This Cytomat Device will be associated to the Conveyor inner position in the Biomek Deck Editor.
Biomek Configuration and Framing

Setup of the Cytomat MPH in Biomek Software requires adding the correct Conveyor ALP or Servo
Shuttle ALP to the deck, specifying the Cytomat Device to use, and framing the position.
1. Make sure that the Random Access Storage steps are available in Biomek Software (see
Device.
2. Open the Deck Editor in Biomek Software. Add the appropriate Conveyor ALP to the Biomek
deck that matches the type of conveyor provided.
Figure 3.39-3 Conveyor ALP Added to Biomek Deck
3-140 B54476AB
3. Double-click on the inner position for the Conveyor ALP or Cytomat ALP to open the Position
Properties window. Associate the Cytomat Device configured in Hardware Setup with the inner
position on the Conveyor ALP, or with the Cyto position of the Cytomat ALP (see Figure 3.39-4).
Figure 3.39-4 Conveyor ALP inner Position Properties
NOTE Do not associate a device to the outer Conveyor ALP position.
4. Teach the inner position of the Conveyor using the AccuFrame fixture.
5. Configure and teach the remaining positions on the Biomek deck if they haven’t been taught
yet.
Biomek Setup for Biomek Gripper Direct Access Procedure

1. Open Biomek Hardware Setup by selecting Utilities > Hardware Setup from the Biomek Software
menu.
B54476AB 3-141
Figure 3.39-5 Cytomat Device using Cytomat for Direct Access in Biomek Hardware Setup
3. A Cytomat Device in Biomek Software references the SILAS Module used to control the Cytomat
and allowing device setup and labware data to be included with the labware. Highlight the
newly created Cytomat Device and specify the Storage Device module. Specify None for the
Conveyor/Shuttle module to access the Cytomat directly.
NOTE This Cytomat Device will be associated to the Cytomat OneByOne position in the Biomek Deck
Editor.
4. Make sure that the Random Access Storage (highlighted green) tool bar palette is enabled in
Biomek Software (see Figure 3.39-6). These steps are used when creating a Biomek Method that
utilizes the Cytomat Device.
3-142 B54476AB
5. Open the Deck Editor in Biomek Software. Add the CytomatLeft ALP to the Biomek deck.
Figure 3.39-7 Cytomat ALP Added to Biomek Deck
B54476AB 3-143
Framing the Cytomat ALP
CAUTION
Framing a Cytomat ALP sets the correct position for the current deck; it does not
change framing information for other decks. If a different deck is used, this ALP
must be re-framed for that deck before it is used in a method.
A Cytomat ALP is framed using the gripper framing technique instead of using the AccuFrame tool.
An error will occur if the Cytomat initializes while framing using the gripper. Perform the following
steps to frame the Cytomat Device using the gripper framing technique:
1. To prevent the Cytomat error from occurring, open Biomek Hardware Setup and uncheck
(disable) the check mark box to Initialize modules at the beginning of method for CytomatDevice1
(refer to Figure 3.39-8).
Figure 3.39-8 Disable Initialization of the Cytomat Device
2. Click the Accept button to save the hardware changes.
3-144 B54476AB
3. Open the Biomek Deck Editor. Double-click the Cytomat ALP position square to open the
Cytomat ALP Position Properties window.
Figure 3.39-9 Cytomat ALP Position Properties
4. Click Manual Teach to open the Manual Framing Wizard. Follow the instructions to frame the
position using the gripper framing technique (refer to Figure 3.39-10).
Figure 3.39-10 Manual Framing Wizard
B54476AB 3-145
5. Click OK to close the Cytomat ALP Position Properties window.

6. Click Save to save changes to the Biomek Deck and close the Biomek Deck Editor.
7. Open Biomek Hardware Setup and click (enable) the check mark box to Initialize modules at the
beginning of method for CytomatDevice1 (refer to Figure 3.39-11).
Figure 3.39-11 Enable Initialization of Cytomat Device
8. Click Accept to save the hardware changes.
3-146 B54476AB
3.40 Cytomat MPH Options 3
3.40 Cytomat MPH Options
Purpose
Configure the Options dialog for the Cytomat MPH. The Cytomat MPH Options dialog can be opened
from within the Biomek Software Device Editor or the SAMI EX Installer Tool.
Options Settings
Figure 3.40-1 Cytomat MPH Options Configuration Dialog
Specify the basic settings for the device.
Communication Port – Specify the communication port connected to the device.
Hotel Setup – Specify the shelf type for the hotel stacks installed in the device.
Write Settings To Device – Clicking this button will store the hotel type selected in the Cytomat MPH
device, as well as save the hotel settings for use in SAMI EX. If the hotel type is changed, the settings
must be written to the Cytomat MPH.
B54476AB 3-147
3.40 Cytomat MPH Options
3-148 B54476AB
3.41 Cytomat MPH SAMI EX Software Setup and Configuration (Optional) 3
3.41 Cytomat MPH SAMI EX Software Setup and Configuration (Optional)
Purpose
Setup of the Cytomat MPH in SAMI EX Software requires configuring the device in the SAMI EX
Installer Tool.
SAMI EX Installer Tool Configuration Procedure

Figure 3.41-1 SAMI EX Installer Tool with a Cytomat and Conveyor Linked
1. Open the SAMI EX Installer Tool.

2. Drag the devices to their correct locations on the system, and link them.
3. If a Conveyor is used to access the Cytomat MPH, link the respective Conveyor position to the
transfer station position of the Cytomat MPH. Linked positions are displayed in purple color.
NOTE If a robotic transporter is used to access the Cytomat MPH transfer station, the positions are
usually not linked in the SAMI EX Installer Tool.
B54476AB 3-149
3.41 Cytomat MPH SAMI EX Software Setup and Configuration (Optional)
3-150 B54476AB
3.42 Manual Control / Silas Module 3
3.42 Manual Control / Silas Module
NOTE Manual control of a SILAS Module should generally be done only before or after a run. In some error
situations, it may be useful to use manual control while a run is paused. Extreme care must be taken when
manually executing SILAS Module commands in the middle of a run.
Action Configuration Dialog

Figure 3.42-1 Action Configuration Dialog
There are several ways to open the SILAS Module Action Configuration Dialog (Figure 3.42-1); the
most common are:
(A) From Biomek Software select Instrument > Device Editor, select the Cytomat module, and click
Action Commands.
OR
(B) From the SAMI EX Installer Tool (Start > All Apps > Beckman Coulter Service Tools > SAMI EX
Installer Tool) select the Cytomat MPH SILAS Module, and click the Actions button.
In the Action Configuration Dialog, there are several actions available: Initialize, Reset Device, Load,
Unload, Unload Internal, Unload External, Load External, Load Internal. Select the desired action and
configure any applicable settings that are then displayed. Click the button in the lower corner to run
the configured action.
B54476AB 3-151
3.42 Manual Control / Silas Module
The following table summarizes the available actions:
Table 3.42-1 Cytomat MPH SILAS Module Commands
Action Description
Initialize Initializes the device by seeking the home state of the turntable and placing the
handler in a recognizable starting position.
Reset Device Clears any device errors.
Load The handler retrieves labware from the Transfer Station and places the labware into
the specified hotel position. The Transfer Station must have labware sensed by the
barrel sensor before the command will run. The destination hotel position must be
empty and capable of accommodating the labware being loaded.
Unload The handler retrieves labware from the specified hotel position and places the
labware onto the Transfer Station. The Transfer Station must be empty before the
command will run. The specified source hotel position must have labware in it or an
error will occur when an attempt to get the labware fails.
Unload Internal This is the first half of an Unload command. The handler retrieves labware from the
specified hotel position. The labware will remain on the shovel of the handler. The
handler must be empty and the hotel position must have labware.
Unload External This is the second half of an Unload command. The handler will place the labware it
is already holding onto the Transfer Station. The handler must already have labware
and the Transfer Station must be empty. If the Cytomat MPH is an incubator, the door
will automatically open and close as needed for this command.
Load External This is the first half of a Load command. The handler retrieves labware from the
Transfer Station. The labware will remain on the shovel of the handler, inside the
device. The Transfer Station must have labware and the handler must be empty. The
gate will automatically open and close as needed for this command.
Load Internal This is the second half of the Load command. The handler will place the labware it is
already holding into the specified hotel position. The handler must already have
labware and the specified hotel position must be empty.
3-152 B54476AB
3.43 HEPA Filter Installation and Service 3
3.43 HEPA Filter Installation and Service
Purpose
Install the Biomek i-Series HEPA Fan on an i5 or i7 enclosed system. Install any Multichannel Pod(s)
before installing the HEPA Fan.
NOTE It is easier to install the HEPA system during instrument installation while the instrument is
still located on the installation scissor cart.

 M3 Hex Driver
 M4 Hex Driver
 Flat Head Screwdriver
 i5 HEPA Kit (115V or 230V)
 C11012 Bracket, HEPA i5 (Qty 2)
 C01583 Panel, Top HEPA i5 (Qty 2)
 C12025 Power Strip Mounting Bracket
 A81383 Power Strip, Universal Voltage
 A48480 Power Cord (C13 – C14 6 ft)
 i7 HEPA Kit
 C11011 Bracket, HEPA i7 (Qty 2)
 C01238 Panel, Top HEPA i7 (Qty 2)
 C12025 Power Strip Mounting Bracket
 A81383 Power Strip, Universal Voltage
 A48480 Power Cord (C13 – C14 6 ft)
 Ladder or Step Stool (optional)
B54476AB 3-153
Installation
1. Remove the M5 button-head screws securing the top panels on the instrument. Set screws aside
for future use in the installation (Figure 3.43-1). Remove and store the panels.
Figure 3.43-1 Remove button-head screws and panels
Biomek i5 Biomek i7
2. Remove the M5 socket-head screws securing the panel support(s) (B90994) to the front and back
of the halo on the enclosure (Figure 3.43-2). Remove the panel supports. Optional: Remove or
leave M5 T-Nuts in halo.
Figure 3.43-2 Remove M5 socket-head screws and panel supports
Biomek i5 Biomek i7
3. Install HEPA fan supports to the center of the instrument using halo screws set aside in step 1
(Figure 3.43-3). Do not tighten screws at this step.
Figure 3.43-3 Install HEPA fan supports
Biomek i5 Biomek i7
3-154 B54476AB
4. Install the HEPA panels on each side of the HEPA fan support using screws set aside in step 1
(Figure 3.43-4). Once screws are installed, tighten all screws securing the panels to the halo.
Figure 3.43-4 Install additional panel support
Biomek i5 Biomek i7
CAUTION
Risk of injury and risk of damage to equipment. The fan units are large and heavy.
Use caution when lifting and securing units.
5. Place the HEPA Fan Unit on top of the halo. Rest it securely in the mounting brackets by pushing
on the front of the fan unit until it is seated correctly and does not slide off of the instrument
(Figure 3.43-5).
NOTE A 2’ x 2’ fan unit is used on the Biomek i5 and a 2’ x 3’ fan unit is used on the Biomek i7.
Figure 3.43-5 Fan Unit installed on halo
Biomek i5 Biomek i7
OPTIONAL: A power supply and holder are provided with each HEPA integration. If the customer
has access to the back of the instrument, install the power supply and holder using steps below.
If not, skip to step 11.
6. Remove 2 M5 button-head screws from the top rear panel (left or right side).
B54476AB 3-155
7. Install the Power Supply Holder on the top rear panel using screws removed in step 6
(Figure 3.43-6).
Figure 3.43-6 Install power supply holder
Biomek i5 Biomek i7
8. Using a flat screwdriver, remove the black mounting brackets on each end of the power strip
bracket (Figure 3.43-7).
Figure 3.43-7 Remove black mounting brackets on power strip bracket
9. Attach the black mounting brackets from the power strip using (4) M5 screws provided with the
kit.
3-156 B54476AB
10. Reattach the power strip to the black mounting brackets.
Figure 3.43-8 Reattach power strip to black mounting brackets
11. Attach supplied power cord to HEPA Fan unit.

12. Use the included cable clamps and screws from the top back panel to fix the power cable along
the back of the Biomek instrument.
13. Plug power cord into wall outlet or supplied power strip.
NOTE Note: On the Biomek i5, the Power Supply Holder and Cable Clamps can be mounted on either
side of the instrument. On the Biomek i7, Power Supply Holders and Cable Clamps will be mounted
on both sides of the instrument to accommodate the two HEPA Fan Units.
Operation
CAUTION
Risk of equipment damage. The Biomek i-Series instrument must be plugged
directly into an electrical wall socket in a circuit branch dedicated solely to
instrument. A separate circuit must be used for ALPs, cytomats, filters, and other
peripheral equipment. Do not plug other devices into the same circuit as the
Biomek instrument, and do not plug the Biomek instrument into a power strip or
extension cord.
CAUTION
Risk of equipment damage. Exceeding the electrical current rating of the power
strip may cause a circuit breaker fault in the strip. Ensure the electrical current
rating of the power strip is not exceeded.
The HEPA Fan has a variable speed knob located at the top of the fan unit. This controls the air flow.
As the knob is not easily accessible to the end user, the fan can be turned on and speed set at
B54476AB 3-157
installation using the knob, and the power can be turned off to the fan, when needed, using the
power strip.
1. Ensure fan pre-filters are installed.

2. Ensure power cord is connected to HEPA fan unit.
3. Connect power cord to a power source.
4. Turn on air flow control knob.
5. Fan should turn on and air should flow inside of the instrument.
The customer may need to adjust air flow, depending on installed equipment, accessories, and
application. A third party vendor should be contacted to test air flow rate, once environment and
application is established.
Preventive Maintenance
 Soft cloth
 Water
 Ladder or Step Stool (Optional)
 HEPA Filter Kit Pre-filter(s), PN C15950
 i5 HEPA Filter Kit Filter, PN C18027
or i7 HEPA Filter Kit Filter, PN C18026
 #2 Phillips head screw driver
Preventive Maintenance Checklist

 Advise the customer to routinely change the pre-filter(s) on the HEPA Filter Kit.
(Recommendation is every 2-3 months or every 6 months if no discoloration or dirt build up is
seen every 2-3 months.)
 Replace the HEPA Filter Kit pre-filter(s) (see Pre-filter Replacement Procedure below).
 Replace the HEPA Filter Kit filter (see HEPA Filter Replacement Procedure below).
 Verify proper operation of the power switch.
 Verify proper operation of the air flow adjustment knob, carefully returning the air flow
adjustment to the starting setting.
 With a soft cloth and water, wipe clean the HEPA Filter Kit surfaces with a damp cloth.
 Inspect the top panels for cracks. Replace as needed.
 Inspect the HEPA Filter motors for dirt build up. Clean as needed.
 Check all hardware for tightness. Adjust as needed.
3-158 B54476AB
Pre-filter Replacement Procedure

1. Pre-filters should not be washed or cleaned and should be changed regularly. The customer is
required to change the pre-filter every 2-3 months unless the filter is found free of dirt build up
or discoloration, in which case, the pre-filter can be changed every 6 months.
2. Disconnect the HEPA Filter Kit from the power source prior to servicing the unit.
3. To change the pre-filter(s), simply lift the used pre-filter off the housing and replace it with a
new pre-filter, with the airflow indicator pointing down.
Figure 3.43-9 Pre-filter replacement
HEPA Filter Replacement Procedure

1. HEPA filters cannot be cleaned and must be replaced when necessary. The preventive
maintenance routine recommends replacing the HEPA filter on an annual basis.
2. Disconnect the HEPA Filter Kit from the power source prior to servicing the unit.
3. Remove the #8-32 Phillips tooth lock screws and the six catches (on the i7, four on the i5 unit)
holding the filter housing to the HEPA filter.
B54476AB 3-159
Figure 3.43-10 Remove screws and catches (i7 HEPA Kit shown)
4. Once the screws and catches are removed, simply lift the filter housing from the HEPA filter.
5. Remove the new filter from its packaging and visually inspect it for signs of damage.
6. Carefully line up the filter housing with the new filter and place on the filter.
7. Re-attach the catches and screws that were removed in previous steps.
3-160 B54476AB
CHAPTER 4
Service and Repair Procedures
Part D General Procedures
4.100.1 General Guidelines
Safety Precautions
• Review and heed the general safety warnings and cautions listed under Heading 1.2, Safety
Precautions.
• Safety is the individual responsibility of each Field Service Engineer. Use general safety
precautions when handling equipment. It is recommended that the Field Service Engineer use
laboratory coat, gloves, and glasses while in the Laboratory.
• Decontamination of surfaces, labware holders, tools, and additional accessories may be

required before service repairs or preventive maintenance activities.
• Consult with the Laboratory Manager or Safety Officer before servicing equipment. Ask for
MSDS to review hazards associated with Biologicals or Chemicals used on equipment. Work
with the customer to coordinate decontamination.
• Make sure all covers are reinstalled to ensure proper operation of the instrument when you
leave the account.
• Ensure the electrical current of the circuit branch used for the ALPs, filters, and peripheral
equipment is sufficient.
Accessibility
Ensure adequate space is available to work and to access the instrument components safely.
Tools and Supplies

You can do most procedures using common service tools. Any special tools, supplies, or equipment
required are identified under the Tools/Supplies Needed heading at the beginning of the procedure.
Instrument Performance Verification

• When a service or repair procedure required some type of instrument performance verification
upon completion, a verification heading is provided with the necessary steps that must be
completed.
B54476AB 4-1
• When you have finished servicing the Biomek i-Series Automated Workstation, always verify
total instrument performance by running the single service checkout method through Biomek
Software. See Part A, Operational Checks.
System Power Down

There is no special power down sequence required for the Biomek i-Series Laboratory Automated
Workstation controller. However, it is recommended that you perform the following steps:
Before powering down the Automation Controller

1. Close Biomek software and all applications.
2. If any Integrated Devices are present on the system, use the SILAS module Cache, located in
Start > All Apps > Beckman Coulter Service Tools folder > SILAS Module Monitor and select Clear
Module Cache.
3. Shut Down the Windows 10 Automation Controller, then power off any accessories.
Before powering down the Biomek i-Series Laboratory Automated Workstation

1. Ensure that all disposable tips are unloaded and the grippers are not holding labware.
2. Power off the instrument.
IMPORTANT Note how the power down process of the following integrated devices work:
• Shut off the power to the instrument to power down a CAN device, as the instrument supplies power
to these devices.
• Switch off the power source for all RS-232 integrated devices, such as the FlyBy bar code reader, as
they have a separate power source.
• Switch off the power source for all USB-integrated devices, such as the Peltier ALPs, as they have a
separate power source with a device controller (Single TEC Controller).
System Power Up
A special power-up sequence is required for the Biomek i-Series Laboratory Automated Workstation
and Windows 10 Automation Controller.
Before powering up any devices or the instrument, ensure that all covers are replaced and secured.
Ensure that all power and data cables are attached and secured.
To power up the Automation Controller

1. Power on the Windows 10 Automation Controller and Monitor. Wait for the boot sequence to
complete.
To power up the Biomek i-Series Laboratory Automated Workstation

1. Power up the Biomek i-Series Instrument.
2. Verify the successful start-up with the following:
a. The status light turns on and displays solid amber.
b. The automation controller will recognize the Biomek i-Series instrument as a USB device
with an audible sound.
4-2 B54476AB
4.100.1 General Guidelines 4
3. Launch Biomek Software.

4. From Biomek Software, select Utilities > Hardware Setup. Biomek Software should recognize the
instrument.
NOTE If the instrument is not recognized, check the communication cables. Select Reconnect.
5. Select Method > Home All Axes.

