BacTALERT 3D 60 Service Manual 452501-1EN1

452501-1EN1
(3/2010)
Service Manual
For Internal Use Only
[05]
Liability Disclaimer
bioMérieux, Inc. makes no express or implied warranty regarding this manual, its
quality, performance, or appropriate use regarding any type of specific procedure.
Furthermore, this manual may be modified by bioMérieux without notice and without
implying any obligation or liability on the part of the company.
Intellectual Property
bioMérieux, the blue logo, BacT/ALERT, BacT/LINK, and FAN are used, pending,
and/or registered trademarks of bioMérieux, SA or one of its subsidiaries.
WinSystems is a registered trademark of WinSystems, Inc.
Zip is a registered trademark of Iomega, Inc.
Microsoft, Windows, and MS-DOS are registered trademarks of the Microsoft

Corporation.
HP is a registered trademark of Hewlett-Packard Development Company, L.P.
Lexmark is a registered trademark of Lexmark Industries, Inc.
Velcro is a registered trademark of Velcro Industries B.V.
© 2010 bioMérieux, Inc. All rights reserved.
No part of this publication may be reproduced, transmitted, transcribed, stored in a

retrieval system, or translated into any language (human or computer) in any form, or
by any means whatsoever, without the prior express written permission of bioMérieux,
Inc.
Intended Audience
Standard Symbols
The following table presents symbols that may appear in the instructions for use or on
the instrument, package inserts, or packaging.
CE-Marking of Conformity
Consult Instructions for Use
Use by
Manufacturer
Date of manufacture
Contains sufficient for <n> tests
Keep dry
Fragile, handle with care
Caution, consult accompanying documents
Biological risks
Electric shock warning
Radiation warning
i
Standard Symbols
Potential pinch-point warning
Laser
Temperature limitation
Upper limit of temperature
Lower limit of temperature
In Vitro Diagnostic Medical Device
Batch code
Authorized Representative in the European Community
Catalog number
Serial Number
Do not reuse
Recyclable
Separate collection for waste electrical and electronic

equipment
Very toxic
Corrosive
Sodium azide
ii
Standard Symbols
Irritant
Positive control
Negative control
Keep away from sunlight
Protect from light
This way up
Do not stack
Humidity limitation
Fuse
Direct current
Alternating current
Both direct and alternating current
Three-phase alternating current
Earth (ground) terminal
Protective conductor terminal
Frame or chassis terminal
iii
Standard Symbols
Equipotentiality
ON (supply)
OFF (supply)
ON (only for a component of the system equipment)
OFF (only for a component of the system equipment)
Equipment protected throughout by double insulation or

reinforced insulation (Equivalent to Class II of IEC 536)
Potential tip over/crush hazard
iv
Table of Contents
Standard Symbols................................................................................................ i
List of Figures ................................................................................................. xiii
List of Tables .................................................................................................. xxv
1 How to Use this Manual ............................................................................. 1-1

1.1 Purpose of this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Organization of the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 Chapter Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.5 Finding Topics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6 Typographic and Usage Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.6.1 Click . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.6.2 Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.6.3 Genus and Species Names . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.6.4 Keyboard Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.6.5 Mouse Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.6.6 Names and Titles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.6.7 Press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.6.8 Procedural Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.6.9 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.6.10 Select. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.6.11 User Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.6.12 Configuration Screen Checkboxes . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.7 Warnings, Cautions, and Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.8 Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.9 Electrical Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.10 Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.11 Hazardous Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.12 Cleaning Agent Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.13 Health Risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.14 ESD Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.15 Moving Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.16 Heating Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.17 Existing Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
2 System Setup.............................................................................................. 2-1

2.1 Reference Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3.1 Verifying Site Requirements Are Met . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3.2 Verifying Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
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2.4 BacT/ALERT® 3D 60 Unpacking Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.5 Installing the Optional Restraint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.6 Instrument Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.6.1 Setting the AC Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.6.2 Choosing Instrument Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.6.3 Making Instrument Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.6.4 Powering Up the Instrument. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.6.5 Verifying BIOS Time and Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.7 Configuring the Instrument Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.7.1 Verifying Instrument Temperature Using the Digital Thermometer . 2-16
2.7.2 Selecting Instrument Installation Options. . . . . . . . . . . . . . . . . . . . . 2-16
2.7.3 Configuring the Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2.7.4 Configuring the Instrument. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
2.7.5 Setting User Preferences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
2.7.6 Configuring the LIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
2.7.7 Activate Industry Bottle Barcodes . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
2.7.8 Checking for Disabled Components. . . . . . . . . . . . . . . . . . . . . . . . . 2-26
2.7.9 Checking for Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
2.8 Calibrating the Instrument Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
2.9 Logging In for the First Time — 21 CFR Part 11 Mode. . . . . . . . . . . . . . . . . 2-28
2.10 Functional Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
2.10.1 Configuring the BacT/ALERT® 3D 60 Modem . . . . . . . . . . . . . . . . . 2-32
2.10.2 Modem Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
2.10.3 Barcode Reader Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
2.10.4 Verifying Plastic Bottle Algorithms . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
2.10.5 UPS Functional Test (APC UPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
2.10.6 Installing the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
3 Instrument Components............................................................................ 3-1

3.1 Equipment Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2 Assembly Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3 Module Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3.1 DC Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3.2 Electronics Compartment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.3.3 Chassis-mounted Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.3.4 Incubation Chamber. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.4 Power Supply Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.5 Input/Output Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3.5.1 56K Fax Modem (Domestic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3.5.2 56K Fax Modem (International) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3.5.3 Uninterruptible Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3.6 Display Configuration Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3.6.1 Operator Panel Screens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3.6.2 Configuration Screen Checkboxes. . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
3.7 Diagnostic Test Screens, Buttons, and Values . . . . . . . . . . . . . . . . . . . . . . . 3-32
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3.7.1 Diagnostic Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

3.7.2 Diagnostic Screens Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
3.7.3 Incubator Diagnostic Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
3.7.4 Controller Module Diagnostic Values . . . . . . . . . . . . . . . . . . . . . . . 3-51
3.7.5 LIS Module Diagnostic Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
3.7.6 Scandisk Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88
3.8 Using the Keyboard in Place of the Mouse . . . . . . . . . . . . . . . . . . . . . . . . . 3-93
3.9 Special Function Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94
3.10 Quick Reference Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94
4 Operating Procedures................................................................................ 4-1

4.1 Power Up/Down Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.1 Power Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.2 Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Compact Flash Disk Data Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.3 Compact Flash Disk Data Backup Restore . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.4 3D 60 Module Data Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.5 3D 60 Module Data Backup Restore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.6 DOS Controller Module Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.7 Incubator Temperature Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.8 Digital Reference Thermometer Operation. . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.9 Configuring Users — 21 CFR Part 11 Mode . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.9.1 Add Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.9.2 Delete Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4.9.3 Clear User Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
5 Component Replacement .......................................................................... 5-1

5.1 Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.2 Components Covered. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.2.1 Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.2.2 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.2.3 Incubation Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.2.4 Agitation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.2.5 Operator Input Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.2.6 External Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.3 CPU PCBA (P/N 750-0070-902) Replacement . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.3.1 CPU PCBA (P/N 750-0070-902) Initial Checks . . . . . . . . . . . . . . . . . 5-7
5.3.2 CPU PCBA (P/N 750-0070-902) Removal . . . . . . . . . . . . . . . . . . . . 5-8
5.3.3 CPU PCBA (P/N 750-0070-902) Installation . . . . . . . . . . . . . . . . . . 5-10
5.3.4 Restore CPU Configuration Data . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.3.5 Re-enter Configuration and Operation Option Data . . . . . . . . . . . . 5-13
5.3.6 CPU PCBA (P/N 750-0070-902) Final Checks . . . . . . . . . . . . . . . . 5-15
5.4 CPU PCBA (P/N 750-0070-01) Replacement . . . . . . . . . . . . . . . . . . . . . . . 5-16
5.4.1 CPU PCBA (P/N 750-0070-01) Initial Checks . . . . . . . . . . . . . . . . . 5-16
5.4.2 CPU PCBA (P/N 750-0070-01) Removal . . . . . . . . . . . . . . . . . . . . 5-18
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5.4.3 CPU PCBA (P/N 750-0070-01) Installation . . . . . . . . . . . . . . . . . . . 5-20

5.4.4 Restore CPU Configuration Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
5.5 CPU BIOS Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
5.5.1 CPU BIOS Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
5.5.2 CPU BIOS Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
5.6 Quad Serial PCBA Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
5.6.1 Quad Serial PCBA Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
5.6.2 Quad Serial PCBA Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
5.7 Compact Flash Disk Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
5.7.1 Compact Flash Disk Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
5.7.2 Compact Flash Disk Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
5.8 Compact Flash Adapter PCBA Replacement . . . . . . . . . . . . . . . . . . . . . . . . 5-33
5.8.1 Compact Flash Adapter PCBA Removal . . . . . . . . . . . . . . . . . . . . . 5-33
5.8.2 Compact Flash Adapter PCBA Installation . . . . . . . . . . . . . . . . . . . 5-35
5.9 ModSig PCBA Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
5.9.1 ModSig PCBA Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
5.9.2 ModSig PCBA Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
5.10 ModSig PCBA Fuse(s) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
5.10.1 ModSig PCBA Fuse(s) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
5.10.2 ModSig PCBA Fuse(s) Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
5.11 Step-5 PCBA Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
5.11.1 Step-5 PCBA Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
5.11.2 Step-5 PCBA Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
5.12 Step-5 Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
5.12.1 Step-5 Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
5.12.2 Step-5 Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
5.13 Outlet Thermistor PCBA Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
5.13.1 Outlet Thermistor PCBA Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
5.13.2 Outlet Thermistor PCBA Installation . . . . . . . . . . . . . . . . . . . . . . . . 5-52
5.14 Inlet Thermistor PCBA Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
5.14.1 Inlet Thermistor PCBA Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
5.14.2 Inlet Thermistor PCBA Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
5.15 Zip® Drive Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55
5.15.1 Zip® Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55
5.15.2 Zip® Drive Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
5.16 System Power Panel Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . 5-60
5.16.1 System Power Panel Assembly Removal . . . . . . . . . . . . . . . . . . . . 5-60
5.16.2 System Power Panel Assembly Installation . . . . . . . . . . . . . . . . . . . 5-62
5.17 Power Supply Transformer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62
5.17.1 Power Supply Transformer Removal . . . . . . . . . . . . . . . . . . . . . . . . 5-63
5.17.2 Power Supply Transformer Installation . . . . . . . . . . . . . . . . . . . . . . 5-64
5.18 Power Supply Metal Oxide Varistor (MOV) Replacement. . . . . . . . . . . . . . . 5-65
5.18.1 Power Supply Metal Oxide Varistor (MOV) Removal. . . . . . . . . . . . 5-65
5.18.2 Power Supply Metal Oxide Varistor (MOV) Installation . . . . . . . . . . 5-66
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5.19 Power Supply Solid State Relay(s) Replacement . . . . . . . . . . . . . . . . . . . . 5-67

5.19.1 Power Panel Solid State Relays Removal. . . . . . . . . . . . . . . . . . . . 5-67
5.19.2 Power Panel Solid State Relays Installation . . . . . . . . . . . . . . . . . . 5-69
5.20 DC Power Supply Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70
5.20.1 DC Power Supply Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70
5.20.2 DC Power Supply Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-71
5.21 Power Entry Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72
5.21.1 Power Entry Module Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72
5.21.2 Power Supply Transformer Removal. . . . . . . . . . . . . . . . . . . . . . . . 5-72
5.21.3 Power Entry Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73
5.22 Power Entry Module Fuse(s) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 5-74
5.22.1 Power Entry Module Fuse(s) Removal . . . . . . . . . . . . . . . . . . . . . . 5-74
5.22.2 Power Entry Module Fuse(s) Installation . . . . . . . . . . . . . . . . . . . . . 5-75
5.23 Fan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76
5.23.1 Fan Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76
5.23.2 Fan Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-79
5.24 Heater Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-80
5.24.1 Heater Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-80
5.24.2 Heater Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-82
5.25 Thermal Switch Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-82
5.25.1 Thermal Switch Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-82
5.25.2 Thermal Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-84
5.26 Blower Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-84
5.26.1 Blower Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-84
5.26.2 Blower Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-86
5.27 Blower Motor Capacitor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-86
5.27.1 Blower Motor Capacitor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 5-86
5.27.2 Blower Motor Capacitor Installation . . . . . . . . . . . . . . . . . . . . . . . . . 5-88
5.28 Digital Reference Thermometer Replacement . . . . . . . . . . . . . . . . . . . . . . . 5-88
5.28.1 Digital Reference Thermometer Removal . . . . . . . . . . . . . . . . . . . . 5-88
5.28.2 Digital Reference Thermometer Installation . . . . . . . . . . . . . . . . . . 5-89
5.29 Digital Reference Thermometer Battery Replacement. . . . . . . . . . . . . . . . . 5-89
5.29.1 Digital Reference Thermometer Battery Removal . . . . . . . . . . . . . . 5-89
5.29.2 Digital Reference Thermometer Battery Installation . . . . . . . . . . . . 5-90
5.30 Rack Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-90
5.30.1 Rack Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-90
5.30.2 Rack Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-94
5.31 Bottle Holder Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95
5.31.1 Bottle Holder Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95
5.31.2 Bottle Holder Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-96
5.32 Link Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97
5.32.1 Link Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97
5.32.2 Link Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-99
5.33 Step-5 Drive Agitation Linkage Assembly Replacement . . . . . . . . . . . . . . 5-100
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5.33.1 Step-5 Drive Agitation Linkage Assembly Removal. . . . . . . . . . . . 5-100