IMPORTANT Please note how the power up process of the following integrated devices work:
1. Any CAN-device attached to the Instrument will be powered on with the instrument (the instrument
supplies power to these devices).
2. Any RS-232 integrated device, such as a bar code reader, will have a separate power source and
communication with the Windows 10 Automation Controller.
a. Turn the power source or sources on for these devices.
b. With Biomek Software open, select Utilities > Device Editor to select a device.
c. Use Action Commands to initialize the device or devices.
3. At present, USB-integrated device, such as the Peltier ALPs, will have a separate power source with
a device controller (Single TEC Controller) and communication with the Windows 10 Automation
Controller.
a. Turn the power source or sources on.
b. With Biomek Software open, select Utilities > Device Editor to select a device.
c. Use Action Commands to initialize the device or devices.
Troubleshooting
Table Table 4.100.1-1 provides troubleshooting information for Home All Axes.
Table 4.100.1-1 Instrument Connection Troubleshooting
Problem Solution
“The Pipe has ended” error message appears. The software is trying to connect to the instrument
too early after the instrument power cycle. Wait a
short period of time, and reconnect to the
instrument through Utilities > Hardware Setup >
Reconnect.
B54476AB 4-3
4-4 B54476AB
4.100.2 Automation Controller Backup/Restore 4
4.100.2 Automation Controller Backup/Restore
Purpose
This procedure can be used to:
• Create a backup of the customer’s configured system

• Restore the recovery image
• Restore a backup image
 Recovery DVD
 Blank Media
Preparation
Power on and log into the Automation Controller PC. The default user name is ‘Beckman Coulter’
and the default password is ‘AdvancingScience123’. If the customer has changed user name and
password, obtain from the customer. Obtain the vendor supplied image disc for the automation
controller PC. For creating backups and restoring backups from the network, ensure the Ethernet
cable is plugged into the network port on the controller motherboard and not the network card.
B54476AB 4-5
Backup
1. In the Windows search box, type Backup and select the item titled, Backup and Restore.
Figure 4.100.2-1 Windows Search- Backup and Restore
2. Select Create a System Image link.
Figure 4.100.2-2 Create a System Image link
3. The image can be saved to a network location or to removable media. For network location,
proceed to step 4. For removable media, skip step 4 and proceed to step 5.
4-6 B54476AB
4. Select On a network location radio button.

a. Click Select….
b. Enter a pathway for network location and enter credentials, if prompted.
c. Create User name.
d. Create Password.
e. Wait while Windows validates your network credentials and click Next.
f. On the Confirm your backup settings dialog, click Start Backup. Wait while Windows creates
the backup. This may take some time.
g. When prompted to create a system repair disc, select No.
h. Close the Create a system image window.
5. If DVD, Select One or more DVDs radio button; if USB drive, Select On a Hard Disk radio button.
and choose from the drop down.
a. Click Next and confirm your backup settings. Then click on the Start Backup button.
Figure 4.100.2-3 Click on Start backup
B54476AB 4-7
b. Wait while Windows creates the backup. This may take some time.
Figure 4.100.2-4 Windows creating backup
c. When prompted to create a system repair disc, select No.
6. Close the Create a system image window.
Verification
1. For network backup, click the Windows icon and select File Explorer. Navigate to the location
where the system backup was created. If prompted, enter your credentials as used previously to
connect to the network share. Explore the folder.
2. For DVD backup, insert DVD into DVD drive and select File Explorer. Navigate to the DVD drive.
Explore the content on the DVD drive.
3. For USB drive, insert the external media device and select File Explorer, then navigate to the
appropriate drive.
Restore
If backup is a recovery DVD, a backup DVD, or a USB Drive, insert media into the appropriate drive.
1. Click Start > Settings.

2. Select Update & security.
3. Select the Recovery tab.
4. Under Advanced startup, select the Restart now option. (the ‘Please Wait’ will take a while to
finish).
5. Wait until the Choose an option screen appears.
6. Select Troubleshoot. On the Troubleshoot screen, select Advanced options. On the Advanced
options screen, select System Image Recovery. The screen will go black for 5-10 seconds, then
the system will restart. Wait for the PC to restart.
7. When prompted to select an account, select the controller user name (default is Beckman
Coulter). Enter the password (default is AdvancingScience123). Click Continue.
4-8 B54476AB
8. When prompted that Windows cannot find a system image on this computer, click Cancel.
Ensure the Select a system image radio button is selected and click Next.
9. Click the Advanced… button.
10. If image is on network, proceed. If not, skip to step 11.
a. Select Search for a system image on the network.
b. When prompted Are you sure you want to connect to the network?, select Yes.
c. Enter the location for the backup image and click OK.
d. When prompted for credentials, enter your user name and password. Click OK.
e. Select the system image displayed in the grid and click Next.
f. Leave default settings and click Next again. Click Finish.
g. When prompted that all data on the drives to be restored will be replaced with the data in
the system image, select Yes.
h. Wait for the restore process to complete. This may take some time.
i. When the restore is complete, the PC will automatically restart.
11. If image is on removable media,

a. Select Search for a system image on the appropriate drives > Add Drivers and insert the
install media device which has the image (DVD or USB).
b. Select the system image displayed and click Next.
c. Leave default settings and click Next again. Click Finish.
d. When prompted that all data on the drives to be restored will be replaced with the data in
the system image, select Yes.
e. Wait for the restore process to complete. This may take some time.
f. When the restore is complete, the PC will automatically restart.
Verification
1. After the PC has restarted, login to Windows using the user name and password.
2. Examine the Desktop.
B54476AB 4-9
4-10 B54476AB
4.100.3 Covers Removal and Replacement 4
4.100.3 Covers Removal and Replacement
• Side Panel Removal and Replacement

• Front Door (if enclosure) Removal and Replacement
• Rear Panels Removal and Replacement
• MC Arm Covers Removal and Replacement
• Span-8 Arm Covers Removal and Replacement
• Gripper Covers Removal and Replacement
• Multichannel Pod Cover Removal and Replacement
Purpose
The procedures in this section provide instructions on how to correctly remove, reinstall, or open
the covers of the Biomek i-Series instruments. Refer to Figure 4.100.3-1 for the location of the
covers.
Figure 4.100.3-1 Biomek i-Series Front, Top, and Side covers
1. Top Cover (Halo) (closed enclosure only)

2. Sides Covers
3. Door (closed enclosure only)
4. Rear top and bottom covers (not shown, see Figure 4.100.3-2)
B54476AB 4-11
Figure 4.100.3-2 Biomek i-Series Rear Covers
1. Rear Top Cover

2. Rear Bottom Cover
 10 mm box wrench (side panels)
 #2 Phillips head screwdriver (arm covers)
 Metric driver set
Side Panel Removal and Replacement
Removal
The instrument power and communication cables are attached through the right side panel.
1. Power down the instrument.

2. Remove the power and communication cables.
3. Loosen the 10 mm retainer bolts at the bottom of the side panels below the front and back
towers. Do not remove them (Figure 4.100.3-3).
4-12 B54476AB
Figure 4.100.3-3 Side Panel Retainer Bolts.
4. Remove the two thumbscrews on the inside of the instrument at the top (Figure 4.100.3-4).
Figure 4.100.3-4 Side panel thumbscrews
B54476AB 4-13
5. Pull the side panel away from the instrument and set aside.
Replacement
1. Slide the side panel into position so the slots at the bottom of the panel will be secured by the
retainer bolts. Ensure that the panel is inserted between the frame and the washer/retaining
bolt.
2. Finger-tighten the retainer bolts to hold the panel in place.
3. Replace the two thumbscrews on the inside of the Y-support frame at the top and tighten them
down.
4. Push in on the side panels to ensure they are fully seated. Using a 10mm box wrench, tighten
the retainer bolts.
5. For the right side panel, reconnect the power and communication cable.
Verification
2. Home all axes successfully.
Front Door (if enclosure) Removal and Replacement

Use Option 2 Removal and Option 2 Replacement when side panel removal/replacement is not
possible.
Option 1 Removal
If accessible, remove side panels (see Side Panel Removal and Replacement).
CAUTION
Risk of injury. The door frame is weighted down by the front door assembly. If the
door frame is in a closed position and not secured when removing the front door
assembly, the door frame will spring upwards. Secure the door frame before
removing the door assembly.
1. Close the front door.

2. With side panels removed, remove the door frame stopper screw spacers and engage the
stopper screws to above the roller guides on the door frame (Figure 4.100.3-5).
4-14 B54476AB
Figure 4.100.3-5 Door Frame Stopper Screw
1. Door frame stopper screw with spacer

2. Door frame stopper screw spacer removed and screw engaged
3. Using a 3mm metric driver, remove the screws from the front panel along the bottom and top
of the door panel (Figure 4.100.3-6). The door will rest on the light curtain sash.
Figure 4.100.3-6 Door Cover Removal
4. Remove the door and set it aside.
B54476AB 4-15
Option 1 Replacement
1. With door frame locked in place, reinstall the door. Replace screws removed in step 2.
(Figure 4.100.3-7 and Figure 4.100.3-8).
Figure 4.100.3-7 Door panel and frame, top
Figure 4.100.3-8 Door panel and frame bottom
2. Loosen door frame stopper screws and replace spacers.
3. Reinstall side panels.
Option 2 Removal
Use when side panel removal/replacement is not possible.
1. Move the door to the fully open position.

2. Use a 3 mm metric driver and remove screws from door panel.
3. Remove front door and set aside.
4-16 B54476AB
Option 2 Replacement
1. Reinstall front door on door frame.
2. Reinstall screws removed in step 2.
Verification
1. Front door should remain closed when closed.
2. Front door should remain open when opened.
3. Front door should remain open when left partially opened.
4. Front door should operate smoothly with no scratching or scraping noises.
Rear Panels Removal and Replacement
Removal
This procedure is the same for the top and bottom back panels.
Figure 4.100.3-9 Top and Bottom Back Panels Removal and Installation
1. Using a 3 mm metric driver, loosen the screws along the bottom of the panel. Do not remove
them.
2. Remove the screws along the top of the panel.
3. Lift the panel up and off the bottom screws.
Replacement
1. Place the panel on the instrument with the slots seated on the screws along the bottom of the
opening. If a Span-8 is installed, route the tubing through the cutout in the bottom rear panel.
2. Replace the screws along the top of the panel and tighten them.
3. Tighten the screws along the bottom of the panel.
B54476AB 4-17
Verification
1. Ensure Span-8 tubing is not pinched or kinked through rear panel.
2. Purge syringes.
3. Run service checkout method for arm motion tests. Ensure instrument operates without errors.
MC Arm Covers Removal and Replacement
Removal
1. Using a Phillips head screwdriver, remove the six screws from the front Multichannel arm
cover.
2. Remove the front arm cover and set aside.
3. Using a #2 Phillips screwdriver, loosen the rear screws on the Multichannel arm right side cover.
Do not remove the screws (Figure 4.100.3-10).
Figure 4.100.3-10 Rear cover screws
4. If the instrument has two arms, remove the rubber bumper and screw from the arm cover
(Figure 4.100.3-11).
Figure 4.100.3-11 Remove bumper pad
5. Repeat step 3 for the left side arm cover.
4-18 B54476AB
6. Lift the arm cover and remove.
Replacement
1. Install the arm cover on the screws at the rear of the arm.
2. Reinstall the front arm cover and screws removed in step 2.
3. Tighten the rear screws.
4. Replace the bumper and screw on the right arm cover, if present.
Verification
1. Move the instrument arm or arms to safe locations.
2. Home all axes. Ensure the instrument homes successfully. Refer to 5.100.1, Home All Axes.
Span-8 Arm Covers Removal and Replacement
Removal
1. Using a Phillips head screwdriver, remove the four screws from the front Span-8 arm cover.
2. Remove the front arm cover.
3. Using a Phillips head screwdriver, loosen the rear screws on the Span-8 pod right arm cover
(Figure 4.100.3-10). Do not remove the screws.
4. Lift the right arm cover and remove.
5. Repeat steps 3, 4 for the left arm cover. If the instrument is a dual arm instrument with Span-8
as Pod 2, remove the bumper and screw from the left arm cover before removing arm cover
(Figure 4.100.3-11).
Replacement
1. Reinstall the cover on the screws at the rear of the arm.
2. Reinstall the front arm cover and screws removed in steps 1 and 2.
3. Tighten the rear screws.
4. Replace the bumper on the left side cover.
Verification
B54476AB 4-19
Gripper Covers Removal and Replacement
Purpose
Follow this procedure to remove the gripper covers.
 #1 Phillips screwdriver
 B91761 Cover, Gripper, left
 B91762, Cover, Gripper, right
Removal
1. Use a Phillips screwdriver to remove the four flat head screws securing the gripper cover to the
gripper assembly (Figure 4.100.3-12).
Figure 4.100.3-12 Gripper Covers Securing Screws
1. button-head screw
2. Flat head screws
2. Use a #1 Phillips head screwdriver to remove the button-head screw securing two gripper cover
pieces together.
3. Remove the right-side gripper cover.
IMPORTANT Remove the left-side cover carefully so as not to damage the gripper and motor cables nested
in the left-side gripper cover.
4. Remove the left-side cover carefully.
Replacement
1. Connect the Rotate Motor Cable to the E-chain cable connect (Figure 4.100.3-13).
4-20 B54476AB
Figure 4.100.3-13 Rotate motor cable connected to the e-chain cable
2. Nest the gripper flat cable connector into the slot in the left-side gripper cover
(Figure 4.100.3-14).
Figure 4.100.3-14 Gripper flat cable connector in left gripper cover
B54476AB 4-21
3. Slide the left cover over the gripper so that the gripper Y/Z assembly cable is positioned in the
circle cutout and the Z-axis linear rail is positioned in the slot (Figure 4.100.3-17). Verify the
cables are clear of the rotating components inside the gripper (Figure 4.100.3-18).
4-22 B54476AB
Figure 4.100.3-17 Gripper Y/Z assembly cable in circular cut-out and Z-axis linear rail cable in slot.
Figure 4.100.3-18 Verify cables are clear of rotating components
4. Slide the right cover over the gripper. Ensure the gripper covers fit tightly together.
5. Reinstall the screw removed in step 2 of the removal procedure.
6. Reinstall the four screws removed in step 1 of the removal procedure.
B54476AB 4-23
Verification
Multichannel Pod Cover Removal and Replacement
Preparation
Multichannel Pod Covers can be removed when Multichannel Pod is installed in instrument at
Z Max height. If power is applied and pod can move, use Manual Control to move MC Pod to Z Max.
Removal
1. Use a 2 mm Allen wrench and remove MC Pod cover screws from front cover.
Figure 4.100.3-19 Installed Covers
2. Lift pod cover up and remove.

3. Repeat steps 1, 2 for rear cover.
Replacement
1. With slot facing down, reinstall MC pod front cover by sliding cover between yoke and interface
plates. Install screws removed in steps 1, 2.
2. Tighten screws.
3. Repeat steps 1, 2 for rear pod cover.
4-24 B54476AB
Verification
Use Manual Control to move Multichannel Pod between Z Min and Z Max. Pod should move without
errors and without binding or scraping.
B54476AB 4-25
4-26 B54476AB
4.100.4 LED Status Light Segment Removal and Replacement on Open Enclosure 4
4.100.4 LED Status Light Segment Removal and Replacement on Open

Enclosure
Purpose
Follow this procedure to replace an LED status light on an Open Enclosure system. The LED strip
assemblies are fragile. Use care when handling. Do NOT use excessive pressure or force when
installing.
 ESD strap
 C03515 Large LED Strip Assembly (i7 open system)

 C03514 Medium LED Strip Assembly (i5 open system)
 M3 driver
Removal
2. Disconnect the power and USB cable.
3. Remove the left and right side panels (refer to Side Panel Removal and Replacement).
4. Use a 3mm hex driver and remove the front logo panel screws (Qty 6 on i7; Qty 4 on i5). Set aside.
5. Disconnect the LED strip from the left and right side towers.
6. Remove the LED strip from the sticky tape and discard.
Replacement
1. Install the LED Strip assembly.
a. Orient the LED Strip assembly so that the side with two connectors is facing the front left
corner.
b. Install LED strip assembly into the left side extrusion. The strip should make contact with
the magnets installed in the extrusion channel.
c. Center the strip in the extrusion so that ends do not protrude from either side.
2. Connect C88 to C172 and connect C93 to C173.
3. Reinstall the front logo cover panel with screws removed in step 4.
4. Reinstall the left and right side panels.
5. Reconnect the power and USB cables.
B54476AB 4-27
4.100.4 LED Status Light Segment Removal and Replacement on Open Enclosure
Verification
2. Home all axes. Ensure that the instrument homes successfully.

3. Complete the 5.100.4, Instrument Function Checklist Procedure.
4-28 B54476AB
4.100.5 LED Light Segment Removal and Replacement on Closed Enclosure 4
4.100.5 LED Light Segment Removal and Replacement on Closed

Enclosure
Purpose
Follow this procedure to replace an LED status light on a Closed Enclosure system. The LED strip
assemblies are fragile. Use care when handling. Do NOT use excessive pressure or force when
installing.
The LED strip is comprised of a series of individually addressable SK6812 RGBW combined
LED/Driver ICs. Each halo assembly is outfitted with four discrete LED strips that are chained
together. Communication to the LED strips is established by connecting the input of the first strip
in the chain and the output of the last strip back to the chassis board. The chassis board provides a
power line in each of the rear corners of the halo assembly to prevent excessive voltage drop across
the chain.
A spring steel strip is secured to the backside of the LED strip with clear packaging tape. This serves
to reinforce the LED strip and protect it from damage during handling. The spring steel strip also
allows the LED strip to be easily installed and removed from the system by snapping it onto a set of
magnets.
 ESD strap
 C03516 Side LED Strip Assembly (i5 or i7 enclosed system)
 C03515 Large LED Strip Assembly (i7 enclosed system)
 C0351X Medium LED Strip Assembly (i5 enclosed system)
 M3 driver
Removal
Removal
2. Use M3 driver and remove corner caps from each corner of the halo (Figure 4.100.5-1).
B54476AB 4-29
4.100.5 LED Light Segment Removal and Replacement on Closed Enclosure
Figure 4.100.5-1 Corner cap and screws
3. Remove diffuser lenses from halo extrusion channels (Figure 4.100.5-2) by sliding them out the
ends of the channels.
Figure 4.100.5-2 Remove diffuser lenses
4. Disconnect LED strip assemblies at each corner.

5. Remove LED strips. LED strips are mounted on a strip of spring steel, which is held in place by
magnets mounted on the halo extrusion.
Replacement
1. Install left side LED strip assembly.
a. Orient the left side LED strip assembly so that the side with two connectors is facing the rear
left corner of the halo frame assembly.
b. Install LED strip assembly into left side extrusion. The strip should make contact with the
magnets installed in the extrusion channel.
c. Center strip in extrusion so that ends do not protrude from either side.
4-30 B54476AB
Figure 4.100.5-3
2. Install front Large LED strip assembly.

a. Orient the front large LED strip assembly so that the side with two connectors is facing the
front left corner of the halo frame assembly.
Figure 4.100.5-4
3. Install right side LED strip assembly.

a. Orient the front Large LED strip assembly so that the side with two connectors is facing the
front right corner of the halo frame assembly.
B54476AB 4-31
Figure 4.100.5-5
4. Install rear Large LED strip assembly.

a. Orient the rear Large LED strip assembly so that the side with two connectors is facing the
rear right corner of the halo frame assembly.
Figure 4.100.5-6
5. Connect four LED strips together:
a. Connect C169 to C174 at the rear left corner

b. Connect C171 to C172 at the front left corner
c. Connect C169 to C174 at the front right corner
d. Connect C171 to C172 at the rear right corner
4-32 B54476AB
6. Reinstall diffuser lenses into front and rear extrusion channels.
7. Reinstall diffuser lenses into side extrusion channels.

8. Reinstall corner caps at each corner of halo frame. Make sure the flanges on the bottom of the
halo cap are fitted behind the wall of the extrusions to make a snap fit.
Figure 4.100.5-7 Reinstall corner caps
9. Reinstall M5 screws caps and tighten with M3 driver.
Verification

3. Complete the 5.100.4, Instrument Function Checklist Procedure.
B54476AB 4-33
4-34 B54476AB
4.200.1 Magnet Top Cover Removal and Replacement Procedure 4
Part E MC POD
4.200.1 Magnet Top Cover Removal and Replacement Procedure
Purpose
Follow this procedure to remove the top magnet on the MC Pod brake assembly to allow manual
movement of the pod when instrument power is off. Instrument power MUST be ON to release the
brake to allow the magnet top cover to be removed.
 ESD strap
 2.5 mm Allen wrench
 Feeler gauges
Removal
1. Loosen the set screw on the top magnet cover for the brake assembly (Figure 4.200.1-1). Remove
the top and set aside.
Figure 4.200.1-1 Magnet top cover set screw
Replacement
1. Fan feeler gauge to .006” and .007” shims on top of magnet. Place top magnet cover on shims
and tighten set screw. Remove shim.
B54476AB 4-35
4.200.1 Magnet Top Cover Removal and Replacement Procedure
Verification
2. Run the service checkout procedure.
4-36 B54476AB
4.200.2 MC Pod Removal and Replacement 4
4.200.2 MC Pod Removal and Replacement
Purpose
Use the removal procedure to remove an installed pod for pod repair. Use the replacement
procedure to install a Multichannel pod.
If instrument is a closed system, it is helpful to remove the top halo panel to provide access from the
top of the instrument for pod removal. Move the pod to a higher Z location to facilitate easier
grasping of the pod.
If a HEPA fan filter is installed, or the top of the instrument is not accessible, it is helpful to remove
the side panel to provide access from the side of the instrument for pod removal.
If top and side access are not available, remove MC Pod through the front of the instrument.
The instrument installation cart and/or a step ladder are helpful for this procedure.
CAUTION
damage circuit boards and other electronic components. Perform any procedure
where there is a possibility of ESD damage at an ESD workstation or wear an
antistatic wrist strap attached to a metallic part of the chassis connected to an
earth ground.
 ESD Strap
 #1 and #2 Phillips Screwdriver
 Small flat head screwdriver
 3 mm straight hex driver (long)
 Step stool (optional)
Removal
2. Remove multichannel head. Refer to Biomek i-Series Hardware Reference Manual (B54474).
3. Remove Multichannel Arm covers (front, left side, and right side covers). Refer to MC Arm
Covers Removal and Replacement. Set covers aside.
4. Use #1 Phillips screwdriver to loosen screws holding the Multichannel Arm board bracket cover
(Figure 4.200.2-1). Remove cover and set aside.
B54476AB 4-37
Figure 4.200.2-1 MC Arm Board Bracket Cover
5. Loosen top cable clip by pulling on the small tab.

6. Disconnect cables C156, C266, C271, C273, C275, C277, and C278 from the top motion board and
breakout connectors (see Figure 4.200.2-2).
Figure 4.200.2-2 MC Pod Connections
4-38 B54476AB
4.200.2 MC Pod Removal and Replacement 4
7. Remove the encoder cables from the plastic clips on the back of the arm board mounting
bracket (Figure 4.200.2-3).
Figure 4.200.2-3 MC Pod Encoder Cable Clips
8. Use a Phillips screwdriver to remove E-chain from E-chain bracket.

9. Use an M3 straight handled driver (long handled) and loosen 4 MC Pod mounting screws.
Figure 4.200.2-4 MC Pod Mounting Screws
10. Lift the MC pod straight up to clear the bridge, and remove it from instrument through the top,
side, or side and front access.
B54476AB 4-39
Replacement
1. Install four mounting screws on the Multichannel pod.
2. Install Multichannel Pod onto bridge by aligning pins from the Multichannel arm with the
alignment holes on the Multichannel pod. Make sure the Multichannel Pod is installed with the
E-chain facing the right side (towards the right side of the Multichannel arm).
3. Use a long 3 mm straight handled driver and tighten mounting screws.
4. Install the pod E-chain to the E-chain bracket using screws removed in Removal step 8. (If the
pod is being installed on the instrument for the first time, E-chain screws will be installed in the
E-chain bracket for shipment. Remove E-chain screws before installing E-chain.).
5. Route Z encoder cables through cable clips. Ensure cable clips are fully pressed into the bracket.
Figure 4.200.2-5 MC Pod Encoder Cable Clips
6. Open cable holder clip for E-chain bundle. Reconnect the cables removed in step 6. above. Close
the E-chain bundle cable clip.
7. Replace the Multichannel arm board bracket cover. Tighten the screws.
8. Replace the arm covers. Refer to the MC Arm Covers Removal and Replacement procedure.
Verification
3. Install Multichannel Head.
4. Run the 4 Post Framing tool method to check for Multichannel Pod rotation. Refer to 5.100.2, 4
Post Framing Tool Procedure Procedure.
5. Run the service checkout method. Refer to 5.100.3 Service Check Out method.
4-40 B54476AB
4.200.3 D-Axis Ball Screw Assembly and Motor Removal/Replacement 4
4.200.3 D-Axis Ball Screw Assembly and Motor Removal/Replacement
Purpose
Follow this procedure to replace the D-axis ball screw assembly. To physically move the pod in Z axis
when pod is not installed and/or when power is off on instrument, first remove the top magnet of
the brake assembly or the motor pulley cover with the brake assembly. Power MUST be on to remove
the magnet top cover. Power relaxes the brake assembly and allows for magnet removal.
Figure 4.200.3-1 D-Axis Ball Screw Assembly
 3 mm Allen wrench
 10 mm nut driver
 Channel lock pliers (small)
 Optional small hammer
 Optional extra-long straight handle 3 mm hex driver (to remove D-axis motor assembly)
Removal
1. With the power on, remove the top magnet cover from the MC Pod brake assembly.
a. Use a 1.5 mm Allen wrench and loosen the set screws on the top magnet cover
(Figure 4.200.3-2).
B54476AB 4-41
Figure 4.200.3-2 Top Magnet cover set screw
b. Remove the top magnet and set aside.

Alternatively, remove the motor pulley cover with the brake assembly. With the power on,
a. Use a 3 mm Allen wrench and remove screws for the motor pulley cover (Figure 4.200.3-3).
Figure 4.200.3-3 Z pulley cover with brake assembly
b. Turn the power off, and disconnect the brake assembly. Set aside the motor pulley cover.
2. Remove head and set aside.

3. Power on the instrument.
4. Disconnect pod from arm. Refer to 4.200.2, MC Pod Removal and Replacement.
5. Remove MC Pod Arm covers. Refer to Multichannel Pod Cover Removal and Replacement
procedure.
4-42 B54476AB
6. Use a 10 mm nut driver and remove the nut and washer from the bottom of the D-axis ball screw
assembly (Figure 4.200.3-4).
Figure 4.200.3-4 Nut and washer at bottom of D-axis ball screw assembly
7. Use a 3 mm driver to remove eight screws on the front linear rail and four screws from the
linear bearings on the front linear rail. This is the slave rail and not the master rail
(Figure 4.200.3-5).
Figure 4.200.3-5 Screws on front linear rail and linear bearings
B54476AB 4-43
8. Remove the linear rail and bearing assembly carefully. Be careful with handling linear rail. Do
not let bearings fall off rails.
9. Unplug cables from bulkhead connectors.
10. Use small channel lock pliers to remove the bulkhead connectors from the motion board
bracket.
11. Remove D-axis wire connectors from motion board.
12. Use 2.5 mm hex driver and loosen the bottom motion board bracket screws and remove the top
motion board bracket screws (Figure 4.200.3-6).
Figure 4.200.3-6 Top and bottom motion board bracket screws
Picture is shown without motion board installed.
13. Use a 3 mm Allen wrench to remove the four screws for the D-axis nut (Figure 4.200.3-7).
4-44 B54476AB
Figure 4.200.3-7 D-axis nut screws
14. OPTION 1 — Hold the shaft of the D-axis ball screw and rotate the D-axis nut to move the ball
screw up. Use a small hammer to tap the bottom of the D-axis ball screw assembly to loosen the
locating pin from the D-axis stroke plate. Pull the D-axis stroke plate down and remove the
D-axis ball screw assembly.
IMPORTANT Don’t remove the nut from the ball screw assembly. You will lose bearings.
15. OPTION 2 — Rotate D-axis ball screw counterclockwise to move the D-axis ball screw through
the nut to disconnect from the D-axis stroke plate. Remove the D-axis ball screw assembly.
16. Remove the belt from the D-axis ball screw.
17. Pull the D-axis shaft assembly up and out of the back of the MC pod (Figure 4.200.3-8).
Figure 4.200.3-8 D-Axis ball screw assembly
If you are removing the D-axis motor, proceed to step 18. If not, stop.
B54476AB 4-45
18. Use a 2.5 mm hex driver to loosen the set screw on the D-axis motor pulley (access is through
the D-axis top plate)(Figure 4.200.3-9).
Figure 4.200.3-9 D-axis motor pulley set screw
19. Use a 3 mm hex driver to remove the D-axis motor screws from the bottom of the MC pod.
Replacement
1. Reinstall the D-axis motor and pulley.
2. Reinsert the D-axis ball screw assembly from the top.
3. Finger tighten the D-axis nut flange.
4. While the D-axis ball screw is still loose, reattach the D belt to the D ball screw
(Figure 4.200.3-10).
Figure 4.200.3-10 Putting belt on pulley and D-axis gear
NOTE Spin both the pulley and the ball screw to walk the belt back onto the pulley.
4-46 B54476AB
5. Add D-axis stroke plate and insert nut and washer on the bottom of the D-axis ball screw
(Figure 4.200.3-11).
Figure 4.200.3-11 Add D-axis stroke plate & insert nut and washer on D-axis ball screw
6. Move the D-axis stroke plate to max position (Figure 4.200.3-12).
Figure 4.200.3-12 Move D-axis stroke plate to max position
B54476AB 4-47
7. Tighten the D-axis nut flange. Torque to 25 in-lbs. (Figure 4.200.3-13)
Figure 4.200.3-13 Tighten D-axis nut flange
8. Reconnect the bulkhead connectors to the motion board bracket (Figure 4.200.3-14).
Figure 4.200.3-14 Route E-Chain cable ends
4-48 B54476AB
Figure 4.200.3-15 Motor Connectors
Figure 4.200.3-16 Left and front view
9. Replace the motion board bracket. Reconnect motors and dress cables.
NOTE Be careful with handling linear rail and bearing assembly. Do not let bearings fall off rails.
10. Insert the front linear rail with bearing behind the yoke plate with the datum edge (plain with
a line -- not printed edge) to the right edge of the MC pod with the bearing block facing out.
Figure 4.200.3-17 Datum edge of bearing
11. Move the bearing to the yoke plate. Tighten bearing (four screws).
B54476AB 4-49
12. Bottom out the yoke plate to the interface plate. Torque the bearing block screws to 25 in-lbs
(Figure 4.200.3-18).
Figure 4.200.3-18 Top plate, yoke plate, interface plate
13. Tighten two screws on the bottom of rail. Move up yoke plate. Tighten top two screws on the
bottom of rail. Torque all screws to 25 in-lbs.
Figure 4.200.3-19 Tighten bottom screws, move yoke, tighten upper screws.
14. Move the yoke plate all the way to the top of rail. Tighten top two screws.
4-50 B54476AB
Figure 4.200.3-20 Move yoke all the way up and tighten top screws
15. Move down the yoke plate and tighten bottom two screws at top of rail. Torque all screws to
25 in-lbs.
Figure 4.200.3-21 Move yoke plate down and tighten bottom screws at top of rail
16. Move down the yoke up and down three times. The yoke movement should be smooth.
17. If Z axis motor pulley was previously removed, reinstall and torque to 15 in-lbs and skip to step
20. If top magnet cover to brake assembly only was removed, skip step 18.
18. Reconnect brake assembly to E-chain cable (Figure 4.200.3-22).
B54476AB 4-51
Figure 4.200.3-22 Reconnect the brake assembly to the E-chain cable
19. Fan feeler gauge to .006” and .007” shims on top of magnet. Place top magnet cover on shims
and tighten set screw. Remove shim.
20. Reinstall the MC Pod the MC arm.

21. Reconnect MC arm cables.
22. Reconnect instrument power supply.
Verification
1. Power on instrument and ensure it completes the startup successfully.
3. Reinstall MC pod covers.
4. Reinstall MC head.
5. Run the service checkout procedure.
4-52 B54476AB
4.200.4 MC Pod Rotation Adjustment Procedure
Purpose
Follow this procedure to correct pod rotation results when Four Post Framing Tool method fail.
Figure 4.200.4-1 MC Pod underside and alignment brackets
The picture above shows the underside of the Multichannel Pod and alignment brackets. Clocking
is defined as the rotation of the pod in the XY plan and is measured as the angle between the XZ
plane of an ALP and the XZ plane of the pod (red arrow). Clocking is adjusted by slightly loosening
the four bolts (yellow) that hold the brackets (green and red) to the bearing plate (blue) and using
two set screws (orange) on the left hand side to push the bracket into position. Two jam nuts
(purple) lock the set screws in place when the adjustment is complete.
 10 mm box end wrench or nut driver
 3 mm metric driver
Rotation Adjustment
1. With a 3 mm metric driver, slightly loosen the four pod alignment mounting bracket screws.
B54476AB 4-53
Figure 4.200.4-2 Pod alignment bracket screws
2. Use a 10 mm wrench or nut driver to loosen the front and back locking nut on the rotation set
screws.
Figure 4.200.4-3 Pod alignment bracket screws
3. With a 3 mm driver, adjust the rotation using the set screws. The set screw that is in the
direction to be adjusted is backed off (e.g. when rotating pod clockwise or rearwards, the rear
set screw is loosened) and the set screw in the opposite direction is tightened clockwise to push
the assembly.
Use Four Post Framing tool results to inform your adjustment.
4. Lock nuts on front and back of set screws.
5. Tighten four pod alignment mounting bracket screws.
4-54 B54476AB
Verification
1. Repeat Four Post Framing tool method (see 5.100.2, 4 Post Framing Tool Procedure). Ensure that
the method results pass for Y values.
2. Run the 5.100.3, Service Check Out Method.
B54476AB 4-55
4-56 B54476AB
4.300.1 MC Head Removal and Replacement 4
Part F MC Head
4.300.1 MC Head Removal and Replacement
Purpose
Follow this procedure to remove or replace a damaged or defective MC head.
 3 mm and 5 mm Hex T-handle driver set
 ESD strap
Removal
CAUTION
Risk of equipment damage. The head weighs between 2.54 - 3.85 kg (5.6 - 8.4
pounds), and is connected to the multichannel pod by four screws. Before
removing the fourth screw, take hold of the head firmly to make sure it does not
fall once all of the screws are removed.

2. Remove the MC head from the MC pod. Refer to Biomek i-Series Hardware Reference Manual,
B54474, Multichannel Head, Interchangeable Heads.
3. Place to the side for servicing.
Replacement
1. Reinstall the MC head on the MC pod. Refer to Biomek i-Series Hardware Reference Manual,
B54474, Multichannel Head, Interchangeable Heads.
Verification
1. Move the instrument arm, or arms, to safe locations.
2. Power on the instrument and ensure it completes the startup successfully.
3. Home all axes. Ensure the instrument homes successfully. Refer to Heading 5.1, Home All Axes.
4. Run the service checkout method. Refer to 5.100.3, Service Check Out Method.
B54476AB 4-57
4.300.1 MC Head Removal and Replacement
4-58 B54476AB
4.400.1 Span-8 Pod Probe Alignment 4
Part G SPAN-8 POD
4.400.1 Span-8 Pod Probe Alignment
Purpose
Follow this procedure to align Span-8 probes with the updated probe alignment hardware.
Figure 4.400.1-1 Span-8 Y-Axis Adjustment Screws
B54476AB 4-59
Figure 4.400.1-2 Span-8 X-Axis Adjustment and Lock Screws
1. X-Axis Locking Screws

2. X-Axis Adjustment Screws
For the Y-Axis adjustment, turning clockwise with the Allen wrench moves the probe tip towards
the front of the deck, and counterclockwise moves the probe towards the back of the deck.
For the X-axis adjustment, the alignment for probes 1, 3, 5, and 7 is slightly different from aligning
probes 2, 4, 6, and 8.
• For probes 1, 3, 5, and 7, turn the Allen wrench clockwise to move the probe tip towards the left
side of the deck (view of the user); turn the Allen wrench counterclockwise to move the probes
towards the right side.
• For probes 2, 4, 6, and 8, turn the Allen wrench counterclockwise to move the probe tip towards
the left side of the deck (view of the user); turn the Allen wrench clockwise to move the probe
tip towards the right side.

• M7 wrench
• 2 mm driver or Allen wrench

• 1/16” driver or Allen wrench
• BC80 or BC80_LLS tips (for disposable mandrels)
• 384 square well plate
• ESD strap
4-60 B54476AB
Preparation
To facilitate access to the alignment features on the probe guide assemblies, prepare the instrument
by removing the closest side panel to the arm. Use Side Panel Removal and Replacement procedure.
If the system setup requires service to break the light curtain, avoid manually moving the probes
during probe alignment process. Use Advanced Control to move probes in Z between alignment
corrections to reset 9 mm probe spacing.
CAUTION
Risk of equipment damage. Electrical Static Discharge (ESD) can damage sensitive
electrical equipment. To prevent damage due to electrical static discharge, wear
an antistatic wrist strap attached to a metallic part of the chassis connected to an
earth ground.
CAUTION
Risk of equipment damage. Manually moving the Span-8 probes can cause the
systems that move them to be damaged. Never pull or push the Span-8 probes
manually. Always use Advanced Manual Control to move the probes.
Perpendicularity Check and Adjustment

Probe 1 should be checked for perpendicularity to the deck in both X and Y directions using a
machinist square. Probe 1 sets the alignment that all other probes reference. Check before
proceeding with probe alignment.
1. Check Probe 1 X and Y manual alignment (perpendicular to deck) using a square.
2. (Optional) Remove Probe 1 Tactile tip Interface
a. Use an ALP and square to line up square to probe (right side) for X probe alignment check.
b. Use an ALP and square to line up square to probe (front rib next to teeth) for Y probe
alignment check.
c. If probe 1 is out of alignment, adjust using the screws in Figure 4.400.1-1 and
Figure 4.400.1-2.
NOTE If Probe tactile tip interface was removed, reinstall.
Probe Alignment
If the customer has fixed tips installed, skip step 1 and proceed to step 2.
1. Create and run a simple method in Biomek Software to load BC80_LLS tips onto the Span-8 pod.
Uncheck the Finish step to unload tips.
B54476AB 4-61
Figure 4.400.1-3 Uncheck Finish step.
2. Place a 384 square well plate on a framed Span-8 position located near the front and side of the
instrument.
3. Using Manual Control, select to move the Span-8 pod to the position selected in step 2.
4. Select Advanced Control for the Span-8 pod. Use Advanced Control to position the probes just
over the 384 square well plate so that Probe 1 is aligned with the cross hairs of a well.
Figure 4.400.1-4 Probe 1 aligned with cross hairs of a well
4-62 B54476AB
Figure 4.400.1-5 Probes aligned with cross hairs of a well
5. Inspect the alignment of all 8 probes. Make sure there is a visible gap between each of the Tactile
Tip interface Assembly housings. If a tip detector is touching an adjacent detector, adjust the
orientation of the detectors to provide a visible gap. If needed, loosen the tip detector set screw
with a 1/16” Allen wrench to re-position and tighten.
B54476AB 4-63
Figure 4.400.1-6 Inspect alignment of all eight probes
6. Using a 7 mm wrench, loosen the LOCK SCREW (Hex bolt) on probes 7 and 8. Using a 2 mm hex
driver or Allen wrench, adjust probes 7 and 8 in the x-axis and y-axis using the x and y
alignment screws until the tips are centered with the center line of the target (cross hairs of 384
well plate). Tighten the LOCK SCREWS. Be careful not to overtighten.
7. Physically move probes 7 and 8 out of the way by holding the guide mounts. Using a 7 mm
wrench, loosen the LOCK SCREW (Hex bolt) on probes 5 and 6. Using a 2 mm hex driver or Allen
wrench, adjust probes 5 and 6 in the x-axis and y-axis using the x and y alignment screws until
the tips are centered with the center line of the target (cross hairs of 384 well plate). Tighten
the LOCK SCREWS. Be careful not to overtighten.
4-64 B54476AB
10. Select Home Z, X, Y.
11. Open Utilities > Hardware Setup and select Span-8 pod. Complete 4.400.3, Span-8 Probe
Correlate Axes Procedure.
12. Frame or re-frame Span-8 deck positions.
Verification
1. Verify all 8 tips are centered with the center line of the target (cross hairs of 384 well plate).
2. Run service checkout method.
B54476AB 4-65
4-66 B54476AB
4.400.2 Probe Guide Assembly Removal and Replacement Procedure 4
4.400.2 Probe Guide Assembly Removal and Replacement Procedure
Purpose
Follow this procedure to replace a probe guide assembly if the locking nut or adjustment screws are
stripped.
 ESD protection
 #2 Phillips screwdriver
 1/16” driver
 10 mm box end wrench
 T-10 Torx driver
 Adjustable torque driver
Preparation
Remove an disposable tips, disposable mandrels, or fixed mandrels from the Span-8 probes.
Removal
1. Power off and disconnect the instrument from the AC power source.
2. For open systems, skip to step 3. For closed systems:
a. Remove power cord and network cord.
b. Use 10 mm box end wrench to loosen bolts/washers on side panels. Remove thumb screws
from left and right side panels and set hardware and panels aside.
c. Close front door and use locking screws to lock front door frame in place.
d. Use 3 mm metric driver and remove front door assembly and screws and set aside.
3. Use Phillips screw driver and remove the front and right side Span-8 arm covers and screws. Set
aside.
4. Use Phillips screw driver and remove bushing block cover and screws and set aside.
5. Use ESD strap and 1/16” driver and remove tip interface assembly for appropriate probe guide
assembly. Set aside on deck.
6. Use torx driver and loosen square shaft from flex motor couplings for right or left side of pod
(right side for an even probe or left side for an odd probe).
B54476AB 4-67
7. Remove square shafts and bushings. Set aside.