5.33.2 Step-5 Drive Agitation Linkage Assembly Installation . . . . . . . . . . 5-103
5.34 Gas Spring Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-105
5.34.1 Gas Spring Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-105
5.34.2 Gas Spring Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . 5-106
5.35 Magnetic Door Switches Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-107
5.35.1 Magnetic Door Switches Removal . . . . . . . . . . . . . . . . . . . . . . . . . 5-107
5.35.2 Magnetic Door Switches Installation . . . . . . . . . . . . . . . . . . . . . . . 5-109
5.36 Keyboard Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-109
5.36.1 Keyboard Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-109
5.36.2 Keyboard Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-110
5.37 Barcode Scanner Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-110
5.37.1 Barcode Scanner Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-110
5.37.2 Barcode Scanner Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-111
5.38 Fax Modem Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-111
5.38.1 Fax Modem Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-111
5.38.2 Fax Modem Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-112
5.39 UPS Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-112
5.39.1 UPS Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-112
5.39.2 UPS Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-113
5.40 UPS Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-114
5.40.1 UPS Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-114
5.40.2 UPS Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-116
5.41 Reflective Standard Discs Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-116
5.41.1 Reflective Standard Discs Removal. . . . . . . . . . . . . . . . . . . . . . . . 5-117
5.41.2 Reflective Standard Discs Installation . . . . . . . . . . . . . . . . . . . . . . 5-117
5.42 Post Service Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-124
5.42.1 Required Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-124
5.42.2 Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-124
6 Alignment and Adjustment Procedures................................................... 6-1

6.1 System Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 Temperature Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.3 MB Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.4 Optics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.5 Operator: Single Slug Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.6 Rack Calibration — Cal 10 Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.7 Single Cell Calibration — 3D 60 Software . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
6.8 Single Cell Calibration — Cal 10 A Software . . . . . . . . . . . . . . . . . . . . . . . . 6-19
6.9 Adjust the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
6.10 Drawer Micro Switch Check Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
7 Diagnostics and Troubleshooting Information ....................................... 7-1

7.1 Diagnostics and Troubleshooting Introduction . . . . . . . . . . . . . . . . . . . . . . . . 7-3
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7.2 Symptomatic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7.3 Fault/Status Code Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
7.4 Special Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
7.5 Incubator Diagnostic Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52
7.5.1 Access the Diagnostic Test Selection Screen . . . . . . . . . . . . . . . . . 7-52
7.5.2 Loopback Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53
7.5.3 Port Stats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54
7.5.4 Message Stats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55
7.5.5 Message Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56
7.5.6 Temperature Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
7.5.7 Reading Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58
7.5.8 Flag Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59
7.5.9 Drawer/Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61
7.5.10 LED Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-62
7.6 Controller Module Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-64
7.6.1 Zip® Drive Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-64
7.6.2 Barcode Loopback. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-66
7.6.3 Modem Loopback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67
7.6.4 Power Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-68
7.6.5 View Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-69
7.6.6 Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-72
7.6.7 Scandisk Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75
7.7 LIS Diagnostic Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-77
7.7.1 Loopback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-77
7.7.2 Port Stats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-78
7.7.3 Message Stats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79
7.7.4 Message Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-80
A Specifications .............................................................................................A-1
A.1 Physical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
A.2 Environmental Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
A.3 Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
B Decontamination Procedures ...................................................................B-1

B.1 Spills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
B.2 Shipment of Instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
B.3 Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
C Installation Checklist .................................................................................C-1

C.1 BacT/ALERT® 3D 60 Part Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
C.2 BacT/ALERT® 3D 60 Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
D Schematics and Diagrams.........................................................................D-1

D.1 CPU PCBA (P/N 750-0070-01 / -902) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
D.1.1 CPU PCBA (P/N 750-0070-01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
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D.1.2 CPU PCBA (P/N 750-0070-902) . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3

D.2 UPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-5
D.3 ModSig PCBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-6
D.4 ModSig PCBA Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-8
D.5 Quad Serial PCBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-9
D.6 Step-5 PCBA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-9
D.7 Outlet Thermistor PCBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-10
D.8 Inlet Thermistor PCBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-10
D.9 Power Supply Terminal Strip TB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-11
D.10 Power Supply Solid State Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-12
D.11 Power Entry Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-13
E Instrument Improvements ......................................................................... E-1

E.1 CPU PCBA (P/N 750-0070-902) Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2
E.1.1 CPU PCBA Upgrade Installation Procedures (P/N 750-0070-902) . . E-2
E.1.2 CPU PCBA (P/N 750-0070-902) BIOS and Jumper Settings
Reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-13
E.1.3 CPU BIOS Settings Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-14
E.2 CPU BIOS Version Update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-19
E.2.1 BIOS Version Verification Procedure . . . . . . . . . . . . . . . . . . . . . . . . E-19
E.2.2 Zip® Drive and UPS Functionality Verification Procedure . . . . . . . . E-20
E.2.3 CPU BIOS Version Update Installation Procedure . . . . . . . . . . . . . E-23
E.3 CPU BIOS Clock Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-24
E.3.1 CPU BIOS Clock Battery Installation Procedure for Older CPU
PCBAs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-25
E.3.2 CPU BIOS Clock Battery Installation Procedure for Newer CPU
PCBAs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-32
E.4 Barcode Scanner Kit (P/N 248013). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-39
E.4.1 Barcode Scanner Kit (P/N 186208-910) Installation Procedures . . . E-39
F Electrostatic Discharge (ESD) .................................................................. F-1

F.1 Equipment, Materials, or Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-2
F.2 General Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-2
F.3 Work Area Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-2
Glossary .............................................................................................. Glossary-1
Index .......................................................................................................... Index-1
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Figure 1-1: Checkboxes .................................................................................................... 1-6

Figure 1-2: Electrical Grounding Requirements ................................................................ 1-8
Figure 2-1: Countertop/Surface Mounting Diagram .......................................................... 2-4
Figure 2-2: Mounting Surface Diagram ............................................................................. 2-5
Figure 2-3: Mounting Surface (Drilling) Template ............................................................. 2-5
Figure 2-4: Power Entry Module with Fuse Holder Removed ........................................... 2-7
Figure 2-5: PEM with 115 VAC Version ............................................................................ 2-8
Figure 2-6: PEM with 230 VAC Version ............................................................................ 2-9
Figure 2-7: Additional Fuse Holder Views ......................................................................... 2-9
Figure 2-8: Installation and Setup Diagram — Port and Power Connections ................. 2-12
Figure 2-9: BIOS Screen ................................................................................................. 2-13
Figure 2-10: Main Screen ................................................................................................. 2-14
Figure 2-11: Setup Screen ................................................................................................ 2-14
Figure 2-12: Set Maximum Test Time Button ................................................................... 2-15
Figure 2-13: Set Audible Alarm Options Button ................................................................ 2-15
Figure 2-14: Set Date/Time Button ................................................................................... 2-15
Figure 2-15: Calibrate Module Temperature Button ......................................................... 2-16
Figure 2-16: Setup and Configuration Button ................................................................... 2-16
Figure 2-17: Setup and Configuration Screen .................................................................. 2-17
Figure 2-19: Setup Screen ................................................................................................ 2-18
Figure 2-20: Setup and Configuration Button ................................................................... 2-18
Figure 2-21: Configure Screen Button .............................................................................. 2-18
Figure 2-22: Configuration Screen .................................................................................... 2-19
Figure 2-23: Configure Instrument Screen Button ............................................................ 2-19
Figure 2-24: Instrument Configuration Screen .................................................................. 2-20
Figure 2-25: User Preferences Button .............................................................................. 2-21
Figure 2-26: User Preferences Screen ............................................................................. 2-21
Figure 2-27: LIS Configuration Button .............................................................................. 2-23
Figure 2-28: LIS Configuration Screen ............................................................................. 2-24
Figure 2-30: Setup Screen with Field Engineer Password Activation ............................... 2-27
Figure 2-31: Next Screen Button ...................................................................................... 2-27
Figure 2-32: Main Screen While Logged Out — 21 CFR Part 11 Mode ........................... 2-28
Figure 2-33: Login Button ................................................................................................. 2-28
Figure 2-34: 21 CFR Part 11 User Login Screen .............................................................. 2-29
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List of Figures
Figure 2-35: Main Screen ..................................................................................................2-30

Figure 2-36: Setup Screen ................................................................................................2-30
Figure 2-37: User Configuration Screen ............................................................................2-31
Figure 2-38: Add User Screen ...........................................................................................2-31
Figure 2-39: Add User Screen with User Name Added .....................................................2-32
Figure 2-40: BacT/ALERT® 3D 60 Modem Configuration .................................................2-33
Figure 2-41: Diagnostic Screen .........................................................................................2-34
Figure 2-42: Line Scroll Up Button ....................................................................................2-34
Figure 2-43: Plastic Bottle Algorithms ...............................................................................2-35
Figure 2-44: Plastic Barcodes ...........................................................................................2-37
Figure 2-45: Backup Management Button .........................................................................2-38
Figure 2-46: Manual Backup Button ..................................................................................2-38
Figure 3-1: BacT/ALERT® 3D 60 ......................................................................................3-3
Figure 3-2: Comm Ports ....................................................................................................3-4
Figure 3-3: Electronics Compartment ................................................................................3-6
Figure 3-4: CPU PCBA (Older Model LBC-586 PLUS) .....................................................3-7
Figure 3-5: CPU PCBA (Newer Model LBC-GX500) .........................................................3-7
Figure 3-6: Quad Serial Interface PCBA ...........................................................................3-8
Figure 3-7: ModSig PCBA .................................................................................................3-9
Figure 3-8: ModSig Block Diagram ..................................................................................3-11
Figure 3-9: Step-5 PCBA .................................................................................................3-12
Figure 3-10: Step-5 PCBA Motor Phases .........................................................................3-13
Figure 3-11: Step-5 PCBA Block Diagram ........................................................................3-15
Figure 3-12: Compact Flash Disk (Example Only, Actual Part May Vary) ........................3-16
Figure 3-13: Compact Flash Adapter PCBA ......................................................................3-17
Figure 3-14: Power Panel Assembly with Transformer .....................................................3-17
Figure 3-15: Heater/Blower Assembly ...............................................................................3-18
Figure 3-16: Agitation Motor ..............................................................................................3-18
Figure 3-17: Internal Fan Assembly ..................................................................................3-19
Figure 3-18: Thermistor PCBA ..........................................................................................3-19
Figure 3-19: Incubation Chamber ......................................................................................3-20
Figure 3-20: Rack Controller PCBA ...................................................................................3-22
Figure 3-21: Rack Controller Block Diagram .....................................................................3-23
Figure 3-22: Rack Address Concept .................................................................................3-25
Figure 3-23: Power Distribution Block Diagram .................................................................3-26
Figure 3-24: UPS Domestic Model — Front and Rear View .............................................3-29
Figure 3-25: UPS International Model — Front and Rear View .........................................3-30
Figure 3-26: Configuration Screen ....................................................................................3-31
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Figure 3-29: Checkbox ...................................................................................................... 3-32
Figure 3-30: Inc Module/Flag Check ................................................................................. 3-34
Figure 3-31: Inc Module/Temperature Log (Find Text String) ........................................... 3-35
Figure 3-32: Inc Module/Temperature Log (Text String Output) ....................................... 3-35
Figure 3-33: Inc Module/Temperature Log (Save Output to Zip) ...................................... 3-36
Figure 3-34: Diagnostic Test Selection (Setup) Screen .................................................... 3-38
Figure 3-35: Inc Module/Temperature Log ....................................................................... 3-39
Figure 3-36: Loopback Screen .......................................................................................... 3-41
Figure 3-37: Port Stats Screen ......................................................................................... 3-42
Figure 3-38: Message Stats Screen ................................................................................. 3-43
Figure 3-39: Message Log Screen .................................................................................... 3-45
Figure 3-40: Temperature Log Screen .............................................................................. 3-46
Figure 3-41: Reading Log Screen ..................................................................................... 3-47
Figure 3-42: Flag Check Screen ....................................................................................... 3-48
Figure 3-43: Flag Check Screen ....................................................................................... 3-48
Figure 3-44: Drawer/Heater Screen .................................................................................. 3-49
Figure 3-45: LED Check ................................................................................................... 3-50
Figure 3-46: LED Check (Walking) ................................................................................... 3-50
Figure 3-47: Instrument Cntrl/Barcode Loopback Screen ................................................. 3-51
Figure 3-48: Instrument Cntrl/ Power Event Log Screen .................................................. 3-54
Figure 3-49: FILE : EVENT1.LOG and EVENT0.LOG ...................................................... 3-56
Figure 3-50: Instrument Cntrl/Software Screen ................................................................ 3-61
Figure 3-51: LIS/Loopback Screen ................................................................................... 3-84
Figure 3-52: LIS/Port Stats Screen ................................................................................... 3-86
Figure 3-53: LIS/Message Stats Screen ........................................................................... 3-87
Figure 3-54: LIS/Message Log Screen ............................................................................. 3-88
Figure 3-56: Quick Reference Card (Front Side) .............................................................. 3-95
Figure 3-57: Quick Reference Card (Rear Side) ............................................................... 3-96
Figure 4-1: Main Screen ................................................................................................... 4-3
Figure 4-2: Edit Cell Contents Button ............................................................................... 4-4
Figure 4-3: Edit Cell Contents Screen .............................................................................. 4-4
Figure 4-4: Edit Bottle Detail Screen ................................................................................. 4-4
Figure 4-5: Restore Failed ................................................................................................ 4-6
Figure 4-6: Restore Complete ........................................................................................... 4-6
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List of Figures
Figure 4-8: Barcodes for Plastic Bottles ............................................................................4-9