8. Use 2 mm Allen wrench and remove alignment bracket and screws by loosening the adjustment
screw and the bracket screws little, by little, until the front of the bracket with screws are
removed (Figure 4.400.2-1). Set aside.
Figure 4.400.2-1 Remove Alignment bracket & screws
9. Remove probe guide assembly locking screw with M4 driver from top of probe guide assembly.
Set aside.
10. Remove locking nut from bottom of aluminum bracket (Figure 4.400.2-2).
Figure 4.400.2-2 Remove the locking nut from the aluminum bracket
At this point, the only screw holding the probe guide assembly to the aluminum bracket is the
X adjustment screw and washers. Be careful.
4-68 B54476AB
4.400.2 Probe Guide Assembly Removal and Replacement Procedure 4
11. Loosen X adjustment screw and washers but do not remove. Leave in slotted hole in bracket on
arm.
Figure 4.400.2-3 Loosen X adjustment screw and washers. Do not remove.
12. Remove the probe guide assembly.
Replacement
1. Install new probe and probe guide assembly and top locking screw. Leave top locking screw
finger loose.
2. Use X adjustment screw and washers to set gap even with the top of the guide assembly.
3. Reinstall the Y alignment bracket. Set gap with y adjustment screw by centering the probe
guide assembly with the aluminum bracket.
4. Reinstall bottom locking nut loosely.
5. Reinstall square shafts and bushings. Torque shafts to motor couplings with 20 in-lbs.
6. Push all guide assemblies to back of arm.
7. Tighten top X locking screw as tight as possible.
8. Complete fine adjustments for probe alignment.
9. Tighten bottom locking nut to “just snug”. Don’t over-tighten.
10. Complete Correlate Axes for Span-8 probes.
11. Check and/or reframe deck positions as necessary.
12. Save instrument file and backups.
Verification
1. Verify all 8 tips are centered with the center line of the target (cross hairs of 384 well plate).
2. Run service checkout method.
B54476AB 4-69
4-70 B54476AB
4.400.3 Span-8 Probe Correlate Axes Procedure 4
4.400.3 Span-8 Probe Correlate Axes Procedure
Purpose
Follow this procedure to correlate the Span-8 probes following a probe repair procedure, probe
alignment procedure, or when setting up a new instrument file. This procedure will use the
correlate axes utility in Biomek Software and will write the Z hysteresis values to the Master
Controller database.
 Biomek Software v5.0
 AccuFrame
 AccuFrame hard stop
 Span-8 framing shaft (Qty or Qty8)
 ESD Strap
Preparation
A wrist ground strap must be attached to the instrument prior to installing or removing Span-8
pipettors. Refer to Electrostatic Discharge (ESD) Protection.
CAUTION
damage electronic components. Perform any procedure where there is a
Frame a passive ALP on deck with the Span-8 pod. Remove all disposable tips and disposable
mandrels or fixed tips and set aside. Insure the AccuFrame hard stop is installed on the AccuFrame.
Install a Span-8 framing shaft on Probe 1. This procedure takes several minutes. Optional: If you
have 8 Span-8 framing shafts, the procedure time can be reduced. Install all 8 Span-8 framing shafts,
one on each probe.
Correlate Axes
1. Launch Biomek Software and go to Utilities > Hardware Setup.
B54476AB 4-71
2. Select the Span-8 pod.
4-72 B54476AB
3. Select Correlate Axes. The Correlate Axes utility will display several screens. Read all dialogs
carefully.
a. Select Next to advance.
B54476AB 4-73
b. Make sure the position used for Span-8 Correlate Axes is accessible by the Span-8 and is
framed.
c. Select Frame if you only have 1 Span-8 Framing Shaft installed on Probe 1. If you have 8
framing shafts, proceed with Frame All Probes. Proceeding screens are for a single framing
shaft.
4-74 B54476AB
d. Remove the Span-8 framing shaft from Probe 1 and install it on Probe 2. Select Next and
then Frame. Repeat steps through remaining probes.
B54476AB 4-75
e. After the last probe completes, the following screen will appear.
Probe 1 Absolute Position values are provided. Probes 2-8 are correlated in Z to Probe 1.
Probes 2-8 X and Y positions are noted relative to Probe 1 with a nominal spacing of 0.9 cm
expected between probes. Values are displayed and described:
• A negative X error means the probe is to the left of Probe 1.
• A negative Y error means the probe is behind the nominal target.
If values for X and Y are greater than ±0.2 cm, adjust probe alignment. Refer to
4.400.1, Span-8 Pod Probe Alignment. Values 0 ≤ x/y ≤ 0.20 cm, alignment is good. For small
well pipetting, such as round-well 384 plates, alignment may need to be adjusted to ±0.10
cm or less.
4. Select Finish. Correlate Axes has been completed and Z hysteresis values are now stored in
Master Controller.
5. Reinstall Span-8 mandrels.
6. Reframe all Span-8 accessible positions.
7. Select File > Save > Instrument to instrument file.
Verification
1. Run the service checkout method. Verify Span-8 tips load/unload and access wells without
clipping. For low volume pipetting, verify tip access near or at the bottom of a plate.
4-76 B54476AB
4.500.1 Gripper Assembly Removal and Replacement 4
Part H Gripper
4.500.1 Gripper Assembly Removal and Replacement
Purpose
Follow this procedure to remove and replace the gripper assembly
CAUTION
earth ground such as a deck plate mounting screw.
 ESD protection
 Phillips screwdriver
 Rail, Z-axis gripper, PN B73568
Removal
1. Power off the instrument and disconnect it from the AC power source.
2. Remove the bridge covers. Refer to 4.100.3, Covers Removal and Replacement.
3. Disconnect the cables from the cable bulkhead. Refer to Figure 4.500.1-1.
B54476AB 4-77
Figure 4.500.1-1 Bulkhead Connections
1. GZ Gripper Z Power/Encoder 3. GR-Gripper Rotate Axis

2. GG-Gripper Grip Axis 4. GY-Gripper Y Motor
4. Use a 2.5 mm Allen wrench and remove screws holding gripper assembly back plate to the
bridge assembly. Refer to Figure 4.500.1-2.
Figure 4.500.1-2 Remove the Gripper Assembly Back Plate From the Bridge Assembly
5. Use a 2.5 mm Allen wrench and loosen alignment screws that hold the gripper assembly back
plate to the bridge.
4-78 B54476AB
4.500.1 Gripper Assembly Removal and Replacement 4
Figure 4.500.1-3 Loosen the Alignment Screws Securing the Gripper Assembly To the Bridge
1. Alignment screw keyhole slots
6. Carefully remove the complete gripper assembly from the bridge.
NOTE Every other hole in linear rail is used to attach rail to Z-rack
Replacement
1. Insert the alignment screws, then hang the gripper back plate on them using the key-hole slots
at the front and back.
2. Tighten the alignment screws to secure the gripper back plate to the arm.
3. Reconnect the cables to the cable bulkhead.
4. Replace the bridge cover. Refer to 4.100.3, Covers Removal and Replacement.
5. Reconnect the instrument to the AC power supply.
Verification
1. Move instrument arm, or arms, to safe locations.
3. Home all Axes. Ensure the instrument homes successfully. Refer to Heading 5.1, Home All Axes.
4. Correlate all axes successfully. Refer to Biomek i-Series Automated Workstation Hardware Manual,
(B54474) Auto Correlate the Gripper on a Multichannel or Span-8 Pod.
B54476AB 4-79
4-80 B54476AB
4.500.2 Gripper Grip Motor Removal and Replacement 4
4.500.2 Gripper Grip Motor Removal and Replacement
Purpose
Follow this procedure to replace the gripper grip motor when:
• The gripper grip motor is damaged

• The motor wire or cable connector is pinched
 ESD protection
 1.5- mm Allen wrench
 Needle nose pliers
 Grip Motor with Pinion assembly, PN B73535
Removal
CAUTION
earth ground.
1. Power off and disconnect the instrument from the AC power source.
2. Remove the gripper covers. Refer to 4.100.3, Gripper Covers Removal and Replacement.
3. Disconnect the grip motor flat cable from the gripper motor interconnect board.
4. Rotate the lower gripper housing so that it is parallel with the upper gripper housing. Use your
hand to prevent the lower gripper assembly from rotating. Refer to Figure 4.500.2-1.
B54476AB 4-81
Figure 4.500.2-1 Rotate the Gripper Housing.
5. Use the 2 mm Allen wrench to remove four bearing retainer screws that attach the gripper grip
motor to the upper gripper housing. Refer to Figure 4.500.2-2.
Figure 4.500.2-2 Remove the Gripper Grip Motor From the Upper Gripper Housing
6. Twist the lower gripper housing 90° to access the rotate motor pinion and belt. Refer to
Figure 4.500.2-3.
4-82 B54476AB
Figure 4.500.2-3 Twist the Lower Gripper Housing 90°
7. Remove the gripper belt from the rotate motor pinion. Refer to Figure 4.500.2-4.
Figure 4.500.2-4 Remove the Gripper Belt From the Rotate Motor Pinion
8. Remove the lower gripper assembly straight down from the upper gripper assembly. Refer to
Figure 4.500.2-5.
B54476AB 4-83
Figure 4.500.2-5 Remove the Lower Gripper Assembly From the Upper Gripper Assembly.
9. Use the 1.5 mm Allen wrench to remove the bearing stopper screw from the inside end of the
right gripper finger rack assembly (Figure 4.500.2-6).
Figure 4.500.2-6 Remove the Bearing Stopper Screw From the Right Gripper Finger Rack Assembly.
10. Carefully slide the gripper finger rack assemblies away from the grip motor pinion but stop
before reaching the start of the bearing carriages. (Figure 4.500.2-7).
4-84 B54476AB
Figure 4.500.2-7 Slide the Gripper Finger Rack Assemblies Away From the Grip Motor Pinion
CAUTION
Risk of damage to linear rails. Do not let the end of the teeth go past the blue line
on the front edge of the bearing block. The bearings are not captive and may fall
out.
11. Remove the spring from one of the screws using needle nose pliers.
12. Use the 1.5 mm Allen wrench to remove the six grip motor mounting screws. Remove the grip
motor from the hub and pulley assembly (Figure 4.500.2-8).
Figure 4.500.2-8 Remove the Grip Motor Mounting Screws
B54476AB 4-85
Replacement
1. Insert the grip motor through the top of the gripper finger rack assembly.
2. Use the 1.5 mm Allen wrench to replace the six mounting screws securing the motor.
3. Gently slide the left and right gripper finger rack assemblies over the grip motor pinion.
NOTE Ensure the pinion engages both left & right finger rack assemblies at the same time so that the
fingers move symmetrically.
4. Use the 1.5 mm Allen wrench to insert the bearing stopper screw to the inside end of the right
gripper finger rack assembly.
5. Replace the gripper spring using needle nose pliers.
6. Check that the belt is positioned over the rotate motor pulley. If the wave washer over the grip
motor housing fell off during motor replacement, ensure that it is put back in place.
7. Insert the lower gripper housing assembly through the upper gripper housing assembly at a
90° angle to expose the rotate motor pinion.
NOTE Make sure the grip motor cable is positioned through the slot in the upper gripper housing
assembly and bearing retainer.
8. Slide the grip belt over the rotate motor pinion.

9. Twist the lower gripper assembly 90° so the it is parallel with the upper gripper housing
assembly.
NOTE The gripper can be dropped down to a tipbox lid on an ALP to stabilize the assembly while
inserting screws.
10. Use the 2 mm Allen wrench to insert four screws to mount the upper gripper housing assembly
bearing retainer to the grip motor. Tighten the screws in a cross-pattern.
11. Reconnect the grip motor cable to the gripper board.
12. Replace the gripper covers. Refer to the Gripper Covers Removal and Replacement procedure.
13. Reconnect the AC power supply.
Verification
3. Home all Axes. Refer to Heading 5.1, Home All Axes.
4-86 B54476AB
4.500.3 Gripper Finger Assembly Removal and Replacement 4
4.500.3 Gripper Finger Assembly Removal and Replacement
Purpose
Follow this procedure to remove and replace a damaged or defective gripper finger assembly,
gripper finger, and/or gripper pad.
 Assy, Finger Offset, Left, PN B73527 (Finger, Offset, PN B73528), (Pad, Finger, Stepped,
PN B73529)
 Assy, Finger Offset, Right, PN B73530 (Finger, Offset, PN B73528), (Pad, Finger, Stepped,
PN B73529)
Finger Removal
1. Manually move the gripper to front.
2. Use a 2.0 mm Allen wrench to remove two screws. Refer to Figure 4.500.3-1.
Figure 4.500.3-1 Remove the Gripper Finger Screws
3. Remove the finger assemblies.
NOTE Gripper finger assemblies may be removed and replaced as assemblies or as fingers and pads.
Use a 2.0 mm Allen wrench to remove the gripper pads from the finger assemblies.
B54476AB 4-87
Replacement
Secure the new fingers to the arm using a 2.0 mm Allen wrench.
Verification
Gripper Pad Removal

1. Using a 2mm Allen wrench, remove the screws holding the pads to the fingers.
Figure 4.500.3-2 Gripper fingers
1. Gripper fingers
2. 2mm Allen screws
Gripper Pad Replacement

1. Replace pads, ensuring the orientation matches Figure 4.500.3-3.
4-88 B54476AB
4.500.3 Gripper Finger Assembly Removal and Replacement 4
IMPORTANT Make sure the 2mm Allen screws are tightened.
Figure 4.500.3-3 Gripper Pad Correct Orientation
B54476AB 4-89
4-90 B54476AB
4.500.4 Gripper Motion Board(s) Removal and Replacement for Multichannel Arm 4

Multichannel Arm
Purpose
Use this procedure to replace the Grip and Rotate or the Gripper Y and Z motion boards in the
instrument. The location of these boards is arm-dependent.
CAUTION
earth ground.
 ESD protection
 Motion control board, PN B69411
Removal
1. Power off the instrument and disconnect it from the AC power source.
2. On the rear of the instrument, remove the bridge cover. Perform the procedure in Heading
4.100.3, Gripper Covers Removal and Replacement.
B54476AB 4-91
4.500.4 Gripper Motion Board(s) Removal and Replacement for Multichannel Arm
3. Locate the motion control board to be replaced. Refer to Figure 4.500.4-1.
Figure 4.500.4-1 Locate the Motion Control Board
4. Disconnect the power, communication, motor and encoder cables from the motion control
board being replaced. Refer to Figure 4.500.4-2.
Figure 4.500.4-2 Disconnect the Cables from the Motion Control Board
5. Remove the four Phillips screws securing the motion control board to the board bracket. Refer
to Figure 4.500.4-3.
4-92 B54476AB
4.500.4 Gripper Motion Board(s) Removal and Replacement for Multichannel Arm 4
Figure 4.500.4-3 Remove the Screws Securing the Motion Control Board
6. Remove the motion control board.
Replacement
1. Install the new motion control board on the board bracket.
2. Reconnect cables disconnected in Step 4.
3. Reinstall the bridge cover. Perform the procedure in Heading 4.100.3, Gripper Covers Removal and
Replacement.
Verification
3. Home all Axes. Ensure the instrument homes successfully. Perform the procedure in
Heading.5.1, Home All Axes.
B54476AB 4-93
4.500.4 Gripper Motion Board(s) Removal and Replacement for Multichannel Arm
4-94 B54476AB
4.500.5 Gripper Motion Board(s) Removal and Replacement for Span-8 Arm 4

Span-8 Arm
Purpose
Use this procedure to replace the Grip and Rotate or the Gripper Y and Z motion boards in the
instrument. The location of these boards is arm-dependent.
CAUTION
earth ground.
 ESD protection
 Motion control board, PN B69411
Removal
2. On the rear of the instrument, remove the bridge cover. Perform the procedure in Heading
4.100.3, Gripper Covers Removal and Replacement.
B54476AB 4-95
4.500.5 Gripper Motion Board(s) Removal and Replacement for Span-8 Arm
3. Locate the motion control board to be replaced. Refer to Figure 4.500.5-1.
Figure 4.500.5-1 Locate the Motion Control Board
4. Disconnect the power, communication, motor and encoder cables from the motion control
board being replaced. Refer to Figure 4.500.5-2.
Figure 4.500.5-2 Disconnect the Cables from the Motion Control Board
5. Remove the four Phillips screws securing the motion control board to the board bracket. Refer
to Figure 4.500.5-3.
4-96 B54476AB
4.500.5 Gripper Motion Board(s) Removal and Replacement for Span-8 Arm 4
Figure 4.500.5-3 Remove the Screws Securing the Motion Control Board
6. Remove the motion control board.
Replacement
1. Install the new motion control board on the board bracket.
2. Reconnect cables disconnected in Step 4.
3. Reinstall the bridge cover. Perform the procedure in Heading 4.100.3, Gripper Covers Removal and
Replacement.
Verification
3. Home all Axes. Ensure the instrument homes successfully. Perform the procedure in
Heading.5.1, Home All Axes.
B54476AB 4-97
4.500.5 Gripper Motion Board(s) Removal and Replacement for Span-8 Arm
4-98 B54476AB
4.500.6 Gripper Rotate Motor Removal and Replacement 4
4.500.6 Gripper Rotate Motor Removal and Replacement
Purpose
Follow these procedures to replace a defective or damaged gripper rotate motor.
 ESD protection
 1.5 mm allen wrench
 Rotate motor with pulley assembly, PN B73539
Removal
CAUTION

2. Manually lower the gripper assembly and rest it on top of a tall tip box. Ensure that the gripper
fingers are not obstructed (Figure 4.500.6-1).
Figure 4.500.6-1 Lower the Gripper Assembly.
B54476AB 4-99
4. Disconnect the gripper rotate motor from the gripper Y/Z-axis power cable assembly
(Figure 4.500.6-2).
Figure 4.500.6-2 Disconnect the Gripper Rotate Motor
5. Rotate the lower gripper housing assembly by 90 degrees to expose the gripper rotate motor
pinion and belt.
6. Use a 1.5 mm Allen wrench and remove two hex screws attaching the gripper rotate motor to
the upper housing assembly.
Figure 4.500.6-3 Remove the Gripper Rotate Motor From the Upper Housing Assembly
Replacement
1. Install the gripper rotate motor and pinion through the top of the upper housing assembly.
Orient the motor so that the motor ribbon cable is pointed towards the rear of the instrument.
4-100 B54476AB
4.500.6 Gripper Rotate Motor Removal and Replacement 4
Pointing the cable towards the front or side will cause them to interfere with the covers and
prevent them from fully seating.
Figure 4.500.6-4 Gripper rotate motor and pinion oriented with motor ribbon to the left
2. With your fingers, work the rotate belt onto the rotation motion pinion (Figure 4.500.6-3).
3. Use the 1.5 mm Allen wrench to replace two hex screws attaching the gripper rotate motor to
the upper housing assembly.
4. Connect the gripper rotate motor to the gripper Z-axis power cable assembly.
5. Replace the gripper covers.
Verification
3. Home all Axes. Ensure the instrument homes successfully. Refer to 5.100.1, Home All Axes.
B54476AB 4-101
4-102 B54476AB
4.500.7 Gripper Rotate Belt Removal and Replacement 4
4.500.7 Gripper Rotate Belt Removal and Replacement
Purpose
Follow this procedure to remove and replace a defective or damaged gripper rotate belt.
 ESD protection
 Rotate Axis Timing Belt, PN B80228
Removal
CAUTION
earth ground.

3. Disconnect the grip motor gripper adapter board (Figure 4.500.7-1).
Figure 4.500.7-1 Disconnect grip motor gripper adapter board
4. Rotate the lower gripper housing so that it is parallel with the upper gripper housing. Use hand
to prevent the lower gripper assembly from rotating.
B54476AB 4-103
Figure 4.500.7-2 Rotate lower gripper housing to be parallel to upper gripper housing
5. Use a 2.0 mm Allen wrench to remove four bearing retainer screws that attach the gripper grip
motor to the upper gripper housing.
6. Twist the lower gripper housing 90° to access the grip motor pinion and belt.
Figure 4.500.7-3 Motor Pinion and Belt
7. Remove the gripper belt from the rotate motor pinion.

8. Remove lower gripper assembly straight down from upper gripper assembly.
9. Remove the gripper belt from the grip motor pulley assembly.
Replacement
1. Install the gripper belt over the grip motor pulley assembly.
4-104 B54476AB
4.500.7 Gripper Rotate Belt Removal and Replacement 4
2. Insert the lower gripper housing assembly through the upper gripper housing assembly at a 90°
angle to expose the rotate motor pinion.
3. Slide the gripper belt over the rotate motor pinion.
4. Twist the lower gripper assembly 90° to be parallel with the upper gripper housing assembly.
5. Reconnect the bearing retainer to the grip motor.
6. Reconnect the grip motor cable to the gripper adapter board.
Verification
3. Home all Axes. Ensure the instrument homes successfully. Refer to 5.1, Home All Axes.
B54476AB 4-105
4-106 B54476AB
4.500.8 Gripper Z-Rail and Bearings Removal and Replacement 4
4.500.8 Gripper Z-Rail and Bearings Removal and Replacement
Purpose
Follow this procedure to remove and replace the gripper Z-rail and bearings.
CAUTION
 ESD protection
 Rail, Z-axis gripper, PN B73568
Removal
4. Disconnect the cables from the cable bulkhead. Refer to Figure 4.500.8-1.
B54476AB 4-107
Figure 4.500.8-1 Bulkhead Connections
5. Use a 2.5 mm Allen wrench and remove screws holding gripper assembly back plate to the
bridge assembly. Refer to Figure 4.500.8-2.
Figure 4.500.8-2 Remove the Gripper Assembly Back Plate From the Bridge Assembly
6. Use a 2.5 mm Allen wrench and loosen alignment screws that hold the gripper assembly back
plate to the bridge.
4-108 B54476AB
4.500.8 Gripper Z-Rail and Bearings Removal and Replacement 4
Figure 4.500.8-3 Loosen the Alignment Screws Securing the Gripper Assembly To the Bridge
7. Carefully remove the complete gripper assembly from the bridge and set aside for servicing.
8. Disconnect the rotate motor from the gripper Z chain assembly.
9. Disconnect the gripper motor from the gripper board.
10. Use a 2.0 mm Allen wrench to remove the screws holding the gripper board to the upper
housing. Refer to Removal in 4.500.15, Z-Axis E-chain Removal and Replacement
11. Use a 2.5 mm Allen wrench and remove 2 screws holding the gripper Z E-chain assembly to the
gripper cover cable holder.
12. Use a 2.5 mm Allen wrench and remove 2 screws holding the gripper cover cable holder to the
vertical housing assembly.
13. Use a 2.5 mm Allen wrench and remove 2 screws holding the Z-axis linear rail to the gripper
upper housing assembly. Set aside lower grip and rotate assembly.
14. Use a 2.5 mm Allen wrench and remove 8 screws mounting the Z axis linear bearings to the
vertical housing assembly. The gripper Z axis linear rail is now disconnected from the gripper
back plate assembly.
15. Remove the Z axis linear rail assembly from vertical housing assembly.
16. Use a 2.5 mm Allen wrench to remove the Z axis linear rail from the Z axis rack.
NOTE Every other hole in linear rail is used to attach rail to Z-rack
Replacement
1. Install the Z rack assembly to the Z-axis linear rail assembly.
2. Place the positive rail on top of the rack.
NOTE Leave two empty holes on the linear rail at the opposite end of the rack stopper bolt.
3. Position the rack with the teeth pointed up.

4. Reinstall Z axis rail and bearings assembly to the vertical housing assembly.
NOTE Do not tighten the bolts.
5. Roll the bearings across the rail several times to ensure that the bearings are not binding.
B54476AB 4-109
6. Use a star pattern to tighten the bolts.
NOTE There is no specific orientation to the rail and bearings. The bearings have a ground side
and a polished side. Either side can face the installer.)
7. Install the grip and rotate assembly.

8. Reattach gripper cover cable holder to vertical housing assembly.
9. Reinstall the gripper E-chain assembly. Refer to Replacement in Heading 4.500.15, Z-Axis E-
chain Removal and Replacement.
10. Reconnect the grip motor to the adapter board.
11. Reconnect the rotate motor to the gripper Y/Z cable assembly.
12. Use alignment screws to secure the gripper back plate to the arm. Tighten the gripper back
plate to the arm.
13. Tighten the alignment screws.
14. Reconnect the cables to the cable bulkhead.
15. Replace the bridge cover. Refer to 4.100.3, Covers Removal and Replacement.
16. Replace the gripper cover. Refer to Replacement in 4.100.3, Gripper Covers Removal and
Replacement.
Verification
4. Correlate the gripper successfully. Refer to Biomek i-Series Automated Workstation Hardware
Manual, (B54474) Auto Correlate the Gripper on a Multichannel or Span-8 Pod.
4-110 B54476AB
4.500.9 Gripper Grip Axis Finger Rails and Linear Rail Removal and Replacement 4
4.500.9 Gripper Grip Axis Finger Rails and Linear Rail Removal and
Replacement
Purpose
Follow this procedure to replace a damaged or defective gripper grip-axis, finger rail, and bearing
assemblies.
CAUTION
earth ground.
 ESD protection
 Rail, linear grip axis, PN B73524
Removal
2. Remove the gripper covers. Refer to Heading 4.100.3, Gripper Covers Removal and Replacement.
3. Remove gripper finger assemblies. Refer to Heading 4.500.2, Gripper Grip Motor Removal and
Replacement.
4. Disconnect the grip motor from gripper adapter board. Refer to Figure 4.500.9-1.
B54476AB 4-111
4.500.9 Gripper Grip Axis Finger Rails and Linear Rail Removal and Replacement
Figure 4.500.9-1 Disconnect the Grip Motor
CAUTION
Risk of damage to electronic components. When you remove the bearing retainer,
the lower gripper housing may fall if the rotate motor belt disengages from the
motor gear.
5. Rotate the lower gripper housing so that it is parallel with the upper gripper housing. Hold the
lower gripper assembly with your hand to prevent it from rotating.
6. Use a 2.0 mm Allen wrench to remove the four bearing retainer screws that attach the gripper
grip motor to the upper gripper housing. Refer to Figure 4.500.9-2.
Figure 4.500.9-2 Bearing Retaining Screws
7. Twist lower gripper housing 90° to access the rotate motor pinion and belt. Refer to
Figure 4.500.9-3.
4-112 B54476AB
Figure 4.500.9-3 Twist the Lower Gripper Housing 90°
8. Remove the gripper belt from the rotate motor pinion. Refer to Figure 4.500.9-4.
Figure 4.500.9-4 Remove the Gripper Belt From the Rotate Motor Pinion
9. Remove the lower gripper assembly straight down from upper gripper assembly.
Figure 4.500.9-5.
B54476AB 4-113
Figure 4.500.9-5 Remove the Lower Gripper Assembly From the Upper Gripper Assembly
10. Remove the spring from the gripper fingers (Figure 4.500.9-6).
Figure 4.500.9-6 Remove Gripper Finger Spring
11. Use a 1.5 mm Allen wrench to remove the bearing stopper screw from the inside end of the right
gripper finger rack assembly. Refer to Figure 4.500.9-7.
4-114 B54476AB
Figure 4.500.9-7 Remove the Bearing Stopper Screw From the Right Gripper Finger Rack Assembly
12. Carefully slide the gripper finger rack assemblies away from the grip motor pinion to expose the
screws that attach the grip motor pulley to the lower housing assembly. Refer to
Figure 4.500.9-8.
Figure 4.500.9-8 Slide the Gripper Finger Rack Assembly Away From the Grip Motor Pinion
CAUTION
Risk of component damage. Do not slide the gripper finger rack assemblies
beyond the start of the bearing carriages. Bearings are not captive and could fall
out.
13. Use a 1.5 mm Allen wrench and remove six grip motor screws (Figure 4.500.9-9).
B54476AB 4-115
Figure 4.500.9-9 Remove the Grip Motor
14. Use a 2.5 mm Allen wrench and remove three screws holding the rotate motor pulley to the
lower housing assembly. Remove the lower housing assembly.
Figure 4.500.9-10 Remove screws holding rotate motor pulley to lower housing assembly
15. Use a 2.5 mm Allen wrench to remove eight screws mounting the grip finger linear bearings to
the lower housing assembly. The grip finger rail assemblies are now disconnected from the
lower housing assembly (Figure 4.500.9-11).
4-116 B54476AB
CAUTION
Risk of component damage. Do not slide the gripper finger rack assemblies
beyond the start of the bearing carriages. Bearings are not captive and could fall
out.
Figure 4.500.9-11 Remove Grip Finger Linear Bearings from Lower Housing Assembly
16. Use 2.5 mm Allen wrench to remove the grip finger rails and bearings from the gear racks and
finger mounting brackets.
Replacement
1. Use 2.5 mm Allen wrench to secure the new finger rails and bearings to the finger mounting
brackets. Torque to 15 in-lbs.
NOTE There is no specific orientation to the rail and bearings. The bearings have a ground side and a
polished side. Either side facing installer is ok.
2. Reinstall the gear racks to the new finger linear rails and bearings.
3. Reinstall finger rails and bearings assemblies to the lower housing assembly. Use a star pattern
to tighten eight screws to the bearings.
4. Reinstall the rotate motor pulley assembly to the lower housing assembly.
5. Engage both finger racks on the grip motor pinion.
NOTE Ensure that the engagement of the pinion and both racks occur simultaneously with smooth
movement.
6. Install the stopper bolt on the end of the finger rack assembly.
7. While securing the grip belt to the rotate motor pinion, insert the lower gripper housing
assembly into the upper gripper housing assembly.
B54476AB 4-117
8. Verify the orientation of the notch in the bearing retainer matches the notch in the rotate hub
below it.
9. Reinstall the bearing retainer screws. Tighten them in a star pattern.
10. Reconnect the grip motor to the gripper adapter board.
11. Reconnect the rotate motor to the cable harness.
12. Reinstall the gripper finger assemblies.
Verification
2. Power on the instrument and ensure it completes the startup successfully
4. Correlate the gripper successfully. Refer to Biomek i-Series Automated Workstation Hardware
Manual, (B54474) Auto Correlate the Gripper on a Multichannel or Span-8 Pod.
4-118 B54476AB
4.500.10 Gripper Y-Axis Motor Removal and Replacement 4
4.500.10 Gripper Y-Axis Motor Removal and Replacement
Purpose
Follow these procedures to replace a Y-axis motor.
 Gripper Y-axis assembly, PN B73553
Removal
2. Remove the arm right side cover.
3. Disconnect the gripper Y-axis motor cable from the gripper harness bulkhead. Refer to
Figure 4.500.10-1.
Figure 4.500.10-1 Disconnect the Y-Axis Motor Cable
4. Remove the loosened Y-axis belt from the gripper Y-axis motor pulley and idler pulley. Refer to
4.500.11, Y-Axis Belt Removal and Replacement.
5. Loosen the front Allen screw, and remove the rear Allen screw from the Y-axis motor tensioning
bracket. Slide the motor towards the front of the instrument, and slip the belt off the motor
pulley. Remove the Y-axis motor from the gripper main plate. Refer to Figure 4.500.10-2.
6. Remove the Y-motor, pulley, and bracket assembly. Refer to Figure 4.500.10-2.
B54476AB 4-119
4.500.10 Gripper Y-Axis Motor Removal and Replacement
Figure 4.500.10-2 Y-Axis Motor
Replacement
1. Install the Y-axis motor by sliding the tensioning bracket under the loosened Allen screw on the
gripper main plate.
2. Install the Y-belt over the Y-axis motor pulley and idler pulley.
3. Ensure that the tension of the Y-axis belt is appropriate using a BrecoFlex meter. Adjust the
tension to between 39 Hz and 53 Hz.
4. Tighten front Allen screw of the tensioning bracket.
5. Reinstall and tighten the rear Allen screw of the tensioning bracket to secure the Y-motor to
the gripper main plate.
6. Reconnect the cable disconnected in Step 3.
7. Replace bridge covers. Perform the procedure in Heading MC Arm Covers Removal and
Replacement, or Span-8 Arm Covers Removal and Replacement.
Verification
3. Home all Axes. Ensure the instrument homes successfully. Perform the procedure in Heading
5.100.1, Home All Axes.
4-120 B54476AB
4.500.11 Y-Axis Belt Removal and Replacement 4
4.500.11 Y-Axis Belt Removal and Replacement
Purpose
Follow these procedures to remove and replace a defective Y-axis belt.

 Flat blade screwdriver
 Gripper Y-Axis timing belt, PNB80224
 Pulley, Timing, Idle, Y-Axis, PN B73571
Removal
2. Remove the bridge covers. Refer to the 4.100.3, Covers Removal and Replacement procedure.
NOTE Do not remove the idler pulley. It is secured with Loctite.
3. Loosen the front and rear hex screw on the Y-axis motor tensioning bracket to release the belt
tension. See Figure 4.500.11-1.
Figure 4.500.11-1 Remove the Idler Pulley and Loosen the Y-Axis Belt.
4. Use a 2.5 mm Allen wrench to loosen the screw securing the Y-axis belt to the vertical housing
assembly (Figure 4.500.11-2)
B54476AB 4-121
4.500.11 Y-Axis Belt Removal and Replacement
Figure 4.500.11-2 Loosen screw securing Y-axis belt to the vertical housing assembly
5. Remove the loosened Y-axis belt from the gripper Y-axis motor pulley.
Replacement
1. Place one end of the belt around the Y-axis motor pulley and the other end of the belt around
the idler pulley.
2. Push the motor assembly back towards the rear of the instrument to tension the belt. Tighten
the rear and front hex screw of the tensioning bracket.
3. Use the 2.5 mm Allen wrench to reattach the Y-axis belt to the vertical housing.
4. Replace the bridge covers. Refer to the 4.100.3, Covers Removal and Replacement procedure.
Verification
3. Home all Axes. Ensure the instrument homes successfully. Refer to the 5.1, Home All Axes
procedure.
4-122 B54476AB
4.500.12 Y-Axis Idler Pulley Removal and Replacement
Purpose
Use this procedure to replace a damaged or defective Y-Axis idler pulley.
 Flat-bladed screwdriver
 2.5 mm hex driver
 PN B73571 Pulley, Timing, Idle, Y-Axis
Removal
2. Remove the bridge cover. Refer to 4.100.3, Covers Removal and Replacement.
3. Use a flat-blade screwdriver to remove the Y-Axis idler pulley assembly. See Figure 4.500.12-1.
Figure 4.500.12-1 Remove the Y-Axis Idler Pulley.
4. Remove the loosened Y-axis belt from the gripper Y-axis idler pulley.
Replacement
1. Install the Y-Axis belt around the Y-Axis idler pulleys.
2. Reinstall the Y-Axis idler pulley.
3. Ensure that the tension of the Y-axis belt is appropriate using a BrecoFlex meter. Adjust the
tension to between 39 Hz and 53 Hz.
Verification
B54476AB 4-1
3. Home all the Axes. Ensure the instrument homes successfully. Refer to the 5.100.1, Home All
Axes procedure.
4-2 B54476AB
4.500.13 Y-Axis Linear Rail and Bearings Replacement 4
4.500.13 Y-Axis Linear Rail and Bearings Replacement
Purpose
Follow these procedures to replace Y-axis linear bearings and rail if defective or damaged.
 Flat blade screwdriver
 Torque driver
 Rail, Y-axis, and gripper, PN B73557
Removal
CAUTION
Risk of equipment damage. Lower and secure the gripper to prevent damage to
instrument components.

2. Remove the bridge covers (refer to 4.100.3, Covers Removal and Replacement).
3. Remove the gripper assembly (refer to 4.500.1, Gripper Assembly Removal and Replacement).
4. Use the 2.5 mm Allen wrench to remove eight screws mounting the Z-axis linear bearings to the
vertical housing assembly.
NOTE The Gripper and Z-axis linear rail are disconnected from the gripper assembly. Use caution to
prevent component damage.
5. Move the Z-axis components slightly out of the way in order to access the screws mounting the
Y-axis bearing block.
6. Use the 2.5 mm Allen wrench to remove the screws mounting the vertical housing assembly to
the Y-axis linear rail.
7. Using the 1.5 mm Allen wrench, loosen two set screws from the underside of the vertical
housing assembly. Refer to Figure 4.500.13-1.
B54476AB 4-3
Figure 4.500.13-1 Loosen the Set Screws to Remove the Vertical Housing Assembly
NOTE These set screws positively position the vertical housing assembly against the Y linear bearing
carriage.
8. Use the 2.5 mm Allen wrench to remove 10 Y-axis linear rail mounting screws.
9. Lift the vertical housing assembly slightly while removing the &-axis linear rail and bearing
block.
10. Remove the Y-axis linear rail and bearing carriages.
Replacement
1. Replace the Y-axis linear rail.
NOTE Use an alternating pattern to tighten screws, starting from one end of the rail to tighten,
and moving the bearing carriage to the opposite end of the rail to tighten. Repeat this
pattern until all screws are tightened.
NOTE Omit the screws from the gripper back plate mounting screw hole locations.
2. Wipe off excess oil from the Y-axis linear rail.

3. Remove the bearing stopper from both ends of the rail.
4. Install the rail with the logo-printed side of the bearing bracing down towards the base plate.
5. Install the screws to secure the rail to the plate.
NOTE Do not install screws in holes with slots located above or below the hole. these holes are sued for
securing the base plate to the arm.
6. Torque all screws using 15-in lbs torque.
4-4 B54476AB
4.500.13 Y-Axis Linear Rail and Bearings Replacement 4
7. Replace the vertical housing assembly and install the bearing block mounting screws, but do
not fully tighten them.
8. Tighten the set screws to position the vertical housing assembly against the linear bearing
carriage assembly.
9. Tighten the linear bearing screws securing the vertical housing. Torque with 15 in-lbs torque.
10. Do the following to reinstall the gripper assembly and secure the Z-axis linear rail to the vertical
housing assembly:
a. Install the lower Z-axis linear bearing to the vertical housing assembly. Do not tighten the
screws.
b. Install the upper Z-axis linear bearing to the vertical housing assembly do not tighten the
screws.
NOTE Make sure the rack and rail assembly moves freely up and down inside the vertical housing.
c. Torque all screws to 15-in lbs torque.
11. Reattach the gripper assembly back plate to the bridge:

a. Use alignment screws to hang the plate while securing the back plate to the bridge.
b. Insert screws through the open holes with the locating slots on the Y-linear rail.
c. Tighten the alignment screws.
12. Reconnect all cables to the bulkhead connector.

13. Replace the bridge covers.
Verification
3. Home all Axes. Ensure the instrument homes successfully. Refer to 5.1, Home All Axes.
B54476AB 4-5
4-6 B54476AB
4.500.14 Z-Motor Removal and Replacement 4
4.500.14 Z-Motor Removal and Replacement
Purpose
Follow these procedures to replace a damaged or defective gripper Z-axis motor.
 ESD protection
 Torque driver
 Motor, Geared, Z-axis, Gripper, PN B73544
Removal
2. Remove the bridge covers (refer to 4.100.3, Covers Removal and Replacement).
WARNING
Risk of equipment damage. The gripper can drop unexpectedly while the
instrument is being serviced. Manually lower the gripper to prevent it from falling
and damaging components.
3. Manually lower the gripper assembly and rest it on top of a tall tip box. Ensure that the gripper
fingers are not obstructed, and secure it in place.
B54476AB 4-7
Figure 4.500.14-1 Lower the Gripper Assembly
4. Disconnect all the Z-axis motor cables from the bulkhead.