Figure 4-9: Software Screen ...........................................................................................4-10
Figure 4-10: Software Bottle Tables Screen .....................................................................4-10
Figure 4-11: Backup Management Icon ............................................................................4-12
Figure 4-12: Login Button ..................................................................................................4-15
Figure 4-13: User Login Screen ........................................................................................4-15
Figure 4-17: Add User Screen ...........................................................................................4-17
Figure 4-18: Add User Screen with User Name Added .....................................................4-18
Figure 4-24: Delete User Screen .......................................................................................4-21
Figure 4-25: Delete User Screen with User Names Highlighted .......................................4-21
Figure 4-31: Clear User Password Screen ........................................................................4-24
Figure 4-32: Clear User Password Screen with User Names Highlighted ........................4-25
Figure 4-33: Blank Edit Bottle Detail Screen .....................................................................4-26
Figure 5-1: Instrument Icon Pictorial .................................................................................5-7
Figure 5-2: Top Panel Screws ...........................................................................................5-8
Figure 5-3: Quad Serial PCBA ..........................................................................................5-9
Figure 5-4: CPU PCBA Jumper Locations ........................................................................5-9
Figure 5-5: CPU PCBA (Back View) ................................................................................5-10
Figure 5-6: CPU PCBA Jumper Locations ......................................................................5-11
Figure 5-7: Top Panel Screws .........................................................................................5-12
Figure 5-8: CMOS Setup Screen ....................................................................................5-17
Figure 5-9: CMOS Setup Utility Screen ...........................................................................5-17
Figure 5-11: Quad Serial PCBA ........................................................................................5-19
Figure 5-12: CPU PCBA ....................................................................................................5-19
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List of Figures
Figure 5-13: CPU PCBA Connector Locations ................................................................. 5-20

Figure 5-14: Top Panel Screws ........................................................................................ 5-21
Figure 5-16: Quad Serial PCBA ........................................................................................ 5-24
Figure 5-17: 9-Pin Connector Placement .......................................................................... 5-25
Figure 5-18: Jumper and Connector Locations ................................................................. 5-25
Figure 5-19: CPU BIOS Clock Battery .............................................................................. 5-26
Figure 5-21: Quad Serial PCBA ........................................................................................ 5-28
Figure 5-23: Compact Flash Adapter PCBA ..................................................................... 5-31
Figure 5-24: CPU PCBA (Back View) ............................................................................... 5-32
Figure 5-27: Compact Flash Adapter Connector Locations .............................................. 5-35
Figure 5-29: ModSig PCBA Connector Locations ............................................................. 5-38
Figure 5-30: Rear Panel .................................................................................................... 5-39
Figure 5-32: ModSig PCBA Fuse Locations ..................................................................... 5-42
Figure 5-34: Step-5 PCBA Connector Locations .............................................................. 5-44
Figure 5-36: Step-5 PCBA MCJ3 Connector .................................................................... 5-47
Figure 5-37: Motor Offset Round Setscrew Location ........................................................ 5-47
Figure 5-38: Motor Mounting Screw Location ................................................................... 5-48
Figure 5-39: Step-5 Motor Removal .................................................................................. 5-48
Figure 5-40: Motor Mounting Screw Tightening Sequence ............................................... 5-49
Figure 5-42: Outlet Thermistor PCBA ............................................................................... 5-51
Figure 5-44: Inlet Thermistor PCBA .................................................................................. 5-54
Figure 5-47: Zip® Drive Cable Removal ............................................................................ 5-57
Figure 5-48: Zip® Drive Screw Location ............................................................................ 5-58
Figure 5-49: Zip® Drive Cutout ......................................................................................... 5-58
Figure 5-50: Zip® Drive Mounting Bracket Screw Locations ............................................. 5-59
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List of Figures

Figure 5-52: Power Panel Assembly Connector Locations ...............................................5-61
Figure 5-53: Chassis Rear Panel ......................................................................................5-61
Figure 5-54: PEM Wiring ...................................................................................................5-63
Figure 5-55: Transformer ..................................................................................................5-64
Figure 5-58: Terminal Board 1 Wiring ...............................................................................5-66
Figure 5-60: Solid State Relays .........................................................................................5-68
Figure 5-61: DC Power Supply ..........................................................................................5-70
Figure 5-62: Power Panel Assembly — Rear View ...........................................................5-71
Figure 5-63: PEM Ground Wire Lug ..................................................................................5-72
Figure 5-64: PEM Wiring ...................................................................................................5-73
Figure 5-65: Power Entry Module with Fuse Holder Removed .........................................5-74
Figure 5-66: Fuse Holder ..................................................................................................5-74
Figure 5-67: PEM with 115 VAC Version ..........................................................................5-76
Figure 5-68: PEM with 230 VAC Version ..........................................................................5-76
Figure 5-71: Terminal Board 1 Wiring ...............................................................................5-78
Figure 5-72: Fan Assembly ...............................................................................................5-79
Figure 5-74: Heater ...........................................................................................................5-81
Figure 5-76: Thermal Switch .............................................................................................5-83
Figure 5-78: Blower Assembly ..........................................................................................5-85
Figure 5-79: Blower Motor Capacitor .................................................................................5-87
Figure 5-80: Blower Motor Capacitor — Boot Removed ...................................................5-87
Figure 5-81: Digital Reference Thermometer ....................................................................5-89
Figure 5-82: Digital Reference Thermometer ....................................................................5-90
Figure 5-84: Rack Cable Cover .........................................................................................5-92
Figure 5-85: Rack Cable Clamp ........................................................................................5-92
Figure 5-86: Rack Controller PCBA Connections ..............................................................5-93
Figure 5-87: Rack Assembly Removal ..............................................................................5-94
Figure 5-88: Bottle Holder Cover .......................................................................................5-96
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List of Figures
Figure 5-89: Left Link Assembly Bushing Screws ............................................................. 5-97

Figure 5-90: Instrument Left Side ..................................................................................... 5-98
Figure 5-91: Right Link Assembly Bushing Screws .......................................................... 5-99
Figure 5-92: Instrument Right Side ................................................................................... 5-99
Figure 5-93: Top Panel Screws ...................................................................................... 5-101
Figure 5-94: Instrument Rear View ................................................................................. 5-102
Figure 5-95: Motor Offset Round Setscrew Location ...................................................... 5-102
Figure 5-96: Drive Agitation Linkage Assembly with Motor Offset Round ...................... 5-103
Figure 5-98: Top Support Bracket ................................................................................... 5-106
Figure 5-99: Bottom Support Bracket ............................................................................. 5-106
Figure 5-101: Magnetic Door Switches ............................................................................. 5-108
Figure 5-102: Door Switch LEDs ...................................................................................... 5-108
Figure 5-103: Rear Panel .................................................................................................. 5-110
Figure 5-106: Modem Cable Connections ........................................................................ 5-111
Figure 5-107: Modem DIP Switch Settings ....................................................................... 5-112
Figure 5-109: UPS Battery Compartment ......................................................................... 5-113
Figure 5-110: UPS Battery Leads ..................................................................................... 5-114
Figure 5-112: UPS Battery Compartment ......................................................................... 5-115
Figure 5-113: UPS Battery Leads ..................................................................................... 5-116
Figure 5-114: Main Screen ............................................................................................... 5-118
Figure 5-115: View Cell Status Screen ............................................................................. 5-118
Figure 5-116: Cell Information Table Example ................................................................. 5-119
Figure 5-117: Main Screen ............................................................................................... 5-119
Figure 5-118: Setup Screen .............................................................................................. 5-120
Figure 5-119: Module and Rack Information Screen ........................................................ 5-120
Figure 6-2: Setup Screen with Field Engineer Password Activation ................................. 6-3
Figure 6-3: Calibrate Module Temperature Screen .......................................................... 6-3
Figure 6-4: Top Panel Screws .......................................................................................... 6-5
Figure 6-5: Step-5 PCBA .................................................................................................. 6-5
Figure 6-6: Step-5 Motor Wires ......................................................................................... 6-6
Figure 6-7: MB Conversion Lock Screw ........................................................................... 6-7
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List of Figures
Figure 6-8: Calibration Menu ...........................................................................................6-10

Figure 6-9: Retrieving Calibration Data Window .............................................................6-10
Figure 6-10: Retrieving Flag Readings Window ................................................................6-10
Figure 6-11: Cell Status Report Screen ............................................................................6-11
Figure 6-12: Reflectance Calibration Screen .....................................................................6-11
Figure 6-13: Calibrating Cells Window ..............................................................................6-12
Figure 6-14: 50 Percent Window .......................................................................................6-12
Figure 6-15: Remove Standard Window ...........................................................................6-12
Figure 6-18: 5 Percent Window .........................................................................................6-13
Figure 6-19: Readings Complete Window .........................................................................6-14
Figure 6-20: Results Screen ..............................................................................................6-14
Figure 6-22: Setup Screen with Field Engineer Password Activation ...............................6-16
Figure 6-23: Diagnostic Test Selection Screen — Flag Check .........................................6-16
Figure 6-24: Incubator Flag Check — Cell Differences Screen .........................................6-17
Figure 6-25: Flag Check — Cell Calibration Screen ..........................................................6-17
Figure 6-26: Single Cell Mode Calibration Menu ...............................................................6-20
Figure 6-27: Retrieving Calibration Data Window .............................................................6-21
Figure 6-28: Retrieving Flag Readings Window ................................................................6-21
Figure 6-29: Cell Status Report Screen ............................................................................6-22
Figure 6-33: Remove Standard Window ...........................................................................6-23
Figure 6-36: 5 Percent Window .........................................................................................6-24
Figure 6-37: Readings Complete Window .........................................................................6-25
Figure 6-38: Pass or Fail Screen .......................................................................................6-25
Figure 6-40: System Power Panel and DC Supply ............................................................6-26
Figure 6-41: ModSig PCBA with +5 VDC Test Points .......................................................6-27
Figure 6-42: Power Supply ................................................................................................6-27
Figure 6-43: Step 5 PCBA with +12 VDC Test Points .......................................................6-28
xx BacT/ALERT® 3D 60 Service Manual