5. Use the 2 mm Allen wrench to loosen the Z-motor coupler from the Z-axis motor
(Figure 4.500.14-2).
Figure 4.500.14-2 Loosen the Z-Motor Coupler From the Z-Axis Motor.
6. Use the 2.5 mm Allen wrench to remove the Z-axis motor bracket from the gripper plate. See
Figure 4.500.14-3.
4-8 B54476AB
4.500.14 Z-Motor Removal and Replacement 4
Figure 4.500.14-3 Remove the Z-Axis Motor Bracket From the Gripper Plate.
7. Use the 3 mm Allen wrench to remove four screws holding the cable bulkhead to the Z-axis
motor and bracket assembly. Set these pieces aside.
8. Disconnect the Z-axis motor power and encoder cable assembly from the Z-axis motor.
Figure 4.500.14-4 Disconnect the Z-Axis Motor Power and Encoder Cable Assembly
Replacement
1. Reinstall the cable bulkhead to the Z-axis motor assembly.
NOTE Make sure the pin socket on the motor and connector slots on the bulkhead harness holder are
facing up. Orient the Z-Axis motor as shown in figure Figure 4.500.14-4.
2. Reconnect the Z-axis power and encoder cables to the z-axis motor and to the bulkhead
connector.
3. Install the Z-axis motor and bracket assembly to the gripper plate.
NOTE Make sure the Z-axis motor gear is inserted into the Z-axis motor coupling.
B54476AB 4-9
4. Torque the coupler on the Z-axis motor with 20 lbs torque.

5. Refer to Replacement in 4.500.1, Gripper Assembly Removal and Replacement.
6. Reinstall the bridge covers. Refer to the 4.100.3, Covers Removal and Replacement procedure.
Verification
3. Home all Axes. Make sure the instrument homes successfully. Refer to the 5.1, Home All Axes
procedure.
4-10 B54476AB
4.500.15 Z-Axis E-chain Removal and Replacement 4
4.500.15 Z-Axis E-chain Removal and Replacement
Purpose
Use this procedure to replace defective or damaged gripper Z-axis E-chain cables.

 ESD protection
 Assembly B73559, Cable, and Gripper Y/Z
Removal
CAUTION
Risk of equipment damage. Electrostatic discharge (ESD) can damage circuit
boards and other electronic components. Perform any procedure where there is a

3. Remove the gripper covers. Refer to Gripper Covers Removal and Replacement
4. Remove the E-chain cables for the grip and rotate motors from the bulkhead.
5. Disconnect the rotate motor from the Z-axis cable assembly (Figure 4.500.15-1).
Figure 4.500.15-1 Disconnect Rotate Motor
6. Disconnect the grip motor from the interconnect board (Figure 4.500.15-2).
B54476AB 4-1
Figure 4.500.15-2
7. Use the 2 mm Allen wrench to remove the gripper board from the gripper upper housing
assembly.
Figure 4.500.15-3
8. Clip the zip-tie to release the cables in the e-chain (Figure 4.500.15-4).
4-2 B54476AB
4.500.15 Z-Axis E-chain Removal and Replacement 4
Figure 4.500.15-4 Clip cable tie
9. Use the 2.5 mm Allen wrench to remove the Z-axis power and encoder cable E-chain from the
gripper plate.
Figure 4.500.15-5
10. Use the 2.5 mm Allen wrench to remove the four screws securing the E-chain assembly to the
E-chain bracket.
B54476AB 4-3
11. Use the 2.5 mm Allen wrench to remove the E-chain assembly from the vertical housing
assembly and gripper cover.
Replacement
1. Reinstall the E-chain assembly to the E-chain bracket (Figure 4.500.15-5).
2. Reattach the E-chain assembly to the vertical housing assembly.
3. Reattach the E-chain assembly to the gripper back plate.

4. Attach the gripper board to the upper housing assembly.
5. Use a cable-tie to attach the grip-motor cable to the E-chain (Figure 4.500.15-4).
6. Reconnect the grip motor to the interconnect board (Figure 4.500.15-2).
7. Reconnect the rotate motor to the Z-axis cable assembly (Figure 4.500.15-1).
8. Reconnect the Z-axis cable assembly to the bulkhead connectors. The cable tie must be tight
enough to prevent the cable from slipping and ensure that it rotates with the gripper.
9. Reinstall the gripper covers. Refer to the Gripper Covers Removal procedure.
10. Reinstall the bridge covers. Refer to the Gripper Covers Removal procedure.
Verification
1. Move the arm or arms to a safe location.
3. Home all axes. Refer to the 5.100.1, Home All Axes procedure.
4-4 B54476AB
CHAPTER 5
Preventive Maintenance and Verification
Procedures
5.000.1 Preventive Maintenance Checklist
Table 5.000.1-1 Preventive Maintenance Checklist- General
General Description Tools

 Cleaning Use mild cleaner to wipe down the Mild cleaner and soft, absorbent
deck, work surface, ALPs, and all cloth.
exposed parts of the instrument.
 Cleaning Use a mild plastic or glass cleaner to Mild plastic or glass cleaner and soft,
clean both the exterior and interior of absorbent cloth.
the safety shields.
 Cleaning Inspect head(s) for contamination Mild cleaner and soft, absorbent
including mandrels and shuck plates. cloth.
Use mild cleaner to wipe down
surfaces.
 Cleaning Clean the Automation Controller and Soft, lint-free cloth.
Display unit with a soft, lint-free cloth.
 Cleaning Check all tubing on the Span-8 system 10% bleach solution or replacement
including Span-8 Passive Wash ALP for tubing kits.
mold or algae growth. Clean with 10%
bleach solution and water flush or
replace.
 Cleaning Check all tubing on the Active Wash 10% bleach solution or replacement
ALPs for mold or algae growth. Clean tubing kits.
with 10% bleach solution and water
flush or replace.
 Cleaning Empty trash ALPs and dispose of N/A
labware and tips.
 Cleaning Empty waste containers and dispose N/A
of contents following customer
guidelines.
B54476AB 5-1
Preventive Maintenance and Verification ProceduresPreventive Maintenance and Verification Procedures
Table 5.000.1-2 Preventive Maintenance Checklist- Modules
Module Description Tools

 Gripper Check and clean finger pads. Tighten Mild cleaner and soft, absorbent cloth.
or replace, if necessary.
 Gripper Correlate gripper, if necessary. If
gripper movements A1 near and A1
away are both good, do not correlate
again.
 Multichannel Pod Check Pod Alignment. 4 Post Framing tool and method.
 Multichannel Head Leak test. Service Checkout Method
 Multichannel Head Liquid transfer test. Service Checkout Method
 Multichannel Head Volume verification. OQ, if required.
 Span-8 Pod Check all tubing connections. Make
sure tip to tubing connection is neat
and properly seated. Make sure
tubing fittings on syringe ports are
finger tight. Check that syringe
connections on syringe port are finger
tight.
 Span-8 Pod Tubing length between tip and tubing
support bracket is 32 inches for each
probe.
 Span-8 Pod Check that mandrel collars are finger
tight.
 Span-8 Pod Check that mandrel shuck tube
collars are finger tight and not
mushroomed or over-tightened.
Replace, if required.
 Span-8 Pod Check tactile tip interface assembly
spacing. Adjust so tip interfaces are
spaced evenly and not rubbing.
 Span-8 Pod Check Probe 1 alignment in X and Y. Machinist square.
Adjust, if required.
 Span-8 Pod Check Probes 2-8 alignment using 384 Square Well Plate
384 well plate. Adjust, if required.
 Span-8 Pod Check Probe Correlation. Repeat if
needed.
 Enclosure Lubricate front door counterbalance Super Lube
reels.
 Enclosure Check Enclosure Door operation. Door
should remain open when opened.
Door should remain closed when
closed. Door should remain partially
opened, if partially opened. Door
operation should be smooth.
5-2 B54476AB
5.000.1 Preventive Maintenance Checklist 55
Table 5.000.1-2 Preventive Maintenance Checklist- Modules
Module Description Tools

 System Check Power On and Software
Connections.
 System Home all Axes.
 System Check Light Curtain operation. Light Curtain Test Rods
 System Check Status Light operation.
 System Check Deck Light Operation.
 System Check Tower Camera operation and Use Remote View or Manual Control.
focal adjustment.
 System Check Deck Framing for all decks with AccuFrame
both pods. Framing Tools
Table 5.000.1-3 Verification Procedures
Verification Procedure Module / System Notes

 Power on instrument. System Used for most service procedures
(install, general, per module, PM).
 Home All Axes. System Used for most service procedures
(install, general, per module, PM).
 Auto-Correlate the Gripper. System Used for some service procedures
(install, some gripper repair, such as
finger replacement, rotate belt, rotate
and grip motors, Y belt changes,
gripper PM).
 Run 4 Post Framing Tool to check System Used for some service procedures
pod alignment. (install, MC pod repair, MC pod PM).
 Run service check out method. System Used for all service procedures (install,
general, per module, PM).
B54476AB 5-3
5-4 B54476AB
Preventive Maintenance and Verification Procedures
5.100.1 Home All Axes 5
Part A Operational Checks
5.100.1 Home All Axes
Purpose
The Biomek i-Series instrument uses relative encoders, and the zero location of each axis must be
determined each time the power is turned on. This process is called homing and works by driving
each axis to a hard stop. As the starting locations are unknown, homing is not a safe operation. The
user is instructed to move the arm(s) to a safe location before homing.
Use the Home All Axes procedure each time the instrument power is cycled, and use this to verify
power and communication between the host software, master controller, motors, and encoders are
working properly.
 Biomek Software v5.0 or later
Procedure
3. If Biomek Software is closed, launch Biomek Software. Go to the Method ribbon and select Home
All Axes (Figure 5.100.1-1).
Figure 5.100.1-1 Home All Axes
B54476AB 5-5
4. The software will display a Homing dialog with specific preparation instructions. Read message
carefully and adjust physical setup as necessary.
Figure 5.100.1-2 Homing confirmation dialog
5. Select OK. Homing will begin. The homing sequence is described below.
Multichannel Pod
a. Home Pod
1) Home Z
b. Home Gripper
1) Move GZ to maximum height
2) Home GG
3) Move GG to 1.95 cm
4) Move GR
5) Move GR through full travel to make sure it homes against hard stop
6) Move GR to face the front
7) Home GY
8) Home GZ
9) Move GY to 24 cm from its hard stop so that the gripper is safe to rotate
c. Home Pod
1) Home Y
d. Home Gripper
1) Move GR to face the right
5-6 B54476AB
5.100.1 Home All Axes 5
e. Home Pod
1) Home X
2) Move left arm in X to 14 cm from its hard stop so that the gripper will not hit the side
shield during a subsequent home command.
3) Move right arm (if applicable) in X to -0.25 cm from its hard stop so that it is within the
margin used by the host software.
f. Park Pod
Span-8 Pod
a. Home Pod
1) Move Z1-8 to maximum height

b. Home Gripper
1) Move GZ to maximum height
2) Home GG
3) Move GG to 1.95 cm from the hard stop. Depending on hard stop location, the gripper
fingers will be roughly 8 cm apart.
4) Move GR
5) Move GR through full travel to make sure it homes against hard stop
6) Move GR to face the front
7) Home GY
8) Home GZ
9) Move GY to 24 cm from its hard stop so that the gripper is safe to rotate
c. Home Pod
1) Home Y1-Y8
2) Home Z1 and Z5
3) Home Z2 and Z6
4) Home Z3 and Z7
5) Home Z4 and Z8
6) Move Z1-8 to a safe height
d. Home Gripper
1) Move GR to face the right
e. Home Pod
1) Home X
2) If left arm, move X to 14 cm from its hard stop so that the gripper will not hit the side
shield during a subsequent home command.
3) If right arm, move X to -1 cm from its hard stop so that it is within the margin used by
the host software.
B54476AB 5-7
f. Park Pod
1) Move Pod to Span-8 Wash Station
2) Move Z1-8 to Span-8 Wash Station
g. Home Syringes
1) Flush system fluid through tubing until commanded to stop by operator.
h. Park Pod
Verification
Homing should finish all actions described in procedure without error.
5-8 B54476AB
5.100.2 4 Post Framing Tool Procedure 5
5.100.2 4 Post Framing Tool Procedure
Purpose
The Four Post Framing Tool is used to measure the Multichannel Pod rotation. The Biomek i-Series
Multichannel Pod is aligned during manufacturing assembly and test. Alignment should be verified
on installation, preventive maintenance, and after any serious instrument crash involving the
Multichannel Pod.
 Four Post Framing Tool Method available through AirWatch
 Four Post Framing Tool, PN B75543
Instructions
1. Open Biomek Software > Service project and import the Four Post Framing method.
2. Use the Select Pod and Deck step UI to select the deck, and to choose the Multichannel pod to
perform the 4-Post framing procedure (Figure 5.100.2-1).
Figure 5.100.2-1 Select Deck and Pod
3. Use the Select Accuframe Position step UI to configure the position to place the AccuFrame on
(Figure 5.100.2-2). The method will automatically choose a position centrally located within the
range of the selected Pod, but the position can be overridden by selecting from the dropdown.
Be sure to choose a position that the Multichannel Pod can access.
NOTE Use only a Static ALP or TipLoad ALP as the AccuFrame Position. The script may not work if using
other ALPs like Peltier or Tuberack, as these ALPs have offsets for the AccuFrame.
B54476AB 5-9
Figure 5.100.2-2 Selecting Accuframe Position
4. Attach the Four Post Framing tool to the selected Multichannel head. The Framing Tool attaches
magnetically to the head. No screws or bolts are required (Figure 5.100.2-3)
Figure 5.100.2-3 Attach 4-post Framing Tool
5. Place an AccuFrame framing tool on the configured ALP position on deck.

NOTE Make sure the AccuFrame cable does not interfere with the Four Post Framing Tool probes.
6. Click on Finish step to validate method.

7. Press the green arrow to start the method.
8. A warning will pop up asking if the 4-post framing tool is installed on the correct Pod, and if the
AccuFrame is placed on the correct position. Click OK if the configuration is correct or Abort if
it is not (see Figure 5.100.2-4).
Figure 5.100.2-4 4 Post Warning
9. The result will display alignment values and suggestion if it failed (Figure 5.100.2-5)).
5-10 B54476AB
5.100.2 4 Post Framing Tool Procedure 5
Figure 5.100.2-5 MC Pod Alignment Values
10. The Acceptable Values for Alignment now only checks Y. Z variance is measured and reported
but not used for clocking. There is no acceptance criteria for Z. Values may be stored and used
later for diagnostic purposes.
Results
Acceptable Values for Alignments:
• Y < ±0.127 mm
Y values greater than ±0.127 mm means that the pod is clocked and may cause tips to clip wells when
accessing higher density labware.
If the values for Y fail, refer to 4.200.4, MC Pod Rotation Adjustment Procedure.
B54476AB 5-11
5-12 B54476AB
5.100.3 Service Check Out Method 5
5.100.3 Service Check Out Method
Purpose
The Single Service Checkout Method is designed to test the key functions of the instrument through
Biomek Software. This method should be used to verify instrument operation at the end of
installation, during preventive maintenance, and before closing out a repair call.
This method is used for all instrument platforms and pod combinations. The method may be run as
a single method, or a single group(s) can be run separately.
Table 5.100.3-1 Single Service Checkout Methods
Instrument
Configuration Single MC Single Span-8 Dual MC Hybrid
Test 1 Checks deck framing and logs to file
Labware None
Test 2 Checks arm range of Checks probe Checks left arm range Checks left arm range
motion alignment of motion of motion
Labware None BC80_LLS None None
Test 3 Checks gripper motion Checks arm range Checks left arm Checks left arm
for smoothness of motion gripper motion for gripper motion for
smoothness smoothness
Labware BC1070 None BC1070 BC1070
Test 4 Loads tips, performs Checks gripper Loads tips, performs Loads tips, performs
leak test, unloads tips motion for leak test, and unloads leak test, and unloads
smoothness tips for left arm tips for left arm
Labware BC1070 or BC1070 BC1070 or BC1070 or
BC50_384 BC50_384 BC50_384
Pump Checks the pump
Configuration and syringes
Test
Labware None
B54476AB 5-13
Table 5.100.3-1 Single Service Checkout Methods
Instrument
Configuration Single MC Single Span-8 Dual MC Hybrid
Test 5 Disposable tips: Checks right arm Checks probe
Loads tips, range of motion alignment on Span-8
performs leak test, pod
unloads tips
Fixed tips:
Performs leak test
Labware BC230 None BC80_LLS
BCFlat96
Test 6 Performs LLS Test Checks right arm Checks right arm
gripper motion for range of motion
smoothness
Labware Disposable tips: BC1070 None
BC80_LLS
BCFlat96
Fixed tips:
BCFlat96
Test 7 Loads tips, performs Checks right arm
leak test, and unloads gripper motion for
tips for right arm smoothness
Labware BC1070 or BC1070
BC50_384
Pump Checks pumps and
Configuration syringes
Test
Labware None
Test 8 Disposable tips:
Loads tips, performs
leak test, unloads tips
from right arm.
Fixed tips: Performs
leak test
Labware BC230
BCFlat96
Test 9 Performs LLS test
Labware Disposable tips:
BC80_LLS
BCFlat96
Fixed tips: BCFlat96
5-14 B54476AB
 Single Service Checkout Method available through AirWatch
 Miscellaneous labware
 For each MC Pod:
• (1) BC1070 tipbox for gripper motion test
• (1) BC1070 tipbox (96 channel head) for leak test
• (1) BC50_384 tipbox (384 channel head) for leak test
 For each Span-8 Pod:
• (1) BC80_LLS for probe alignment test, if using disposable tips
• (1) BC1070 tipbox for gripper motion test
• (1) BC230 tipbox for leak test, if using disposable tips
• (1) BCFlat96 for leak test
• (1) BC80_LLS for LLS test, if using disposable tips
• (1) BCFlat96 for LLS test
Instructions
1. Open Biomek Software > Service project and import the Single Service Checkout method. The
method may not validate right away.
2. Read the note at the beginning of the method. Follow the instructions to configure the method
run.
a. Use the Select Options UI to configure which parts of the run you want to perform.
B54476AB 5-15
b. Use the Override Deck Positions Step UIs to override the automatically chose deck positions
for each pod. If you change the deck in Select Options, any deck position overrides will need
to be reconfigured.
You will be prompted when you need to take action during the execution of this method.
NOTE The method avoids automatically selecting Peltier locations as the Peltier can interfere with
the gripping test and cause method validation issues and it avoids tipload locations by default
to avoid selecting the last tip loader; you may select a TL position in the override steps as long
as you leave one available.
Some custom installations may require additional work to get the method to enqueue or
may require the service engineer to write a custom method to test operation.
3. Start the method run. Select Yes to the following prompts:
4. For single Span-8 systems, skip to step 14. For single Multichannel, dual Multichannel, and
Hybrid systems, proceed.
Select Yes if the four post framing tool has been used prior to start of Single Service Checkout
method. If No and this is an installation, abort method and proceed to 5.100.2, 4 Post Framing
Tool Procedure. If No and this is a PM check, abort method and proceed to 5.100.2, 4 Post
Framing Tool Procedure. If No, and this is to verify a specific repair procedure, you may proceed
or abort method and proceed to 5.100.2, 4 Post Framing Tool Procedure.
5-16 B54476AB
5. Verify the deck setup and click Yes on the following prompt:
NOTE Your deck may differ from the deck in the above image.
6. The instrument arm, pod, and gripper will move and exercise motion around the deck at
specific locations.
7. An Instrument Setup step appears. Place a BC1070 tip box on the selected deck location. Select
OK. This is for the gripper motion test.
Gripper Motion Test:
B54476AB 5-17
8. An Instrument Setup step appears. Place a BC1070 tipbox on the designated deck position.
Remove the tipbox lid and use as a BCUpsideDownTipBoxLid on the designated deck position.
Place a BCFlat96 plate on the designated position.
Leak Test:
9. A dialog will pop up on the screen that informs you to fill the BCUpsideDownTipBoxLid to at
least half-full with water.
10. The system will load tips, aspirate water, move over the BCFlat96 plate, and will pause for 90
seconds. The system will then move back to the reservoir, dispense water, and shuck tips back
to box.
11. A dialog will pop up on the screen that asks whether there were any droplets that fell into the
BCFlat96 plate. Select Yes or No.
5-18 B54476AB
If this is a single arm MC system, the method has ended. If this is a dual MC system, the method
will proceed to the same steps for the right arm. If this is a Hybrid system, proceed to step 12.
12. The next test will be to check probe alignment. The system will load BC80_LLS tips and will
verify the alignment of probes against the Span-8 wash station. Make sure the path to the
Span-8 wash station is clear. Remove any obstacles that may make it difficult to check probe
alignment.
Deck Framing:
B54476AB 5-19
13. An Instrument Setup step appears. This is empty. Clear deck of all labware. The system will now
exercise the motion test on the Span-8 arm.
Motion Test:
14. An Instrument Setup step appears, place a BC1070 tip box on the selected deck location. Select
OK. This is for the gripper motion test.
Gripper Motion Test:
5-20 B54476AB
15. The next test checks that the syringe pumps and syringes are moving as commanded. The
syringes should move to different levels.
Select Yes or No.

16. An Instrument Setup step appears. Place a BC230 tipbox on the designated deck position.
Remove the tipbox lid and use as a BCUpsideDownTipBoxLid on the designated deck position.
Place a BCFlat96 plate on the designated position.
Leak Test:
17. A dialog will pop up on the screen that informs you to fill the BCUpsideDownTipBoxLid to at
least half-full with water.
18. The system will load tips, aspirate water, move over the BCFlat96 plate, and will pause for 90
seconds. The system will then dispense water to the first column in the BCFlat96 plate and will
shuck tips to trash.
B54476AB 5-21
19. A dialog will pop up on the screen that asks whether there were any droplets that fell into the
BCFlat96 plate. Select Yes or No.
20. The next test will check tip detection function on the Span-8. The system will attempt to load
tips from the empty column in the BC230 tipbox. When you receive a failed to detect message,
ignore the error and continue.
21. An Instrument Setup step appears. Place the same BC80_LLS tipbox step on the designated deck
position. Place a BCFlat96 plate on the designated position.
5-22 B54476AB
22. The system will load a column of tips and will LLS sense liquid in the first column of the
BCFlat96 plate used in the Leak Test. The system should detect liquid in all wells. Select OK.
23. The system will now attempt to LLS from the second column in the BCFlat96 which is empty. All
8 probes should fail to detect liquid. Tell the system to pipette air to continue.
The method has ended. All results have been recorded in a log file located in
C:\Users\Public\Documents\Biomek5\Logs. The log file is a Service Checkout log and is date,
time-stamped.
B54476AB 5-23
An example of the log is shown below.
Attach these results to your Field Service Report.
Verification
To successfully complete the service checkout method, the following must be met:
• Deck Framing – all positions reachable by each pod should have Position Framed.
• Probe Alignment – the Span-8 probes should be properly aligned to the dots in the Span-8 wash
station.
• Motion Test – the instrument arms should be able to access all positions without error. If noise
is generated during the motion test, check to see if the arm e-chain for left or right pod is
rubbing against the rear panel. Adjust by pulling the e-chain forward away from panel and
repeat test.
There should be no other binding noise associated with the motion test. There should be no
visible MC pod drooping.
• Gripper Motion Test – the gripper(s) should move the BC1070 tipbox around the deck to each
designated location with smooth, even motion. There should be no visible drooping and no
visible vibration during motion.
• Leak Test – the pipettor should load tips without the tipbox lifting; there should be no droplets
in the microplate; tips should unload appropriately.
5-24 B54476AB
• Syringe Level Detection test – all eight syringes should move:
• Tip Detection – the Span-8 should appropriately detect the absence of tips on all eight probes.
• LLS Detection – the Span-8 should appropriately detect the presence and absence of liquid on
all eight probes.
B54476AB 5-25
5-26 B54476AB
5.100.4 Instrument Function Checklist Procedure 5
5.100.4 Instrument Function Checklist Procedure
Purpose
The instrument function checklist should be used to verify instrument operation at the end of
installation, during preventive maintenance, and before closing out a repair call. This checklist
should be used in combination with the Homing Procedure, the Four Post Framing Tool procedure,
and the Service Checkout procedure.
 Small Light Curtain Test Rod
 Large Light Curtain Test Rod
 Bubble Level
Instructions
Table 5.100.4-1 Instrument Function Checklist Procedures
Test Procedure Results Troubleshooting

Deck Use a bubble level and Deck should be level to Loosen locking nuts on all feet.
levelness verify the deck is level in <0.05 degrees in both Use an M6 driver to level feet.
both X and Y direction directions. Lock nuts. Replace deck plates.
Tubing Verify that pump to tip Tubing should be routed If tubing is damaged, replace
Check tubing and source tubing and connected tubing.
are not damaged. appropriately.
Tubing should not be
kinked or damaged.
B54476AB 5-27
Table 5.100.4-1 Instrument Function Checklist Procedures (Continued)

Door Open Verify that the front door The door should operate Check that the door is attached
Operation opens smoothly and smoothly; remain open in properly.
remains open the open position; remain Ensure that MOD 11984 has been
Door Closed Verify that the front door closed in the closed completed, if applicable.
Operation closes smoothly and position; and remain
partially open. Remove door using door removal
remains closed. procedure. Check that the latch
Door Verify that the door remains spring is attached to the
Partially partially open. counterbalances.
Open Lubricate counterbalances.
Operation
Adjust tension or replace both
counterbalances.
Check that the roller guides and
rails operate smoothly. Adjust or
replace.
Check that top and side magnets
are attached to chassis frame.
Reattach door.
5-28 B54476AB

Tower Open Biomek Software > Cameras should be If cameras are not connected,
Camera Utilities > Hardware connected. Images from delete camera devices and add
Operation Setup and Select Vision each camera should be camera devices again. Rename
System clear and focused. each camera appropriately
(LeftTowerCamera or
RightTowerCamera).
If image is blurry, clean camera
lens with soft, clean cloth.
Unlock lens focus ring using a
small Phillips screwdriver. Rotate
lens ring until image is adjusted.
Lock lens adjustment ring.
The Vision System should

be connected (no visible red
X).
Open Remote View link and

check Left and Right Tower
Camera operation and
image.
USB Port Attach a USB mouse to one Mouse should operate If mouse fails to operate, check
Check USB port on the Left Tower when connected. tower board and cable
Board. connections at the tower board
Attach a USB mouse to one and the chassis board locations.
USB port on the Right Tower Re-seat or replace, as needed.
Board.
B54476AB 5-29

AccuFrame Power down the instrument. The AccuFrame should be Check that the AccuFrame is
Port Attach an AccuFrame to the connected in Utilities > plugged into the lower left
AccuFrame port on the Left Hardware Setup (no red AccuFrame port on the Left Tower
Tower Board. Power up the X). board. Check AccuFrame
instrument. Home All Axes. The system should display connector and chassis board
Open Utilities > Deck no error messages. cable connections.
Editor and select a position. If an error is displayed indicating
Select Auto-Teach. The AccuFrame should
light up all 3 LEDs using that the AccuFrame is not
AutoTeach and pod compatible with the Biomek
framing tools. i-Series, connect the AccuFrame
that shipped with the Biomek i-
Series instrument
If the AccuFrame fails to light up,
power down the instrument.
Remove the AccuFrame. Use a
Phillips screwdriver and remove
the base plate. Check that all
cables are connected on the
board. Re-seat connections.
Reattach the base plate.
Reconnect the AccuFrame to the
AccuFrame port. Repeat test.
CAN Port Power down the instrument. The CAN device should be If the device is not
Attach a compatible, connected to the communicating, check tower
functional CAN device to a instrument and recognized board connections.
CAN port on the Left Tower by the system.
Board. Power up the The device can be
instrument. Home All Axes. initialized through Manual
Open Utilities > Hardware Control.
Setup. The CAN device
should be listed with no red
X.
Open Method > Manual
Control > select Device.
Repeat test for the Right
Tower Board.
5-30 B54476AB

Interior Switch on the deck light Verify the lights are If the lights fail to work, check
Deck Light switch, located on the right operational. that the LED strips are connected
side of the front right tower. properly.
Check that the light switch is
functional.
Status Light Cycle power on the All status lights should If status lights fail to operate,
Display instrument. display even and correct check cable connections.
Home All Axes. Run the operational colors. If status lights blink or display
service checkout method. Upon cycling power, the fractional colors or sporadic
Manually break the light status light should display motion, replace affected status
curtain. Resume instrument amber. light LED strip(s).
operation. Upon successful If status lights fail to function with
completion of Home All described status display
Axes, the status lights operation, contact Technical
should display blue. Support.
Upon running of a method, If status lights scroll from right to
the status lights should left, remove and reinstall LED
scroll green from left to lights using procedure
right on all sides. 4.100.5, LED Light Segment
Upon breaking the light Removal and Replacement on
curtain, the status lights Closed Enclosure
should alternate solid
red/dark red.
Upon resuming method,
the status lights should
scroll green.
Upon completion of
method, the status lights
should return to blue.
B54476AB 5-31

Light If a door is present, open N/A See 7.2, Light Curtain
Curtain the door. Troubleshooting Procedure.
Operation
Start the service checkout The instrument should
method. start operation and the
status lights should scroll
green.
Insert the large light curtain The large light curtain test
test rod (719724) into the rod should trip the light
top left corner of the curtain.
instrument opening such An LED should light red on
that it extends at least an each light curtain
inch past the light curtain segment, as the test rod
segments towards the moves across the space
inside of the instrument. above that segment.
Move the test rod across the
top of the instrument
opening until it reaches the
top right corner as shown in
Figure 5.100.4-1.
Figure 5.100.4-1 Large Rod Test
5-32 B54476AB

Light Resume instrument The instrument should See 7.2, Light Curtain
Curtain operation. resume operation and the Troubleshooting Procedure.
Operation status lights should scroll
(continued) green after clicking Retry
on the light curtain
violation message.
Insert the small light curtain The small light curtain test
test rod (B99815) into the rod should trip the light
top left corner of the curtain.
that it extends at least an the left-most light curtain
inch past the light curtain segment while the test rod
segments towards the is within the test area (top
inside of the instrument. left corner of the
Move the test rod instrument opening to the
downward at a rate of top camera bracket
approximately 0.5-3.0 mouting screw. Light
in/sec until it reaches the curtain project zone is
bottom of the right side noted in red in
projection zone in line with Figure 5.100.4-2.
the top camera bracket
mounting screw. See
Figure 5.100.4-3. Project
zone area is noted in red in
Figure Figure 5.100.4-2.
Resume instrument The instrument should
operation. resume operation and the
green after clicking Retry
violation message.
Insert the small light curtain The small light curtain test
test rod (B99815) into the rod should trip the light
top right corner of the curtain.
that it extends at least an the right-most light curtain
inch past the light curtain segment while the test rod
segments towards the is within the test area (top
inside of the instrument. right corner of the
Move the test rod downward instrument opening to the
at a rate of approximately top camera bracket
0.5-3.0 in/sec until it
mounting screw. Light
reaches the bottom of the
curtain project zone is
right side projection zone in
noted in red in
line with the top camera
Figure 5.100.4-2).
bracket mounting screw.
See Figure 5.100.4-3.
Project zone area is noted in
red in Figure 5.100.4-2.
B54476AB 5-33

Light Figure 5.100.4-2 Extend one inch into instrument space
Curtain
Operation
(continued)
Figure 5.100.4-3 Camera bracket mouniting screw
5-34 B54476AB

Light Figure 5.100.4-4 Small Rod DetectionTest
Curtain
Operation
(continued)
Resume instrument The instrument should See 7.2, Light Curtain

operation. resume operation and the Troubleshooting Procedure.
green after clicking Retry
violation message.
If a door is present, close The instrument should
the door while the continue to operate and
instrument is running. the status lights should
continue to display
scrolling green when the
door is closed.
MC Pod With power applied to the Pod should not droop or Check that the magnet top cover
Droop Test instrument, watch the fall. is properly shimmed.
Multichannel pod for up to 1 Check that the magnet is
minute. properly connected to the motion
board.
Verification
All tests must successfully pass using results criteria in table.
B54476AB 5-35
5-36 B54476AB
CHAPTER 6
Schematics
6.1 Engineering Documents
Engineering schematics, diagrams, and layouts you may need for troubleshooting the
Biomek i-Series instruments are available to Beckman Coulter trained Field Service Engineers
through Airwatch. It will always have the most current revisions.
NOTE Depending on the configuration of this instrument in the field, more than one revision of an
engineering document can be valid.
If you print this manual and want to include these engineering documents, make printouts of the
electronic files and insert them at the end of this chapter.
Contact Us
If you have any questions, contact our Customer Support Center.
• Worldwide, find us via our website at

www.beckmancoulter.com/customersupport/support.
• In the USA and Canada, call us at 1-800-369-0333.
• Outside of the USA and Canada, contact your local Beckman Coulter Representative.
B54476AB 6-1
Schematics
6.1 Engineering Documents
6-2 B54476AB
CHAPTER 7
Troubleshooting
7.1 Overview
The Biomek i-Series Instrument provides extensive error handling and error prevention capabilities
to help make sure the method being built, edited, set up, and run will execute appropriately.
Included in the Biomek i-Series Instrument error handling and prevention capabilities are:
• Error notification and cause messages

• Error recovery options
• Constant internal validation during method building and editing
• Internal validation before running a method
Error Message Overview

There are several types of error messages that may display while building and running methods
using the Biomek i-Series Instrument. The types of error messages generated depend on the type of
error that has occurred. While errors may originate from more than one source, most errors fall into
the following general categories:
• Configuration errors — occur when a device or step is not configured correctly during method
development or instrument configuration
• Validation errors — occur when a method or step is validating

• Manual Control errors — occur when a manual control movement requested of the bridge, pod,
head, or grippers is not compatible with Biomek i-Series Instrument capabilities
• Run-Time errors — occur while a method is running
• Multiple Errors — numerous errors can occur during validation or method run
• Observed Errors — an error observed by the operator as the method is run
Error Recovery Overview

Error recovery is the process of making changes to ensure a method can be completed. When
changes are made and no subsequent errors are detected, the Biomek i-Series Instrument completes
the method. Depending on the conditions causing the error, the error message displays the
appropriate error recovery options available.
Error recovery options may include:
• Fixing the error and continuing the method from the point of interruption
• Stopping the current method, making modifications, and running the entire method from the
beginning
B54476AB 7-1
Troubleshooting
7.1 Overview
• Ignoring the error and continuing with the method
NOTE If a method using two Biomek i-Series Instrument pods is in progress when an error occurs, one pod
can continue its tasks as long as its operations are not dependent upon the pod with the error.
Error Prevention Overview

Errors may be prevented by validating a method during the method-building process. Validation
detects a large class of common errors before they occur by internally simulating the method prior
to execution. This internal simulation provides an opportunity to change the method before the
method is run.
Operations for validating a method include:
• Validating the method immediately before a run starts by selecting Validate Before Run in
Preferences
• Individually validating steps by highlighting subsequent steps in the Method View

• Individually validating operations by using the Single Step tool, available from the Tools menu
NOTE For a list of Error codes and recovery procedures, refer to the Biomek i-Series Software Reference
Manual, B56358, Handling and Preventing Errors.
7-2 B54476AB
7.2 Light Curtain Troubleshooting Procedure 7
7.2 Light Curtain Troubleshooting Procedure
IMPORTANT After troubleshooting has been completed, the light curtain performance must be verified by
performing all of the tests listed under 5.100.4, Instrument Function Checklist Procedure. These are PCE
Safety tests that must be performed and successfully completed.
Generating Troubleshooting Information

1. Each light curtain segment has an onboard LED located along the back edge of the board. If the
LED on a segment is illuminated red, this indicates that it is actively tripping the interlock. This
LED is useful in diagnosing how a particular segment is behaving (i.e. does it properly detect the
test rods, is it tripping when there is no obstruction).
Figure 7.2-1 Light Curtain Indicator LED
2. The light curtain segments have an onboard potentiometer that can be used to adjust the
current supplied to the IR emitting LEDs. Turning the adjustment screw on the potentiometer
will have the following effect:
Figure 7.2-2 Onboard Potentiometer
a. Turning the screw clockwise: This will increase the intensity of the light outputted by the
light curtain segment. This can help in correcting issues where the light curtain is unable
to detect the test rods.
B54476AB 7-3
b. Turning the screw counterclockwise: This will decrease the intensity of the light outputted
by the light curtain segment. This can help in correcting issues where the light curtain is
exhibiting false trips or hysteresis.
c. It takes 25 turns to go from the potentiometer’s minimum resistance (0 Ω) to its maximum
resistance (50 Ω). The lower the resistance value, the higher the current supplied to the
segment and thus a greater intensity of light emitted by the LEDs. The potentiometer
resistance can be determined by measuring across pins 2 and 3 as shown.
Figure 7.2-3 Potentiometer resistance measurement points
Check That All Relevant Mods Have Been Performed

1. Mod 1: This mod introduces a more robust mechanism for positioning and retaining the light
curtain segments within the light curtain extrusion.
a. Mod number: Cat-3 Mod# 11985
b. This mod applies to all systems.
c. This mod can help correct the following issue:
1) False trips and hysteresis
d. How to determine if this mod has been performed:

1) Remove the light curtain lens cover and determine what type of segments are installed
in the system.
2) If the segments have white plastic card guides as shown in Figure 7.2-4, the mod has not
been performed.
Figure 7.2-4 White Plastic Card Guides
7-4 B54476AB
3) If the segments have black plastic spring clips as shown in Figure 7.2-5, the mod has
been performed.
Figure 7.2-5 Black Plastic Spring Clips
2. Mod 2: This mod adds IR absorbing tape to cover a reflective surface on the front door panel
which can cause false trips.
a. Mod number: Cat-1 Mod# 11930
b. This mod only applies to systems with a front door.
c. This mod can help correct the following issues:
1) False trips that are observed on the first or last light curtain segment.
2) False trips as the door is moved up or down.

1) Look at the bottom left and right edges of the door panel. If the bottom edges have
black tape applied as shown in Figure 7.2-6, the mod has been performed.
Figure 7.2-6 Bottom Edge of Door
2) If the tape is missing or damaged, this mod should be performed.
3. Mod 3: This mod adds a masking component to cover a reflective surface on the front door
assembly which can cause false trips.
a. Mod number: Cat-3 Mod #11971
b. This mod only applies to systems with a front door.
c. This mod can help correct the following issues:
1) False trips that are observed on the first or last light curtain segment.
B54476AB 7-5
2) False trips as the door is moved up or down.
7-6 B54476AB

1) Look at the bottom surface of the linear rail sliders on the left and right side of the front
door assembly. If a black masking piece is attached to the bottom of both linear rail
sliders as shown in Figure 7.2-7, the mod has been performed.
Figure 7.2-7 Black Masking Piece
2) If the slider masks are not present, this mod should be performed.
Initial Checks to Perform Prior to Troubleshooting