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List of Figures
Figure 7-1: Scanner Default Settings Barcode Label for Older Barcode Scanner .......... 7-16
Figure 7-2: Scanner Default Settings Barcode Label for Newer Barcode Scanner ........ 7-16
Figure 7-3: Instrument Icon with Fault Codes ................................................................. 7-17
Figure 7-4: Instrument Status Code #710 ....................................................................... 7-17
Figure 7-7: Diagnostic Test Selection (Setup) Screen .................................................... 7-53
Figure 7-8: Inc Module/Loopback Screen ....................................................................... 7-54
Figure 7-9: Inc Module/Port Stats Screen ....................................................................... 7-55
Figure 7-10: Inc Module/Message Stats Screen ............................................................... 7-56
Figure 7-11: Inc Module/Message Log Screen ................................................................. 7-57
Figure 7-12: Inc Module/Temperature Log Screen ........................................................... 7-58
Figure 7-13: Inc Module/Reading Log Screen .................................................................. 7-59
Figure 7-14: Inc Module/Flag Check Screen .................................................................... 7-60
Figure 7-15: Cell Calibration Screen ................................................................................. 7-61
Figure 7-16: Run Continuously Button .............................................................................. 7-61
Figure 7-17: Inc Module/Drawer/Heater Screen ............................................................... 7-62
Figure 7-18: Inc Module/LED Check ................................................................................. 7-63
Figure 7-19: Inc Module/LED Check (Walking) ................................................................. 7-64
Figure 7-20: Instrument Cntrl/Zip Drive Test Screen ........................................................ 7-65
Figure 7-21: Barcode Scanner Connection ....................................................................... 7-66
Figure 7-22: Instrument Cntrl/Barcode Loopback Screen ................................................. 7-67
Figure 7-23: Instrument Cntrl/Power Event Log Screen ................................................... 7-68
Figure 7-24: FILE : EVENT1.LOG and EVENT0.LOG ...................................................... 7-70
Figure 7-26: LIS/Loopback Screen ................................................................................... 7-78
Figure 7-27: LIS/Port Stats Screen ................................................................................... 7-79
Figure 7-28: LIS/Message Stats Screen ........................................................................... 7-80
Figure 7-29: LIS/Message Log Screen ............................................................................. 7-81
Figure D-1: CPU PCBA .....................................................................................................D-2
Figure D-2: CPU PCBA (Front View) .................................................................................D-3
Figure D-3: CPU PCBA (Back View) .................................................................................D-4
Figure D-4: ModSig PCBA Connector Locations ...............................................................D-6
Figure D-5: ModSig PCBA Fuse Locations .......................................................................D-8
Figure D-6: Step-5 PCBA Connector Locations ................................................................D-9
Figure D-7: Outlet Thermistor PCBA Connector Location ...............................................D-10
Figure D-8: Inlet Thermistor PCBA Connector Location ..................................................D-10
Figure D-9: Terminal Board 1 Wiring ...............................................................................D-11
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List of Figures
Figure D-10: Power Supply Relay Layout ......................................................................... D-12

Figure D-11: Power Entry Module Simplified Schematic .................................................. D-13
Figure E-1: CMOS Setup Screen ..................................................................................... E-4
Figure E-2: CMOS Setup Utility Screen ............................................................................ E-4
Figure E-3: Top Panel Screws .......................................................................................... E-5
Figure E-4: Flash Adapter PCBA ...................................................................................... E-6
Figure E-5: Quad Serial PCBA ......................................................................................... E-6
Figure E-6: CPU PCBA (Back View) ................................................................................. E-7
Figure E-7: CPU PCBA Jumper Locations ....................................................................... E-8
Figure E-8: BIOS Screen .................................................................................................. E-9
Figure E-9: Zip® Driver File ............................................................................................. E-10
Figure E-10: Main Screen ................................................................................................. E-11
Figure E-11: Setup Screen ............................................................................................... E-12
Figure E-12: Set Date/Time Button ................................................................................... E-12
Figure E-13: Top Panel Screws ........................................................................................ E-13
Figure E-14: BIOS Screen ................................................................................................ E-15
Figure E-17: Main Screen ................................................................................................. E-21
Figure E-18: Setup Screen with Field Engineer Password Activation .............................. E-21
Figure E-19: Instrument Cntrl/Zip Drive Test Screen ........................................................ E-22
Figure E-20: BIOS Upgrade Screen Prompt ..................................................................... E-23
Figure E-21: BIOS Upgrade Complete Screen ................................................................. E-24
Figure E-23: CMOS Setup Screen ................................................................................... E-27
Figure E-24: CMOS Setup Utility Screen .......................................................................... E-27
Figure E-25: Quad Serial PCBA ....................................................................................... E-28
Figure E-26: Jumper Pin Locations .................................................................................. E-28
Figure E-27: Velcro® Dot Placement ................................................................................ E-29
Figure E-28: 9-Pin Connector Placement ......................................................................... E-29
Figure E-29: 9-Pin Connector Placement ......................................................................... E-30
Figure E-30: CMOS Setup Screen ................................................................................... E-31
Figure E-31: CMOS Setup Utility Screen .......................................................................... E-31
Figure E-34: Quad Serial PCBA ....................................................................................... E-35
Figure E-35: Jumper and Connector Locations ................................................................ E-36
Figure E-36: Velcro® Dot Placement ................................................................................ E-36
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452501-1EN1
List of Figures
Figure E-37: Battery Cable Tie ..........................................................................................E-37

Figure E-38: BIOS Screen .................................................................................................E-37
Figure E-39: Barcode Scanner Connection .......................................................................E-40
Figure E-40: Main Screen .................................................................................................E-40
Figure E-41: Setup Screen ................................................................................................E-41
Figure E-42: Set Bottle to Edit/Graph Button ....................................................................E-41
Figure E-43: Barcode Scanner Test Screen .....................................................................E-42
BacT/ALERT® 3D 60 Service Manual xxiii

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xxiv BacT/ALERT® 3D 60 Service Manual

452501-1EN1
List of Tables
Table 2-1: Restraint Hardware ........................................................................................... 2-4

Table 2-2: Table of Equivalent Dimensions (Inches to Centimeters) ................................. 2-5
Table 2-3: Facility Power Rating and Conversion Chart .................................................... 2-8
Table 2-4: Plastic Algorithms ............................................................................................ 2-34
Table 3-1: Audio Volume Selection at JP22 ..................................................................... 3-10
Table 3-2: Audio Frequency Selection at JP23 through JP26 .......................................... 3-10
Table 3-3: Power Supply Data ......................................................................................... 3-27
Table 3-4: Pin Chart ......................................................................................................... 3-27
Table 3-5: Diagnostic Setup Screen Buttons ................................................................... 3-33
Table 3-6: Operation Buttons ........................................................................................... 3-34
Table 3-7: Display Output Area Navigation Buttons ......................................................... 3-37
Table 3-8: Slide Bar Button .............................................................................................. 3-37
Table 3-9: Diagnostic Screen Fields ................................................................................ 3-39
Table 3-10: Software Exceptions ....................................................................................... 3-56
Table 3-11: Audit Trail Events ............................................................................................ 3-81
Table 4-1: Plastic Bottle Algorithms ................................................................................. 4-11
Table 5-1: CPU PCBA Connector Locations .................................................................... 5-11
Table 5-2: CPU PCBA Connector Locations .................................................................... 5-21
Table 5-3: ModSig PCBA Fuses ...................................................................................... 5-42
Table 5-4: Transformer to PEM Wires .............................................................................. 5-63
Table 5-5: Power Entry Module Connector Locations ...................................................... 5-73
Table 5-6: Facility Power Rating and Fuse Conversion Chart ......................................... 5-75
Table 5-7: Reflectance Standard Part Numbers ............................................................ 5-117
Table 5-8: Bottle Counts and Software Version ............................................................. 5-125
Table 5-9: Local and CMOS Date/Time ......................................................................... 5-125
Table 5-10: Calculations for Time Spent Replacing CPU PCBA ...................................... 5-125
Table 5-11: Calculations for New CMOS Time ................................................................ 5-125
Table 5-12: Cell Information ............................................................................................. 5-126
Table 7-1: Symptomatic Troubleshooting ........................................................................... 7-4
Table 7-2: Fault/Status Code Troubleshooting ................................................................. 7-17
Table 7-3: Special Equipment List .................................................................................... 7-51
Table D-1: CPU PCBA Connector Locations ......................................................................D-2
Table D-2: CPU PCBA Connector Locations ......................................................................D-4
Table D-3: UPS Connector Locations .................................................................................D-5
Table D-4: UPS DIP Switch Settings ..................................................................................D-5
Table D-5: ModSig PCBA Connector Locations .................................................................D-6
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List of Tables
Table D-6: Audio Volume Selection at JP22 ...................................................................... D-7

Table D-7: Audio Frequency Selection at JP23 through JP26 ........................................... D-7
Table D-8: ModSig PCBA Fuses ........................................................................................ D-8
Table D-9: Quad Serial PCBA Connector Locations .......................................................... D-9
Table D-10: Step-5 PCBA Connector Locations .................................................................. D-9
Table D-11: Outlet Thermistor Connector Location ............................................................ D-10
Table D-12: Inlet Thermistor Connector Location .............................................................. D-10
Table D-13: Power Supply TB1 Connector Locations ........................................................ D-11
Table D-14: Power Supply Solid State Relay Connector Locations ................................... D-12
Table D-15: Power Entry Module Connector Locations ..................................................... D-13
Table E-1: CPU Replacement Kit for 3D 60 Instrument ..................................................... E-2
Table E-2: CPU PCBA Connector Locations ..................................................................... E-8
Table E-3: Motherboard Device Configuration ................................................................. E-13
Table E-4: Jumper Settings .............................................................................................. E-14
Table E-5: BIOS Settings ................................................................................................. E-16
Table E-6: CPU BIOS Clock Battery Kit (P/N 193810-901) ............................................. E-25
Table E-7: Honeywell Barcode Scanner (P/N 248013) .................................................... E-39
Table E-8: Bottle Counts and Software Version ............................................................... E-43
Table E-9: Local and CMOS Date/Time ........................................................................... E-43
Table E-10: Calculations for Time Spent Replacing CPU PCBA ....................................... E-43
Table E-11: Calculations for New CMOS Time .................................................................. E-43
Table E-12: CPU BIOS Version Upgrade Checklist ........................................................... E-44
Table E-13: Barcode Scanner Test Scans ......................................................................... E-44
xxvi BacT/ALERT® 3D 60 Service Manual

452501-1EN1
Chapter 1: How to Use this Manual
About this Chapter
This chapter contains information about how this manual is organized and how to use
this manual. It is recommended that you read this chapter first.
IMPORTANT: Read this manual carefully before you attempt to work on or use the
BacT/ALERT® 3D 60 instrument.
Note: The BacT/ALERT® 3D 60 instrument conforms to the relevant European regulations

for electrical safety and EMC.
Chapter Contents
1.1 Purpose of this Manual • 1-2

1.2 Intended Audience • 1-2
1.3 Organization of the Manual • 1-2
1.4 Chapter Organization • 1-3
1.5 Finding Topics • 1-3
1.6 Typographic and Usage Conventions • 1-4
1.6.1 Click • 1-4
1.6.2 Commands • 1-4
1.6.3 Genus and Species Names • 1-4
1.6.4 Keyboard Entry • 1-4
1.6.5 Mouse Actions • 1-4
1.6.6 Names and Titles • 1-5
1.6.7 Press • 1-5
1.6.8 Procedural Steps • 1-5
1.6.9 References • 1-5
1.6.10 Select • 1-6
1.6.11 User Input • 1-6
1.6.12 Configuration Screen Checkboxes • 1-6
1.7 Warnings, Cautions, and Information • 1-6
1.8 Safety Summary • 1-7
1.9 Electrical Grounding • 1-8
1.10 Fuse Replacement • 1-9
1.11 Hazardous Voltages • 1-9
1.12 Cleaning Agent Hazards • 1-9
1.13 Health Risks • 1-9
1.14 ESD Precautions • 1-9
1.15 Moving Parts • 1-9
1.16 Heating Element • 1-10
1.17 Existing Hardware • 1-10
BacT/ALERT® 3D 60 Service Manual 1-1

452501-1EN1
Purpose of this Manual How to Use this Manual
1.1 Purpose of this Manual
This Service Manual contains information on the operation, installation, maintenance,

and repair of the BacT/ALERT® 3D 60 system. This information is intended to provide
an understanding of how the system performs, possible causes of malfunctions, and
how to isolate and correct performance problems.
IMPORTANT: Figures, schematics and their components are not necessarily shown to scale
in this manual. Figures and schematics are included in this manual for
illustrative purposes or as examples.
1.2 Intended Audience
This manual is for use by bioMérieux Field Service Engineers and factory-trained
Biomedical Engineers to assist in the troubleshooting and repair of the
BacT/ALERT® 3D 60 system. Every effort has been made to ensure that the
information contained in this manual is complete and accurate. All calibration and
adjustment procedures used in this manual are adapted directly from current
engineering documentation.
1.3 Organization of the Manual
The information in this manual is organized into seven chapters, arranged so that the
information you need first is in the beginning of the manual. Information required for
maintenance after the system is operating is found in later chapters.
The following is a brief outline of this manual:

• Chapter 1: How to Use this Manual — Explains how the manual is organized
and how to use the manual.
• Chapter 2: System Setup — Explains how to install and set up the
BacT/ALERT® system.
• Chapter 3: Instrument Components — Describes the components of the
BacT/ALERT® system and how it operates.
• Chapter 4: Operating Procedures — Describes basic operating procedures
already included in the BacT/ALERT® 3D 60 User Manual.
• Chapter 5: Component Replacement — Describes how to remove, install, and
mechanically align the subassemblies that may be encountered during repair of
the BacT/ALERT® system. This chapter is intended for use after you have
completed troubleshooting and problem diagnosis.
• Chapter 6: Alignment and Adjustment Procedures — Provides instructions
and diagnostic commands for the alignment and adjustment of components in the
BacT/ALERT® system.
• Chapter 7: Diagnostic and Troubleshooting Information — Provides error
conditions and problems, and corresponding actions to resolve them.
1-2 BacT/ALERT® 3D 60 Service Manual

452501-1EN1
How to Use this Manual Chapter Organization
Following these chapters are appendices listing specifications, procedures for

decontamination/cleaning, an installation checklist, schematics and diagrams,
instrument improvements, and guidelines for protecting Electrostatic Discharge
Sensitive (ESDS) components. There is a glossary of terms in the back of the manual.
After completing this service manual, you should be able to:

• Identify the BacT/ALERT® 3D 60 instruments and independent subsystems.
• Determine the instrument workflow and explain each subsystem operation.
• Determine and perform alignment/calibration procedures for the
BacT/ALERT® 3D 60 system.
• Troubleshoot errors in the BacT/ALERT® 3D 60 system module.
1.4 Chapter Organization
All of the chapters are organized in the same way and include the following:
• About this Chapter — Summary of the chapter’s content and purpose.
• Chapter Contents — A table of contents for the chapter.
• Descriptions and/or Procedures — Descriptions and procedures appropriate for
this chapter’s subject matter.
• Background Information, where applicable and useful.
1.5 Finding Topics
This manual uses several methods to help you find information and keep your
bearings:
Table of Contents — Located at the front of the manual. It contains the titles of all
chapters/appendices and their sections, and the page number of each title and
section.
List of Figures — Located at the front of the manual. It contains a list of all figures in
the manual and the page number of each figure.
List of Tables — Located at the front of the manual. It contains a list of all tables in
the manual and the page number of each table.
Chapter Contents — Located at the front of each chapter. It lists all sections in the
chapter and their page number.
Page Headers — Located at the top of each page. There are two parts to a header:
the chapter title and the primary section title.
Page Footers — Located at the bottom of each page. There are three parts to a
footer: the manual name, the manual part number, and the page number.
Index — Located at the back of the manual. It contains topical entries and their page
numbers.

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Typographic and Usage Conventions How to Use this Manual
1.6 Typographic and Usage Conventions
1.6.1 Click
This manual uses the word “click” to refer to using a mouse to choose or select a
command, window, button, or option.
Example: Click OK.
See Section 1.6.10, Select for more information.
1.6.2 Commands
Menu, keyboard and button commands are in Proper Case, bold.
Example: Setup > Configure menu command.
1.6.3 Genus and Species Names

Family names and genus/species names of bacteria are italicized.
Example: Enterobacteriaceae
Example: Klebsiella pneumoniae
1.6.4 Keyboard Entry

Most of the actions you take in a graphical interface use the mouse. When keyboard
entry is required, certain conventions are used:
• An instruction to enter data begins with the words “Enter” or “Type.”
• Special function keys are shown in Proper Case, bold.
Example: Enter, Tab, Delete
• An instruction to use one of these keys begins with the word “Press.”
• Function keys that you must press simultaneously are shown together like this:
Shift + Tab
1.6.5 Mouse Actions

This manual uses the word “click” to refer to pressing the left mouse button one time
to choose or select a command, window, button, or option.
Example: Click OK.
The term “right-click” refers to pressing the right mouse button one time to perform
these actions. “Double-click” refers to using two clicks in rapid succession to select a
command, window, button, or option.

452501-1EN1
How to Use this Manual Typographic and Usage Conventions
1.6.6 Names and Titles

The names and titles of menus, dialog boxes, fields, icons, buttons and settings are in
Proper Case, bold.
Example: Setup menu.
The names of windows are in Proper Case, but are not bolded.
Example: Configuration window.
1.6.7 Press
This manual uses the word “press” to refer to pressing a key on the keyboard in order
to initiate action in the software. “Press” is also used to refer to pressing switches and
buttons on the instrument or other hardware components.
Example: Press Enter.
Note: The “press Enter” command is often not stated explicitly in software procedures,
because it is commonly understood that you press this key after you enter data into
the system using a keyboard.
1.6.8 Procedural Steps

Steps in procedures are sequentially numbered. A bullet list in a step indicates
options.
1.6.9 References
References to chapter and section titles in this manual are in Proper Case.
Example: See Chapter 1, How to Use this Manual.
References to other manuals are in Proper Case and italic font.
Example: See the BacT/ALERT® 3D 60 User Manual.
References to steps, sections, procedures, and tasks may be referenced throughout

this manual, requiring you to perform a necessary action before continuing the task at
hand. When you see this, proceed to the referenced item and perform the necessary
action. After you have completed the necessary action, return to the original task and
continue to follow the remainder of the steps in the task.
Quick access to references are available if you are viewing this document
electronically in a portable document format (PDF). References may appear with a
blue font, indicating that they are linked to another step, section, procedure, or task in
this manual. Clicking the reference will take you directly to the location of the
reference in this manual. The Table of Contents, List of Figures, List of Tables,
Chapter Contents, and Index are all linked, but do not appear with a blue font.

452501-1EN1
Warnings, Cautions, and Information How to Use this Manual
1.6.10 Select
The word “select” is generally used for selecting menus, menu commands, and
graphical user interface (GUI) navigation.
Example: Select File > Save.
See Section 1.6.1, Click for more information.
1.6.11 User Input

Instructions for user input begin with the word “type” or “enter.” This manual uses bold
for literal user input and italic for placeholders.
Example of Literal User Input: In the box, type April 1.
In the Literal User Input example, you are to type exactly what you see on the page
(April 1 in this example).
Example of a Placeholder: Enter your password before you...
In the Placeholder example, you are to type your assigned password.
1.6.12 Configuration Screen Checkboxes

Several configuration options are represented by a graphical element called a
Checkbox. As shown in Figure 1-1, a Checkbox can appear with or without an X.
Clicking the Checkbox switches it to the opposite state.
Figure 1-1: Checkboxes
1.7 Warnings, Cautions, and Information
This manual uses different types of symbols to alert you to important information.
Symbols and their associated information are labeled in text where they occur and set
off from surrounding paragraphs, as shown in the following examples.
WARNING
Warning is a statement that alerts the user to the possibility of injury,
death, or other serious adverse reactions associated with the use or
misuse of a device.

452501-1EN1
How to Use this Manual Safety Summary
CAUTION: Caution is a statement that alerts the user to the possibility of

a problem with the device associated with its use or misuse. Such
problems include device malfunction, device failure, damage to the
device, or damage to other property. Where applicable, a caution
statement may include a precaution that should be taken to avoid the
hazard.
IMPORTANT: Important relates to content presented in this manual. It is used to reinforce the
importance of your understanding or remembering something.
Note: Note supplies additional information about a topic.
1.8 Safety Summary
The BacT/ALERT® 3D 60 has been designed and tested pursuant to the standards
listed below and has been supplied in a safe condition. A CB Certification and
Construction File has been established for the apparatus.
• IEC Publication 61010-1: 2001 Safety Requirements for Electrical Equipment for
Measurement, Control, and Laboratory Use — Part 1: General Requirements
• UL 61010A-1: 2002 UL Standard for Safety Equipment for Laboratory Use —
Part 1: General Requirements
• CAN/CSA C22.2 No. 1010.1-92: Safety Requirements for Electrical Equipment for
Measurement, Control, and Laboratory Use — Part 1: General Requirements
1. Before applying power to any module, ensure that the Power Entry Module
(PEM) is properly configured for the specific facility power voltage. Also ensure
that fuse(s) of proper rating value are installed.
2. Any interruption of the protective conductor inside or outside the instrument or
disconnection of the protective earth terminal is likely to make the instrument
dangerous to lab personnel and other users.
3. The instrument must be disconnected from all voltage sources before it is
opened for any adjustments, replacement, maintenance, or repair.
4. Any adjustment, maintenance, or repair of the opened instrument while under
voltage should be avoided. However, if this is unavoidable, it shall be carried out
only by a trained and qualified individual who is aware of the hazard(s) involved
with the task. In addition, a second individual must be nearby to render aid if
necessary.
5. Make sure that only fuses with the required rated current and of the specified
type are used for a replacement. The use of makeshift fuses or the short-
circuiting of any fuse holder is extremely dangerous and prohibited.
6. Whenever it is likely that a BacT/ALERT® 3D module has been impaired, it
should be made inoperative by powering it down and disconnecting the power
cord. If there is evidence of moisture within the instrument, turn the facility

452501-1EN1
Electrical Grounding How to Use this Manual
power off at the circuit breaker junction box before removing the power cable.
The instrument is likely to be impaired if it:
• Shows visible damage.
• Fails to perform an intended operation.
• Has been subjected to storage or operation under unfavorable conditions.
(i.e.: above 80% humidity, dusty environment, prolonged storage, see
Appendix A, Specifications for tolerances.)
• Has been subject to severe transport stresses.
7. If any of the above conditions occur, a qualified service technician must check
the instrument prior to use.
1.9 Electrical Grounding
An electrical ground is required and must be in place for this instrument.
Before installing the instrument, ensure that a grounded wall receptacle is available
for each module. It must be plugged into a mating grounding type wall receptacle in
accordance with the National Electrical Code and applicable local codes and
ordinances for this type of installation. (Refer to Figure 1-2.)
WARNING
Under no circumstances is the ground prong to be removed. If it, the
plug, or the cord has any physical damage, the cord is to be replaced.
It is extremeley hazardous to operate this (or any) instrument with a
missing ground prong or a faulty power cable in place.
USA 115 VAC Standard International 230 VAC Standard
Figure 1-2: Electrical Grounding Requirements

452501-1EN1
How to Use this Manual Fuse Replacement
1.10 Fuse Replacement
There are no user serviceable fuses in the BacT/ALERT® 3D 60. Only trained and
qualified service technicians are to replace any fuse within the instrument.
1.11 Hazardous Voltages
With the exception of the internal circuitry in the display, the DC voltages used within
the modules are low voltage and low current. They do not pose any immediate hazard
to technicians; however, facility power of either 115 VAC or 230 VAC is present while
the instrument power switch is in the energized position, and could pose an electrical
hazard if proper precautions are not observed.
WARNING
Do not insert any object, other than a Zip® disk, into the Zip® drive
under any circumstances.
1.12 Cleaning Agent Hazards
Follow manufacturer’s instructions and MSD information to prevent any possible

hazards that may be present when using cleaning agents (or other chemicals).
1.13 Health Risks
Specimens and inoculated culture bottles are to be treated as though they are
capable of transmitting infectious agents. Handling of any bottles or specimens must
be done with the utmost care. Spills must be cleaned as soon as possible using the
disinfection procedures outlined in the current version of the BacT/ALERT® 3D 60
User Manual and Appendix B of this manual.
1.14 ESD Precautions
The BacT/ALERT® 3D 60 contains several electrostatic sensitive devices within the

modules. Proper ESD precautions, in addition to the use of a grounding strap, are
imperative whenever working on or near any ESD components. (See Appendix F,
Electrostatic Discharge (ESD).)
1.15 Moving Parts
The BacT/ALERT® 3D 60 contains moving parts within the left side of the instrument's
chassis. At times, personnel may be exposed to the Agitation Drive Arm, Motor Offset
Round and other internal moving parts. Care must be taken to avoid exposure of
clothing, hands, fingers, arms, etc. Prior to performing maintenance procedures

452501-1EN1
Heating Element How to Use this Manual
around moving parts, it is advised that loose clothing (i.e. ties, long sleeves, etc.) be
secured.
1.16 Heating Element
The instrument contains a heater to perform the incubation process. The heater may
remain hot for a period of time after the unit is first shut down for maintenance. To
prevent burns, avoid contact with the heater until it is known that it is cool enough to
touch.
1.17 Existing Hardware
The size and measuring standard used for existing hardware (for example, screws,
nuts, and lock washers) may vary on the BacT/ALERT® 3D 60 due to configuration
changes or system setup. To ensure the integrity of the system, it is extremely
important to use care when retaining existing hardware for later use so that the correct
hardware is used at all times.
If a new component is being installed, be sure to use the new hardware or cabling
supplied with the new component and discard the hardware and cabling from the
defective component.