1. Turn off power to the instrument.
2. Remove the side enclosures, chassis board cover, and the light curtain lens cover.
3. Perform the following checks:
a. Confirm that all of the light curtain segments are fully connected.
b. Press down on each of the light curtain segments to ensure that it is fully seated in the light
curtain channel.
c. Confirm that the ends of the first and last light curtain board are seated between the dowel
pins located at each end of the light curtain extrusion as shown in Figure 7.2-8.
Figure 7.2-8 Light Curtain Boards Seated Between Dowel Pins
B54476AB 7-7
d. Confirm that the cables that are connected at each end of the light curtain chain are fully
seated.
1) Make sure that the pink wires are connected to the pin marked GND (Figure 7.2-9).
Figure 7.2-9 Pink Wires Connected to GND
e. Confirm that the light curtain cable that connects to the chassis board is fully seated on the
8 pin header marked J14 (Figure 7.2-10).
Figure 7.2-10 Chassis Board Connection
f. Confirm that the cables which run to the right side emitter board are fully connected.
1) The cable coming from the chassis board should be connected to the 6 pin header
labeled INPUT.
2) The cable going to the light curtain segments should be connected to the 8 pin header
labeled OUTPUT.
3) Make sure that the pink wires on both cables are connected to the pins marked GND
(Figure 7.2-11).
7-8 B54476AB
Figure 7.2-11 Pink Cables Connect to GND
g. Confirm that the cable and jumper that connect to the left side emitter board are fully
seated.
1) The cable coming from the light curtain segments should be connected to the 6 pin
header labeled INPUT. The pink wire should be connected to the pin marked GND.
2) A jumper should be installed on the 8 pin header labeled OUTPUT. The black jumper
wire should be bridged across pins 6 and 7 (for reference, GND is pin 8)(Figure 7.2-12).
Figure 7.2-12 Jumper on OUTPUT 8 pin header
B54476AB 7-9
h. Confirm that the 2 pin jumpers are present and positioned correctly on the emitter boards.
1) The 2 pin jumper on the right side emitter board should be set to the position marked
F (Figure 7.2-13).
Figure 7.2-13 Right Side Emitter Board Jumper set in F position
2) The 2 pin jumper on the left side emitter board should be set to the position marked G
(Figure 7.2-14).
Figure 7.2-14 Left Side Emitter Board Jumper set in G position
7-10 B54476AB
3) Confirm that the red DIP switch on both the left and right emitter boards is set to the
position marked S1 (Figure 7.2-15).
Figure 7.2-15 DIP switch
4. Reinstall the side enclosures, chassis board cover, and the light curtain lens cover.
5. Check light curtain operation with both rods. If an issue persists follow the troubleshooting
steps listed by failure mode below.
Failure Mode – Light Curtain Stays Tripped

a. Confirm that all checks listed in Initial Checks to Perform Prior to Troubleshooting have been
performed.
b. Confirm there are no objects lying in the path of the light curtain.
c. Confirm the light curtain lens cover is clean and free of debris or buildup.
d. Confirm that the arm covers are installed.
e. Confirm that the side enclosures are installed.
f. Confirm that the light curtain brackets are installed.
2. Confirm that the mods listed in Check That All Relevant Mods Have Been Performed have been
performed.
3. Remove the light curtain lens cover.
4. Determine which light curtain segment(s) are tripping by looking at the LEDs located along the
backside of the boards. If the LED on a segment is illuminated red, this indicates that it is
actively tripping the interlock.
B54476AB 7-11
5. Using a small flathead screwdriver, reduce the gain of the segment(s) that are tripping by
turning the adjustment screw of the onboard potentiometer counterclockwise. Continue to
turn the screw counterclockwise until the segment(s) stop tripping.
NOTE Reducing the gain could result in the affected light curtain segment having difficulty detecting the
small and/or large light curtain test rods.
6. Check the segments for hysteresis as follows. (Hysteresis is when a segment remains tripped
after the object that breached it has been removed. Power cycling the system or running your
hand directly over the top of the offending segment can clear this condition but this should not
be misinterpreted as acceptable performance).
a. Insert your hand into the top left corner of the instrument opening so that it is breaching
the light curtain.
b. Orient your hand so that your fingers are outstretched and your palm is facing downward,
parallel to the light curtain segments.
c. Run your hand across the entire length of the top of the instrument opening (top left
corner to top right corner).
d. Remove your hand and confirm that the LED on each of the light curtain segments turns
off.
7. If the LED on a segment remains on, repeat steps 5. - 6. until it is able to pass the check in step 6.
8. If the steps above are unable to resolve the issue:
a. Make note of whether the false trips only occur when the multichannel or span arm are
positioned above the problematic segment(s).
b. Swap the problematic segment(s) to a different position in the light curtain chain and check
performance.
NOTE The segments may require further gain adjustment if positions are swapped.
c. If swapping the segment(s) does not correct the issue, replace the problematic segment(s).
NOTE The newly installed segment may require the gain to be adjusted to ensure proper
performance.
9. Verify proper functionality of the light curtain by performing all of the tests listed under “Light
Curtain Operation” in 5.100.4, Instrument Function Checklist Procedure. These are PCE Safety
tests that must be performed and successfully completed.
Failure Mode – Light curtain fails to detect the 1.5” diameter test rod (P/N 719724)
performed.
b. Confirm the light curtain lens cover is clean and free of debris or buildup.
performed.
7-12 B54476AB
3. Identify which segment(s) are unable to detect the large test rod.
5. Using a small flathead screwdriver, increase the gain of the segment(s) that are failing to detect
the large test rod by turning the adjustment screw of the onboard potentiometer clockwise.
Continue to turn the screw clockwise until the segment(s) are capable of reliably detecting the
large test rod with the lens cover installed.
NOTE Increasing the gain could result in the affected light curtain segment exhibiting false trips.

a. Swap the problematic segment(s) to a different position in the light curtain chain
(preferably the first or last position) and check performance.
b. If swapping the segment(s) does not correct the issue, replace the problematic segment(s).
performance.
Failure Mode – Light curtain fails to detect the .625” diameter test rod (P/N B99815)
performed.
b. Confirm the light curtain lens cover is clean and free of debris or buildup.
c. Confirm that the left and right side enclosures are fully seated and secured.
performed.
3. Identify which segment(s) are unable to detect the small test rod.
5. Using a small flathead screwdriver, increase the gain of the segment(s) that are failing to detect
the small test rod by turning the adjustment screw of the onboard potentiometer clockwise.
Continue to turn the screw clockwise until the segment(s) are capable of reliably detecting the
small test rod with the lens cover installed.
NOTE Increasing the gain could result in the affected light curtain segment exhibiting false trips.

a. Swap the problematic segment(s) to a different position in the light curtain chain and check
performance.
B54476AB 7-13
b. If swapping the segment(s) does not correct the issue, replace the problematic segment(s).
performance.
7-14 B54476AB
7.3 Master Controller Log Collection 7
7.3 Master Controller Log Collection
Purpose
The Master Controller log files are located on the Biomek i-Series instrument controller and contain
useful information for advanced system troubleshooting.
• Large capacity flash drive or USB stick (minimum 64 GB)
Master Controller Log Collection

1. Go to the Start menu and search for Services. Double-click on the Services Desktop App and
open.
2. In the Services window, find the Biomek Master Controller service.

a. Stop the Biomek Master Controller service.
Figure 7.3-1 Services Window
3. Go to File Explorer.
4. Navigate to C:\ProgramData\Beckman Coulter\Biomek Master Controller.

5. Copy all files in this location to a flash drive or other external data storage device. There should
be a .txt file and a .db3 file in this location.
6. Go back to Services window.
a. Find and Restart the Biomek Master Controller Service.
7. Send the files to technical support via Accelion or mail the flash drive to technical support.
NOTE Files are very large and may take some time to load if sending through Accelion.
B54476AB 7-15
7.3 Master Controller Log Collection
7-16 B54476AB
CHAPTER 8
Parts Lists
8.1 Parts List
The parts list for the Biomek i-Series Instruments is available on AirWatch.
B54476AB 8-1
Parts Lists
8.1 Parts List
8-2 B54476AB
Abbreviations
The following list is a composite of the symbols, abbreviations, acronyms, and reference designators
either used in this manual or related to the information in it. When the same abbreviation (or
reference designator) is used for more than one word (or type of component), all meanings relevant
to this manual are included, separated by semicolons.
> — greater than COM — serial communications port
< — less than CPU — Central Processing Unit
 — greater than or equal to CV — check valve; coefficient of variation
 — less than or equal to CV% — coefficient of variation
% — percent dc — direct current
+ — plus DCN — document control number
- — minus DIP switch — dual in-line package switch
± — plus or minus DVM — digital volt meter
°C — degrees Celsius EMI — electromagnetic interference
°F — degrees Fahrenheit EPROM — erasable programmable read only

memory
μL — microliter
ESD — electrostatic discharge
A — ampere
F — Fahrenheit; fuse
ac — alternating current
FF — fitting
ADC — analog-to-digital conversion
FRU — field replaceable unit
Amp — amplifier
ft — foot; feet
ANSI — American National Standards
Institute g — grams
BCI — Beckman Coulter Incorporated GA — gauge
BIOS — basic input/output system gal. — gallon
C — centigrade GND — ground
CD-ROM — compact disk - read only memory Hz — Hertz
CDRH — National Center for Devices and i.d. — internal diameter

Radiological Health
in. — inches
cm — centimeter
I/O — input/output
B54476AB Abbreviations-1
Abbreviations
IPL — illustrated parts list PM — pump
IVD — in vitro diagnostics PN — part number

J — receptacle connector pot — potentiometer
K — constant psi — pounds per square inch
kg — kilogram PWA — printed wiring assembly

L — liter; long PW — printed wiring board
lb — pound QA — quality assurance
LCD — liquid crystal display QC — quality control

LED — light emitting diode R — potentiometer; resistor
M — mega; motor RAM — random access memory
m — meter RG — regulator
max — maximum ROM — read only memory

MB — megabyte S — switch; sensor
MF — manifold SD — standard deviation
MHz — megahertz sec — second

min — minimum SN — sensor
mL — milliliter SRK — Service Resource Kit
mm — millimeter SVP — system verification procedure

ms — millisecond SW — software; switch
MTBF — mean time between failures TBD — to be determined
MTTR — mean time to repair thd — thread

mV — millivolt thk — thick
N/A — not applicable TP — test point
nm — nanometer UL — Underwriter’s Laboratory
o.d. — outer diameter USB — universal serial bus
OS — operating system V — volts
P — plug connector VAC — volts alternating current
PC — personal computer vac — vacuum
PCB — printed circuit board VDC — volts direct current
Abbreviations-2 B54476AB
Abbreviations
VL — valve
W — watt; wide
WM — wire marker
B54476AB Abbreviations-3
Abbreviations
Abbreviations-4 B54476AB
Glossary
This glossary is a collection of specialized terms and their meanings that are either used in this
manual or related to the information in it. If a term has more than one meaning, all meanings
relevant to this manual are included.
accuracy
The ability of the instrument to agree with a predetermined reference (true) value.
ambient temperature
Temperature in the surrounding environment.
assay values
Values for a control established by extensive repeat testing of that control.
assembly
A specific set of components physically attached together or to a common structure. The
components do not have to be related functionally and may not qualify as a sub-system
(completeness of functionality). An assembly is modular only when it has the attributes of
modularity.
background count
Measure of the amount of electrical or particle interference.
board
Circuit board not directly connected to a host board or backplane using a card edge connector;
typically has a moderate to high density of components.
card
Circuit board with a card edge connector that plugs into a host board or a backplane; typically
has a moderate to high density of components.
cleaning agent
A detergent used to flush sample from tubing and eliminate protein buildup.
coefficient of variation (CV or CV%)

An expression, in percent (%), of the data spread (variation) as related to the mean value. CV,
CV%, and coefficient of variation may be used interchangeably. The standard formula for
calculation:
SD
CV% = --------------- × 100
Mean
Controller
The system component that runs the software that lets an operator control the instrument. A
personal computer (PC) used to allow the user to interact with the system.
default
Original setting in the instrument.
B54476AB Glossary-1
Glossary
deionized water
Water freed of salt and some organisms by an ion-exchange process. This water can be used
interchangeably with distilled water in procedures. Also referred to as DI H2O or DI water.
distilled water
Water freed of solids and organisms by distillation. This water can be used interchangeably with
deionized water in procedures.
field replaceable unit (FRU)

A completely functional tested assembly.
Gaussian distribution
A normal or symmetrical distribution; for example, a bell-shaped curve.
ground state
The energy level having the least energy of all its possible states and greatest stability. For
example, the resting state of an atom is referred to as its ground state.
laminar flow
The flow of two liquids side by side in which one does not mix with the other.
laser
Light amplification by stimulated emission of radiation.
mean
Arithmetic average of a group of data.
microprocessor
The integrated circuitry for electronically controlled devices.
module
Self-contained interchangeable unit.
mean time between failures (MTBF)

A measure of the reliability of an instrument.
mean time to repair (MTTR)

A measure of the average time it will take a field service engineer to repair an instrument and
perform verification.
operating system (OS)

Operating system files, libraries, drivers, and so forth, required for running the application.
power down
A predefined sequence of events performed on an instrument before it is powered off.
power off
To remove power from an instrument.
power on
To provide power to an instrument.
Glossary-2 B54476AB
Glossary
power up
A predefined sequence of events performed on an instrument when it is powered on.
reagent
A substance used (as in detecting or measuring a component, or in preparing a product) because
of its chemical or biological activity. (Webster)
reproducibility
Ability of the instrument to produce similar results when the same specimen is run repeatedly.
May also be referred to as precision.
subassembly
An assembly that supplies a specific set of components for a higher level assembly. See also
assembly.
subsystem
A portion of a system selected to provide a complete sub-function of that system. may be
distributed, consolidated, or modularized.
system
A set of components providing functional completeness. May be distributed, consolidated, or
modularized. A group of interacting, interrelated, or interdependent elements forming a
complex whole.
user interface
The display and mechanical devices (keyboard, mouse) used by an operator to interact with the
instrument or instruments.
validated
The test results have been automatically or manually reviewed and confirmed according to
laboratory protocols.
B54476AB Glossary-3
Glossary
Glossary-4 B54476AB
Index
Numerics status lights, 2-18

4 post framing tool procedure, 5-9 Checkout procedure
instrument function, 5-27
service, 5-13
A covers removal
ALPs anchor illustration, 4-11, 4-12
description, 2-8 cytomat
installation, 3-67 2C
arms direct access by gripper installation, 3-83
description, 2-7 electrical and communications
connections, 3-91
hotels, loading, 3-93
B installation, 3-77
bar code reader SAMI EX Installer Tool, 3-109
installation, 3-89 software installation, 3-95
board using device software, 3-107
chassis, 2-14 with conveyor installation, 3-79
light curtain and light curtain emitter, 2-25 MPH
motion, 2-20 cable installation, 3-125
syringe pump controller, 2-24 direct access by gripper
tower, 2-22 installation, 3-119
transport supervisor, 2-19 installation, 3-111
loading hotels, 3-127
options, 3-147
C SAMI EX software setup and
cable configuration, 3-149
electrical setup and operation, 3-139
warnings and cautions, 1-14 software items, installing, 3-135
holder clip transfer station configuration for
E-chain bundle, 3-50 conveyor, 3-123
inspect, 3-42 using device software, 3-129
LLS, 3-43 with conveyor installation, 3-113
monitor power, 3-51
network, 3-51
routing, 3-17 D
system architecture, 2-12 deck
camera board description, 2-8
replacement, 4-77, 4-87, 4-107 lighting, 2-9
chassis plates i5, 2-4
description, 2-7 plates i7, 2-4
chassis board, 2-14 deck observation system
block diagram, 2-14 description, 2-9
power distribution, 2-17
Index-1
Index
E enclosures, 2-9
enclosure gripper, 2-8
closed, 2-9 interior deck lighting, 2-9
covers removal and replacement, 4-11 protective barriers, 2-9
HEPA filter installation, 3-154 status indicator light bar, 2-9
open, 2-9
protective barriers, 2-9 L
LED status light segment removal
F closed enclosure, 4-29
four post framing tool procedure, 5-9 Open Enclosure, 4-27
light curtain and light curtain emitter
board, 2-25
G light curtain protection system
gripper description, 2-9
cover removal and replacement, 4-20
description, 2-8
finger assembly removal and
M
replacement, 4-87 manual
Grip axis finger rails and linear rail removal conventions, 1-5
and replacement, 4-111 intended audience, 1-3
grip motor removal and replacement, 4-81 numbering format, 1-4
rotate belt removal and replacement, 4-103 organization, 1-3
rotate motor removal and replacement, 4-99 scope, 1-1
Y-axis belt removal and replacement, 4-122 special headings, 1-4
Y-axis idler pulley removal and MC
replacement, 4-1 D-axis ball screw, 4-41
Y-axis motor removal and head, 4-57
replacement, 4-119 pod, 4-37
Z-axis e-chain removal and replacement, 4-1 4 post framing tool, 5-9
Z-motor removal and repacement, 4-7 rotation adjustment, 4-53
Z-rail and bearings removal and motion board, 2-20
replacement, 4-107 layout, 2-20
LED descriptions, 2-22
motion boards
H MC
HEPA Filter installation and service, 3-153 gripper removal and replacement, 4-91
Span-8
gripper removal and replacement, 4-95
I motion control boards
installation MC
instrument, 3-1 removal and replacement, 4-91
installation procedures Span-8
ALPs, 3-67 removal and replacement, 4-95
i-Series instruments
standard components
arms, 2-7 O
chassis, 2-7 Operational Checks, 5-5
deck, 2-8
deck observation system, 2-9
Index-2
Index
P instrument connection, 4-3

protective barriers light curtain, 7-3
description, 2-9
Y
R y-belt
removal and replacement procedures removal and replacement, 4-121
mc pod, 4-37 replacement, 4-121
mc pod z-axis top plate, 4-37 y-motor
y-belt, 4-121 removal and replacement, 4-119
y-motor, 4-119
z-motor, 4-7 Z
replacement procedures z-motor
camera board, 4-77, 4-87, 4-107 removal and replacement, 4-7
griiper racks, rails, and bearings, 4-111 replacement, 4-7
y-belt, 4-121
z-motor, 4-7
S
service checkout method, 5-13
software configuration, 3-55
Span-8 pod
alignment, 4-59
span-8 pod
probe correlate axes, 4-71
probe guide assembly removal and
replacement, 4-67
status indicator lights, 2-23
syringe pump bank contoller board, 2-24
system components
ALPs, 2-8
arms, 2-7
chassis, 2-7
deck, 2-8
deck observation system, 2-9
light curtain protection system, 2-9
protective barriers, 2-9
T
tower board, 2-22
connections, 2-23
transport supervisor board, 2-19
block diagram, 2-19
LED status lights, 2-19
Troubleshooting
customer warning, 1-20
engineering documents, 6-1
error messages, 7-1
Index-3
Index
Index-4
Related Documents
Biomek i-Series Hardware Automated Labware SAMI EX Software for
Reference Manual Positioners (ALPs) Biomek i-Series Automated
PN B54474 Instructions For Use Workstations Instructions for
PN 987836 Use
Biomek i-Series PN B58997
Pre-installation Manual Cytomat Device and
PN B54472 Conveyor ALP Instructions SAMI EX Software for
for Use Biomek i-Series Automated
Biomek i-Series Instructions PN B91265 Workstations Reference
for Use Manual
PN B54473 Static Peltier ALP Integration PN B59001
Manual for Biomek FX/FXP,
Biomek i-Series Software Biomek i-Series Automated
NX/NXP, and i-Series
Reference Manual Workstations Safety Manual
Instruments
PN B56358 PN B79871
PN A93392, Rev. AC and up
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PN B54475 Messages and System Help
Integration Manual for
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Accessories, & Devices PN A93393, Rev. AC and up
Instructions for Use
PN B54477
www.beckmancoulter.com
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Service Manual

Laboratory Automated Workstations

Beckman Coulter, Inc.

This Service Manual contains confidential information of

Beckman Coulter, Inc. makes no representation that, upon

All other trademarks, service marks, products, or services

Beckman Coulter, Inc.

Issue AB, 10/2017

• Revised General Safety

• Added 4.200.1, Magnet Top Cover Removal and Replacement Procedure

Alert Definitions for Warning and Caution

WARNING and CAUTION alert you as follows:

Electrical shock hazard. Operate with caution!

Possible laser radiation inside.

Revision History, iii

Instrument Description, 2-1

System Components, 2-1

Installation Procedures, 3-1

Moving the Shipping Crate, 3-5

3.25 Cytomat Electrical and Communications Connections, 3-91

Service and Repair Procedures, 4-1

Multichannel Pod Cover Removal and Replacement, 4-24

Tools/Supplies Needed , 4-91

Preventive Maintenance and Verification Procedures, 5-1

Parts Lists, 8-1

1.2-1 ESD strap attachment location for Span-8 Pod, 1-15

3.7-1 Install Large “L” bracket, 3-22

3.9-4 Align cart and bench, 3-46

3.26-2 Cytomat Hotel Interlock with Hotel, 3-93

3.34-1 Plate Holder and Barrel Sensor, 3-123

3.43-7 Remove black mounting brackets on power strip bracket, 3-156

4.200.2-3 MC Pod Encoder Cable Clips, 4-39

4.400.2-3 Loosen X adjustment screw and washers. Do not remove., 4-69

4.500.8-3 Loosen the Alignment Screws Securing the Gripper Assembly To

5.100.2-3 Attach 4-post Framing Tool, 5-10

1.1-1 Additional Reference Material, 1-1

1.1 Manual Description

Table 1.1-1 Additional Reference Material

For information on... See... PN

Table 1.1-2 Customer Documents Available

Table 1.1-2 Customer Documents Available

Service Manual Updates

To make it easier to access the information:

• In the PDF version -

CHAPTER 7, Troubleshooting, contains problem descriptions, including a comprehensive list of

Signal Words and Special Headings

• Worldwide, find us via our website at

1.2 Safety Precautions

Lifting the Instrument

Warning and Cautions

Electrostatic Discharge (ESD) Protection

To attach a wrist ground strap:

Figure 1.2-1 ESD strap attachment location for Span-8 Pod

1. Side Cover PEM Nuts

Figure 1.2-2 ESD strap attachment location for Multichannel Pod

1. Y-Axis Interior Cover Plate

Disposal of Electronic Instrumentation

Chemical and Biological

Laser Beam Hazard

Laser Warning Labels

IMPORTANT It is the customer’s responsibility to decontaminate components of the instrument before

2.1 Introduction to the Biomek i-Series Automated Laboratory

Figure 2.1-1 Biomek i7 Main Components