452501-1EN1
Chapter 2: System Setup
About This Chapter
This chapter provides the Field Service Engineer with instructions on how to install the
BacT/ALERT® 3D 60 instrument, set up and configure the instrument, and perform
functional testing.
Chapter Contents
2.1 Reference Documents • 2-2

2.2 Requirements • 2-2
2.3 Preparation • 2-2
2.3.1 Verifying Site Requirements Are Met • 2-2
2.3.2 Verifying Contents • 2-2
2.4 BacT/ALERT® 3D 60 Unpacking Instructions • 2-3
2.5 Installing the Optional Restraint • 2-4
2.6 Instrument Installation • 2-6
2.6.1 Setting the AC Power • 2-6
2.6.2 Choosing Instrument Location • 2-10
2.6.3 Making Instrument Connections • 2-10
2.6.4 Powering Up the Instrument • 2-12
2.6.5 Verifying BIOS Time and Date • 2-13
2.7 Configuring the Instrument Software • 2-14
2.7.1 Verifying Instrument Temperature Using the Digital Thermometer • 2-16
2.7.2 Selecting Instrument Installation Options • 2-16
2.7.3 Configuring the Screen • 2-17
2.7.4 Configuring the Instrument • 2-19
2.7.5 Setting User Preferences • 2-20
2.7.6 Configuring the LIS • 2-23
2.7.7 Activate Industry Bottle Barcodes • 2-25
2.7.8 Checking for Disabled Components • 2-26
2.7.9 Checking for Errors • 2-26
2.8 Calibrating the Instrument Cells • 2-26
2.9 Logging In for the First Time — 21 CFR Part 11 Mode • 2-28
2.10 Functional Testing • 2-32
2.10.1 Configuring the BacT/ALERT® 3D 60 Modem • 2-32
2.10.2 Modem Functional Test • 2-33
2.10.3 Barcode Reader Functional Test • 2-33
2.10.4 Verifying Plastic Bottle Algorithms • 2-34
2.10.4.1 Scanning Plastic Bottle Barcodes • 2-35
2.10.5 UPS Functional Test (APC UPS) • 2-38
2.10.6 Installing the Printer • 2-39

452501-1EN1
Reference Documents System Setup
2.1 Reference Documents
• BacT/ALERT® 3D 60 User Manual
• BacT/ALERT® 3D i FA, BacT/ALERT® 3D i FN, and BacT/ALERT® 3D i PF Bottle

Barcode Activation Instructions
2.2 Requirements
If you are replacing a BacT/ALERT® Classic system with a BacT/ALERT® 3D 60

system, data cannot be transferred from the BacT/ALERT® Classic system to the
BacT/ALERT® 3D 60 system. Allow testing to complete for any bottles currently in the
BacT/ALERT® Classic system.
After the BacT/ALERT® 3D 60 instrument is installed, the customer has two options
for handling the bottles in the BacT/ALERT® Classic instrument:
• Allow the BacT/ALERT® Classic instrument to remain operational until the existing
bottles have either turned positive, or have timed out negative.
or
• Perform a terminal subculture on all bottles in the BacT/ALERT® Classic

instrument. The BacT/ALERT® Classic instrument can then be shut down and
packaged for return shipment.
2.3 Preparation
2.3.1 Verifying Site Requirements Are Met
1. Review the mandatory requirements on the BacT/ALERT® 3D 60 Standard

Laboratory Operating Environment Requirements (SLOER) Form in
Appendix C.
2. Indicate that site requirements are met on the BacT/ALERT® 3D 60 Installation
Checklist on page C-2.
2.3.2 Verifying Contents

1. Unpack the contents of the BacT/ALERT® 3D 60 using the
BacT/ALERT® 3D 60 Unpacking Instructions on page 2-3.
2. Verify and inspect contents of the BacT/ALERT® 3D 60 for shipping damage
using the BacT/ALERT® 3D 60 Installation Checklist on page C-2.
3. Indicate that contents are verified on the BacT/ALERT® 3D 60 Installation

452501-1EN1
System Setup BacT/ALERT® 3D 60 Unpacking Instructions
2.4 BacT/ALERT® 3D 60 Unpacking Instructions


452501-1EN1
Installing the Optional Restraint System Setup
2.5 Installing the Optional Restraint
The countertop mounting hardware consists of screws and flat washers

used to attach the instrument to a countertop or other surface of variable
thickness. (Refer to Figure 2-1.) For a list of required parts, refer to
Table 2-1.
Table 2-1: Restraint Hardware
Item Quantity
1/4 in. x 20 x 5 in. Bolt 4 each
1/4 in. Flat Washer 4 each
Figure 2-1: Countertop/Surface Mounting Diagram
1 — Threaded holes are accessible after the four rubber feet are
removed.
1. Determine the desired location of the instrument on the countertop or mounting
surface.
Note: Care should be taken to avoid braces or bulkheads within the counter which could
interfere with hardware installation and mounting. Drilling into these braces may
reduce the integrity of the counter’s strength.
2. Determine the length of the bolts needed for mounting. (Refer to Figure 2-2.)

452501-1EN1
System Setup Installing the Optional Restraint
Drill 3/8 in. holes in surface
Stationary Mounting Surface
¼ in. x 20
A + B = C (Calculated Length)
A = 2 ¾ in. (Equipment Interior Dimension)
B = Thickness of your mounting surface
Figure 2-2: Mounting Surface Diagram
For mounting surfaces up to 2 1/4 in. thick, use the 5 in. bolts supplied
with the instrument. For mounting surfaces or surfaces requiring longer
bolts, use Table 2-2 and Figure 2-2 to determine the required bolt length.
Table 2-2: Table of Equivalent Dimensions (Inches to Centimeters)
Equivalent Dimensions
1/2 in. = 1.3 cm 4 in. = 10.2 cm
2 1/2 in. = 6.4 cm 5 in. =12.7 cm
2 3/4 in. = 7 cm 13 in. = 33 cm
3 1/2 in. = 8.9 cm 21 in. = 53 cm
3. Transfer the dimensions from the Mounting Surface (Drilling) Template to the
actual mounting surface. (Refer to Figure 2-3.)
Rear clearance is
5 in. from hole, Drill 3/8 in. holes (four places)
or 4 in. from
instrument.
Top View
13 in.
Left side clear-

ance: Allow 4½ in. Front
from left side of
hole or 3½ in. 21 in.
from instru-
ment.
Note: Door will swing 3½ inches wide.
Figure 2-3: Mounting Surface (Drilling) Template
4. Properly locate and drill four 3/8 in. diameter holes in the mounting surface.
5. Remove the rubber feet from the instrument.

452501-1EN1
Instrument Installation System Setup
6. Position the instrument. Insert the bolts through 1/4 in. flat washers, through the
mounting surface, and into the threaded inserts of the instrument. (Refer to
Figure 2-3.)
7. Lightly tighten the bolts.
Note: Over-tightening the bolts may loosen the threaded inserts.
8. Indicate that the optional restraint is installed on the BacT/ALERT® 3D 60

Installation Checklist on page C-2.
2.6 Instrument Installation
2.6.1 Setting the AC Power
WARNING
The BacT/ALERT® 3D 60 ships without a default voltage setting. The
procedure that follows describes how to insert the fuse(s) for proper
voltage setting. After installing proper fuse(s), discard the remaining
fuse(s).
Note: The Power Entry Module (P/N 805-0017-02) is located in the rear and lower left corner
of the instrument.
Note: When configured for 115 VAC, the PEM has one 6.3 A, 250 V time-delay fuse
(P/N 870-0008-25). In addition, a conversion clip is located across the neutral line in
the fuse holder.
Note: When configured for 230 VAC, each PEM has two 5.0 A, 250 V time-delay fuses
(P/N 870-0008-24).
1. Ensure the instrument is powered down.

2. Ensure that the main power and interface cables are disconnected.
3. Open the PEM cover using a small flat-blade screwdriver.
4. Slide out the fuse holder. (Refer to Figure 2-4.)

452501-1EN1
System Setup Instrument Installation
Figure 2-4: Power Entry Module with Fuse Holder Removed
1 — Note the fuse orientation to the rear of the fuse holder.

452501-1EN1
5. Install the fuse(s) for the proper voltage rating. Determine the proper fuse
installation to use based on the Facility Power Ratings listed in Table 2-3.
Table 2-3: Facility Power Rating and Conversion Chart
Facility Power Rating Configuration Fuse(s) to Use

110 Volts AC 115 VAC One (1) 6.3 A, 250 V Time-Delay Fuse
(Refer to Step a and Figure 2-5)
200 Volts AC 230 VAC Two (2) 5.0 A, 250 V Time-Delay fuses
(Refer to Step b and Figure 2-6)
240 Volts AC 230 VAC Two (2) 5.0A, 250V Time-Delay fuses
a. To configure the BacT/ALERT® 3D 60 for 115 VAC, see Figure 2-5 to install
a 6.3 A, 250 V time-delay fuse.
Figure 2-5: PEM with 115 VAC Version
1 — Conversion Clip
2 — 6.3 A, 250 V Time-Delay Fuse

452501-1EN1
b. To configure the BacT/ALERT® 3D 60 for 230 VAC, see Figure 2-6 to install
the two 5.0 A, 250 V time-delay fuses. Be sure to remove and dispose of the
conversion clip, if one is present.
1 — 5.0 A, 250 V Time-Delay Fuses (two required)
CAUTION: Installation of the 115 V conversion clip in the 230 VAC

version could result in damage to the unit. (Refer to Figure 2-6.) Ensure
that the 115 V conversion clip has been removed if installing the 230
VAC version.
Top/Bottom View
Side View
Figure 2-7: Additional Fuse Holder Views
6. Reinstall the fuse holder.

452501-1EN1
7. Close the PEM cover.

8. Indicate that AC power is set on the BacT/ALERT® 3D 60 Installation Checklist
on page C-2.
2.6.2 Choosing Instrument Location
WARNING
The BacT/ALERT® 3D 60 has been designed to minimize risks
associated with MB testing. However, to further reduce the risks of
accidental exposure to infectious agents, take additional precautions.
It is strongly recommended that the instrument be placed in a
laboratory used for the routine culture of M. tuberculosis. For
activities involving the propagation and manipulation of M.
tuberculosis or Mycobacterium species grown in culture, Biosafety
Level 3 Practice, Containment Equipment, and Facilities are required
as recommended by CDC and NIH guidelines.
At a minimum, the instrument should be placed in a contained environment with

controlled access and a tuberculosis exposure control plan. The locations should
have surfaces which can be easily decontaminated using an appropriate topical
disinfectant. The instrument must not be placed in an open corridor or hallway that is
accessible to the general public or the patient population.
If it is necessary to move or store the BacT/ALERT® 3D 60 system, contact

bioMérieux Service for assistance.
1. Assemble and install the BacT/ALERT® 3D 60 instrument in the specified

installation location.
Note: If countertop or other permanent (bolted) installation is required, see Installing the
Optional Restraint on page 2-4.
2. Indicate that location for instrument placement is chosen on the

BacT/ALERT® 3D 60 Installation Checklist on page C-2.
2.6.3 Making Instrument Connections

The following steps describe the connections that need to be made prior to powering
up the BacT/ALERT® 3D 60. Figure 2-8 depicts the connections described in the
following steps:
1. Connect the UPS battery per the instructions on the UPS. Place the UPS near
the instrument. Connect the UPS serial cable to the 9-pin connector on the rear
of the UPS and the other end to the UPS connector (not Serial UPS) on the
BacT/ALERT® 3D 60 instrument Communications panel. UPS port connection
is shown in Figure 2-8.

452501-1EN1
Note: The 9-pin cable packed with the UPS should not be used and should be discarded.
Use the UPS Serial Cable (9-Pin) provided in the accessory kit.
2. Connect the BacT/ALERT® 3D 60 instrument’s main power cord into the

properly rated UPS AC receptacle labeled as Surge with Battery Backup.
3. Plug the UPS main power cable into the properly rated AC wall outlet.
4. Connect the external speaker cable (if external speakers are installed) into the
EXT SPKR port on the Communications panel (not supplied — optional). The
external speaker connection is shown in Figure 2-8.
5. Plug in the external speaker’s AC power cord (not supplied — optional) into the
properly rated AC wall outlet.
6. Plug in the monitor’s 15-pin cable into the MONITOR port on the
Communications panel (not supplied — optional). The MONITOR port
connection is shown in Figure 2-8.
7. Plug in the monitor main power cable to the properly rated UPS AC receptacle
labeled as Surge with Battery Backup.
8. Connect the keyboard cable into the KEYBRD port on the Communications
panel. Keyboard port connection is shown in Figure 2-8.
9. Connect the modem’s communications interface cable to the MODEM port on
the Communications panel. The MODEM port connection is shown in
Figure 2-8.
10. Connect the modem telephone cable to the Jack port on the modem (if supplied
and installed).
11. Plug the modem’s power adapter into the modem. Plug in the main power cord
from the adapter into the properly rated AC wall outlet (if supplied and installed).
12. Connect the barcode reader’s communications cable into the BARCODE port
on the Communications panel. The port connection is shown in Figure 2-8.
13. Connect the mouse cable into the MOUSE port on the Communication panel.
The port connection is shown in Figure 2-8.
14. Indicate that all instrument connections are complete on the

452501-1EN1
Mouse Printer
Barcode
13 Reader 12
Communications Panel
COMM
LIS Mouse Printer Bar Code
Modem Serial UPS Monitor Keyboard UPS

Ext Spkr
6 8 4
9 Surge outlets
Speakers with battery
Keybrd 1
backup.
Modem
5 UPS
10 11 Monitor
Telephone 3
Line Jack
Rear
3D 60 Communications View 2
Panel. See detailed view. Surge outlets
3D 60 without
battery backup
Figure 2-8: Installation and Setup Diagram — Port and Power Connections
2.6.4 Powering Up the Instrument

1. Turn the UPS switch to ON.
2. Power up the instrument by turning on the Main Power switch on the rear of the
instrument.
3. Power up the monitor, modem, and printer.
4. Turn on the electric reference thermometer, if applicable, making sure that it is
set for Celsius.
5. Indicate that the instrument is powered up on the BacT/ALERT® 3D 60

452501-1EN1
2.6.5 Verifying BIOS Time and Date

1. Press Esc and type yes to exit the instrument software.
The C:\ prompt appears.
2. Press Ctrl + Alt + Delete to restart the system.

3. While the system is rebooting, press F1 at the bioMérieux splash screen to
enter the Main Menu of the BIOS screen.
Figure 2-9: BIOS Screen
IMPORTANT: The Control Module microprocessor (BIOS) clock is set to and must remain at
the Coordinated Universal Time (UTC), formerly Greenwich Mean Time, in a
24 hour format. The BIOS time is set in manufacturing and should not require
readjustment in the field. The current UTC may be obtained from the National
Technical Information Services WWV radio station by calling 1-303-499-7111, or
by accessing the Internet USNO Master Clock at the following web address:
http://tycho.usno.navy.mil/cgi-bin/timer.pl. Contact Instrument Service for
assistance in setting the BIOS time.
Note: The BIOS date and time are the only settings that get adjusted in the BIOS. Also, the
BIOS time must be set to UTC and not local time, unless the local time is the same as
UTC.
4. To change the time setting:

a. Press the Up or Down Arrow button on the keyboard to highlight A. Time
and press Enter.
b. Enter the correct value and press Enter.
5. To change the date setting:
a. Press the Up or Down Arrow button on the keyboard to highlight B. Date
and press Enter.
b. Enter the correct value and press the Enter key.
6. Highlight Z. Save values to EEPROM and Exit and press Enter to reboot the
system. The BacT/ALERT® 3D 60 software will launch to the main screen.

452501-1EN1
Configuring the Instrument Software System Setup
7. Indicate that the BIOS time and date are verified on the BacT/ALERT® 3D 60
2.7 Configuring the Instrument Software
To verify correct settings:
1. From the Main screen, click the Next Screen button. (Refer to Figure 2-10.)
Next Screen
Button
Figure 2-10: Main Screen
2. Verify the Setup screen appears. (Refer to Figure 2-11.)
Key Symbol
Button
Figure 2-11: Setup Screen
3. From the Setup screen, enter the service password 43432121.

452501-1EN1
System Setup Configuring the Instrument Software
Note: The password is company confidential. Do not provide the password to the customer.
4. Click the Key Symbol button to log into the instrument.

5. From the Setup screen, click the Set Maximum Test Time button.
Figure 2-12: Set Maximum Test Time Button
The Set Maximum Test Time screen (screen ID 2.7) overlays and disables the
Setup screen.
6. From the Set Maximum Test Time screen, verify the maximum test times are
set to the proper values. The site will provide this information.
7. Click the Check button to save the setting.
8. From the Setup screen, click the Set Audible Alarm Options button.
Figure 2-13: Set Audible Alarm Options Button
The Set Audible Alarm Options screen (screen ID 2.8) overlays and disables
the Setup screen.
9. From the Set Audible Alarm Options screen, verify that the audible alarms are
enabled (set to 1).
10. Click the Check button to save the settings.
11. Set the audible volume and tone options to suit the requirements of the site
staff. (Refer to Table 3-1 and Table 3-2 in Section 3.3.2.3.)
12. From the Setup screen, click the Set Date/Time button.
Figure 2-14: Set Date/Time Button
The Set Date/Time screen (screen ID 2.1) overlays and disables the Setup
screen.
13. From the Set Date/Time screen, set the date/time to reflect the current date and
time at the site.
Note: Check with the customer to determine the desired format of the date and time.

452501-1EN1
15. From the Setup screen, click the Calibrate Module Temperature button.
Figure 2-15: Calibrate Module Temperature Button
The Calibrate Module Temperature screen (screen ID 2.3) overlays and

disables the Setup screen.
16. From the Calibrate Module Temperature screen, set the optimal temperature to
reflect the requirements of the site.
18. Indicate that instrument installation options are selected on the
2.7.1 Verifying Instrument Temperature Using the Digital Thermometer
Note: Allow the Incubation Chamber to stabilize and maintain temperature for a minimum of
4 hours prior to calibrating the temperature and cells.
1. Open the Incubation Chamber door.

2. Ensure the thermometer is switched On and is set to Test.
3. Close the door and allow the temperature to stabilize for 30 minutes.
4. Open the door and switch thermometer to the Hold position and remove.
5. Close the door and read the Incubation Chamber temperature.
6. Calibrate the Incubation Chamber temperature if it varies ± 0.5ºC from the Set
Point Temperature.
7. Indicate that the temperature is set on the BacT/ALERT® 3D 60 Installation
2.7.2 Selecting Instrument Installation Options

The Setup and Configuration Screen allows Field Service Engineers to determine the
style of instrument installation (for example, Select or SelectLink) and the type of
instrument installation (for example, 3D 60).
To select instrument installation options:
1. From the Setup screen, click the Setup and Configuration button. (Refer to
Figure 2-11.)
Figure 2-16: Setup and Configuration Button

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The Setup and Configuration screen overlays and disables the Setup screen.
(Refer to Figure 2-17.)
Figure 2-17: Setup and Configuration Screen
2. Select the style and type of instrument installation using the Line Scroll Up/
Down buttons.
3. Click the Check button to save settings.
If changes were made to the settings, the software will exit to the C:\ prompt.
4. At the C:\ prompt, press Ctrl + Alt + Delete to restart the software.
2.7.3 Configuring the Screen

Next Screen
Button

452501-1EN1
Key Symbol
Button

5. Click the Setup and Configuration button.
Figure 2-20: Setup and Configuration Button
6. From the Setup and Configuration screen, click the Configure Screen button.
Figure 2-21: Configure Screen Button
The Configuration screen appears. (Refer to Figure 2-22.)

452501-1EN1
Temperature
Format Rack
Selection Configuration
MB
Configuration
Figure 2-22: Configuration Screen
7. Click the Checkbox button to select the desired temperature format (for
example, 37.0 or 37,0).
Note: This only changes the temperature format and not the temperature.
8. Select the racks installed in the instrument.

9. If applicable, select MB to designate the unit as an MB unit.
11. If the system is configured for MB (Mycobacteria), refer to Section 6.3 for
instructions on how to convert the hardware for MB testing.
2.7.4 Configuring the Instrument

The Instrument Configuration screen contains the settings that can be changed that
are related to the functionality of the main instrument.
IMPORTANT: In this screen, boundary checking is not done on fields that have numerical
entries. Therefore, it is possible to enter out-of-range values.
To configure the instrument:
1. From the Setup and Configuration screen, click the Configure Instrument
Screen button. (Refer to Figure 2-17.)
Figure 2-23: Configure Instrument Screen Button
The Instrument Configuration screen appears. (Refer to Figure 2-24.)

452501-1EN1
Figure 2-24: Instrument Configuration Screen
2. Configure the following settings (input values in seconds):
Printer Installs the Printer Icons (Select or SelectLink)
Disable Auto Backups Manual Backups only
Positive Reminder Period (Sec) Alarms until the Positive bottle is removed. Set
the value to 0 and the alarm will not sound after it
is shut off for the first time.
Idle Logout Timeout (Sec) Do not set this value to less than 60 seconds.
IMPORTANT: The remaining items can be configured; however, bioMérieux recommends

using the default settings.
3. Click the Check button to save settings.
Note: If the printer is enabled, restart the software for this update to take effect.
2.7.5 Setting User Preferences

The User Preferences screen contains the user-defined fields that you can select
during installation.
Note: Consult with the customer to verify user preferences.
To set user preferences:
1. From the Setup and Configuration screen, click the User Preferences button.

452501-1EN1
Figure 2-25: User Preferences Button
The User Preferences screen appears. (Refer to Figure 2-26.)
Figure 2-26: User Preferences Screen
Note: If you select the wrong option, click the Checkbox button again to deselect.
2. Select the following options for the Bottle ID:

• Required — If selected, disables Anonymous Loading.
• First Char Alpha — If selected, the first character of the bottle ID can be A –
Z or a – z. If not selected, the first character of bottle ID cannot be A – Z or
a – z.
• First Char Numeric — If selected, the first character of the bottle ID can be
0 – 9. If not selected, the first character of the bottle ID cannot be 0 – 9.
• First Char Other — If selected, the first character of the bottle ID can be
anything other than alpha or numeric.
• Alert If Generic — If selected, the audible alarm continuously sounds
whenever the Main screen is in the load or unload mode and the bottle type
wheel is set to GENERIC (for example, because the operator has scanned a
generic bottle ID label, or they have manually changed to the bottle type to
GENERIC).
3. Enable (or disable) 21CFR11 mode (see Logging In for the First Time —
21 CFR Part 11 Mode on page 2-28, or the current BacT/ALERT® 3D 60 User
Manual).
If 21 CFR Part 11 mode is enabled, the user needs to enter a user name and
password to log into the instrument. When logged in, the user has full access to

452501-1EN1
the functionality available, similar to how the instrument operates while not in
21 CFR Part 11 mode.
If 21 CFR Part 11 mode is enabled and in a logged-off state (user is not logged
on), the user has limited access to the instrument’s functions. The following
activities can be performed while logged out of the instrument software:
• view error status

• view the bottle count table status
• hear and clear audible alarms
• view screen color changes when a bottle turns positive.
IMPORTANT: Do not select Login Via DBMS mode.
4. Select the following options for the Accession Number:

• Required — This option may be left blank. If selected, the user must enter
data in the Accession Number field when loading bottles.
• First Char Alpha — If selected, the first character of accession can be A – Z
or a – z. If not selected, the first character of accession cannot be A – Z or
a – z.
• First Char Numeric — If selected, the first character of accession can be
0 – 9. If not selected, the first character of accession cannot be 0 – 9.
• First Char Other — If selected, the first character of accession can be
anything other than alpha or numeric.
• Available — If selected, the Accession Number field is enabled. If not
selected, the Accession Number field is disabled. If Select or SelectLink
(LIS) is configured and Lifetime is greater than 0, the Accession Number
field is enabled.
• Force Uppercase — If selected, the accession number entered by the user,
received from the DBMS, or received from the LIS, will be forced to
uppercase. If not selected, the accession number is not forced to uppercase.
• Minimum Length — Enter a number greater than zero if the user requires a
minimum number of characters allowed in the Accession Number field (for
example, if the user requires a minimum of four characters, enter the number
4). Enter a 0 if there is no minimum required.
• Maximum Length — Enter a number greater than zero if the user requires a
maximum number of characters allowed in the Accession Number field (for
example, if the user requires a maximum of 10 characters, enter the number
10). Enter a 0 if there is no maximum required.
Note: Minimum and maximum length only apply to accession numbers entered using the
barcode reader. Accession numbers that are entered manually are not limited to these
settings.
• Lifetime (Days) — Lifetime determines the length of time (in days) after an
accession number may be reused. If a zero (0) is entered, then the accession
number is considered unique. If a database management system is
connected, the Lifetime setting is ignored. If a number is entered, both the

452501-1EN1
Accession Number and Hospital ID fields are automatically enabled

regardless of the accession number and hospital ID settings.
Note: The Lifetime field only accepts integer values in days (for example, 4 or 5). It does not
accept fractional values (for example, 4.5).
5. Select the following options for the Hospital ID Number:

• Required — This option may be left blank. If selected, the user must enter
data in the Hospital ID field when loading bottles.
• Available— If selected, the Hospital ID field is enabled. If not selected, the
Hospital ID field is disabled. If Select or SelectLink (LIS) is configured and
Lifetime is greater than 0, the Hospital ID field is enabled.
• Force Uppercase — If selected, the hospital ID entered by the user, received
from the DBMS, or received from the LIS, will be forced to uppercase. If not
selected, the hospital ID is not forced to uppercase.
6. Select the following options for the Patient Name:
• Available — If selected, Patient First Name and Patient Last Name fields
are enabled. If not selected, the Patient First Name and Patient Last Name
fields disabled.
• Force Uppercase — If selected, the patient name (first and/or last) entered
by the user, received from the DBMS, or received from the LIS, will be forced
to uppercase. If not selected, the patient name (first and/or last) is not forced
to uppercase.
• Last Name Required — If not selected, the Patient Last Name field may be
left blank. If selected, the user must enter data in the Patient Last Name field
when loading bottles.
• First Name Required — If not selected, the Patient First Name field may be
left blank. If selected, the user must enter data in the Patient First Name field
when loading bottles.
• Last Name First — If selected, the last name will appear first in the data field.
If not selected, the last name will appear last in the data field.
2.7.6 Configuring the LIS
Note: This procedure applies to the SelectLink configuration only.
To configure the LIS:
1. From the Setup and Configuration screen, click the LIS Configuration button.
Figure 2-27: LIS Configuration Button
The LIS Configuration screen appears. (Refer to Figure 2-28.)

452501-1EN1
Figure 2-28: LIS Configuration Screen
Note: The values for this screen depend on how the LIS is configured.
2. Select the following options using the Line Scroll Up/Down buttons.
Default Setting Available Setting
BAUD Rate 2400 2400, 4800, 9600, or 19200 Connection
1 Stop Bit 1 or 2 Stop Bits
No Parity No Parity = No Parity Bit

Even = Even Parity
Odd = Odd Parity
8 Data Bits 7 or 8 bits per character
3. Click the Checkbox button next to the following desired options to select.
Note: If you select the wrong option, click the Checkbox button again to deselect.
• Bidirectional Link — If selected, the LIS connection supports data

transmission in both directions. If not selected, the LIS connection only
supports data transmission from the LIS to the 3D.
• Auto Transmits Results — If selected, test results are automatically sent to
the LIS when they occur or whenever LIS polls for test results. If not selected,
test results are only sent when polled by the LIS.
Note: If the bidirectional setting is not selected, then this setting is ignored and results are
not sent to the LIS.

452501-1EN1
• Result On Load — If selected, results will be sent to the LIS when the bottle
is loaded. If not selected, this feature is disabled. Auto Transmit Results
must be selected for this feature to work.
• Result On Unload — If selected, results will be sent to the LIS when the
bottle is unloaded. If not selected, this feature is disabled. Auto Transmit
Results must be selected for this feature to work.
• Result On Negative — If selected, results will be sent to the LIS when the
bottle test result changes from non-negative to negative, or vice versa. If not
selected, this feature is disabled. Auto Transmit Results must be selected
for this feature to work.
• Result On Positive — If selected, results will be sent to the LIS when the
bottle test result changes from non-positive to positive, or vice versa. If not
selected, this feature is disabled. Auto Transmit Results must be selected
for this feature to work.
• Test Order Poll Period (Sec) — Enter a number greater than zero to
periodically poll LIS for test orders, where this value defines the period in
seconds. (For example, a value of 3600 would cause the
BacT/ALERT® 3D 60 to poll for test orders every hour.) Enter a 0 if the user
does not want the BacT/ALERT® 3D 60 to periodically poll the LIS for test
orders.
Note: If the bidirectional setting is not selected, then this setting is ignored and results are
not sent to the LIS.
• Test Link Period (Sec) — Enter a value in seconds to enable this feature so
that when there is a lull in events that require communication with the LIS, a
test message is sent. The value specifies the polling period in seconds. Enter
a 0 to disable this feature.
5. Click the Check button to exit the Setup and Configuration screen. (Refer to
Figure 2-17.)
If changes were made to the Baud Rate, Stop Bit, Parity, or Data Bits, the
software will exit to the C:\ prompt.
6. At the C:\ prompt, press Ctrl + Alt + Delete to reboot the software.
2.7.7 Activate Industry Bottle Barcodes
IMPORTANT: The bottle barcodes for i FA, i FN, and i PF must be activated. Failure to comply
may result in a “generic” algorithm when these bottle types are loaded and not
recognized.
1. Activate the Industry bottle barcodes. (Refer to the BacT/ALERT® 3D i FA,

BacT/ALERT® 3D i FN, and BacT/ALERT® 3D i PF Bottle Barcode Activation
Instructions.)

452501-1EN1
Calibrating the Instrument Cells System Setup
2.7.8 Checking for Disabled Components

To check for a disabled rack or individual cells within a rack:
1. Verify that each component is enabled by viewing the Main screen. Any
disabled component will be displayed by gray “hash marks” denoting the
disabled rack or individual cells within the rack. Use the Enable/Disable Rack,
and Cell screen to enable each component.
2. Indicate that instrument configuration is completed on the BacT/ALERT® 3D 60
2.7.9 Checking for Errors

1. Ensure that no error codes are displayed on the Main screen.
2. Indicate that there are no errors on the BacT/ALERT® 3D 60 Installation
2.8 Calibrating the Instrument Cells
The software will indicate or “flag” any cells that have cell flag readings that vary more
than ± 1.5% from the initial factory calibration. Recalibrate the flagged cells as
required.
To calibrate the instrument cells:
Next Screen
Button

452501-1EN1
System Setup Calibrating the Instrument Cells
Key Symbol
Button
Figure 2-30: Setup Screen with Field Engineer Password Activation
4. Click the Key Symbol button.

5. Click 1.0 Inc Module located on the left side of the screen.
6. Click 1.7 Flag Check located on the right side of the screen.
7. Click the Next Screen button.
Figure 2-31: Next Screen Button
8. Record all cells with a value greater than 1.5%.

9. Press C on the keyboard to start calibration.
10. Configure the display to reflect the cell requiring calibration. Recalibrate every
cell that has a value greater than 1.5%. Repeat as required.
Monitor the temperature on the system. If the temperature alarms appear, close
the door for 30 minutes or until all the alarms disappear and the temperature is
stable.
11. Indicate that the cells are calibrated on the BacT/ALERT® 3D 60 Installation

452501-1EN1
Logging In for the First Time — 21 CFR Part 11 Mode System Setup
2.9 Logging In for the First Time — 21 CFR Part 11 Mode
When 21 CFR Part 11 mode is enabled, users are required to enter a user name and
password.
While logged out of the instrument in 21 CFR Part 11 mode, the Main screen is
displayed with the Login button. (Refer to Figure 2-32.)
Login
Button
Figure 2-32: Main Screen While Logged Out — 21 CFR Part 11 Mode
To log in for the first time:
1. From the Main screen, click the Login button. (Refer to Figure 2-33.)
Figure 2-33: Login Button

452501-1EN1
System Setup Logging In for the First Time — 21 CFR Part 11 Mode
The User Login screen appears. (Refer to Figure 2-34.)
User Name
Password Check
Button
Cancel
Button
Change
Password
Previous Button
Screen
Button
Figure 2-34: 21 CFR Part 11 User Login Screen
When 21 CFR Part 11 mode is first activated, there are no valid users in the
system. The customer may use the User Name setup and the Password setup.
Once there is at least one user added, the User Name (setup) is no longer
valid.
Note: Field Service Engineers may use the User Name service and the Password
biomerieux3d. The User Name (service) is always valid. Do not provide the service
User Name or Password to customers.
Note: Passwords are case-sensitive.
2. Click the User Name field (field turns white) and enter service.
3. Click the Password field (field turns white) and enter biomerieux3d.
4. Click the Check button to log in.
5. At the Main screen, click the Next Screen button. (Refer to Figure 2-35.)

452501-1EN1
Logging In for the First Time — 21 CFR Part 11 Mode System Setup
Next Screen
Button
Key Symbol
Button
Configure
Users
Button
7. Enter the Field Engineer password 43432121.

9. Click the Configure Users button.
Note: The Configure Users button is only active when the instrument is configured for
10. Verify the User Configuration screen appears. (Refer to Figure 2-37.)

452501-1EN1
System Setup Logging In for the First Time — 21 CFR Part 11 Mode
Add User
Previous
Screen Check
Button Button
Figure 2-37: User Configuration Screen
11. Click the Add User button.

12. Verify the Add User screen appears.
User Name
Field
Add User
Button User
List
Previous
Screen Check
Button Button
Figure 2-38: Add User Screen
13. Enter the user name in the User Name field.

15. Click the Check button to save.
16. Verify the user name appears in the user list.

452501-1EN1
Functional Testing System Setup
Add User
Button User
List
Previous
Screen Check
Button Button
Figure 2-39: Add User Screen with User Name Added
17. Repeat Step 11 through Step 16 to add additional users.

18. When all users have been added, click the Previous Screen button until the
Main screen appears.
19. Instructions on how to delete a user or multiple users and how to clear a user
password or multiple user passwords can be found in Chapter 4 in Section 4.9,
Configuring Users — 21 CFR Part 11 Mode.
2.10 Functional Testing
2.10.1 Configuring the BacT/ALERT® 3D 60 Modem

Once you have completed setup and configuration of the instrument, you must
configure the modem and perform a modem functional test. Refer to Section 2.10.2 to
perform the Modem Functional Test Procedure.
Perform the following steps:
1. Connect a phone cable from the wall jack to the TELCO port of the 3D External
Modem. (Refer to Figure 2-40.)
2. Connect a phone cable from the 3D External Modem PHONE port to a
telephone, if available.
3. Connect the serial cable from the 3D External Modem to the
BacT/ALERT® 3D 60 system.
4. Adjust the switch setting on the 3D External Modem so that SWITCHES 3 and 8
are in the down position.
5. Connect AC power to the 3D External Modem.

452501-1EN1
System Setup Functional Testing
Figure 2-40: BacT/ALERT® 3D 60 Modem Configuration
2.10.2 Modem Functional Test

1. Establish a modem connection to verify function. This can be performed using
the Field Service Engineer’s laptop computer or through bioMérieux Support
Services.
2. Indicate that the modem configuration and functional test is complete on the
2.10.3 Barcode Reader Functional Test

1. From the Main screen, click the Load Bottle button.
The Load Bottle screen appears.
2. Scan a bottle ID and verify the scanned ID.

3. Click the Done button to exit the Load Bottle mode and return to the Main
screen.
4. Indicate that the Barcode Reader Functional Test is complete on the

452501-1EN1
2.10.4 Verifying Plastic Bottle Algorithms

Perform the following steps to verify that the plastic bottle algorithms are correct:
1. From the Main screen, press Ctrl + D.

2. Press the 6 key on the keyboard.
The Diagnostic screen appears.
Figure 2-41: Diagnostic Screen
3. Click the Line scroll up button to view the algorithms listed in Table 2-4.
Figure 2-42: Line Scroll Up Button
Table 2-4: Plastic Algorithms
Algorithm Code Sensor Bottle Type
11 LES/Plastic BacT/ALERT SA
12 LES/Plastic BacT/ALERT SN
13 LES/Plastic BacT/ALERT FA
14 LES/Plastic BacT/ALERT FN
15 LES/Plastic BacT/ALERT PF
17 LES/Plastic BacT/ALERT MP
50 LES/Plastic BacT/ALERT iAST
51 LES/Plastic BacT/ALERT iNST
52 LES/Plastic BacT/ALERT iLYM

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Table 2-4: Plastic Algorithms (Continued)
Algorithm Code Sensor Bottle Type
53 LES/Plastic BacT/ALERT BPA
54 LES/Plastic BacT/ALERT BPN
55 LES/Plastic BacT/ALERT iFA
56 LES/Plastic BacT/ALERT iFN
57 LES/Plastic BacT/ALERT iPF
4. Verify that the algorithms are set to plastic.

The algorithms should appear as shown in Figure 2-43.
Figure 2-43: Plastic Bottle Algorithms
5. Perform the following Scanning Plastic Bottle Barcodes procedure for any
bottles that are not set to plastic.
6. Indicate that the plastic bottle algorithms were verified on the
2.10.4.1 Scanning Plastic Bottle Barcodes
To ensure that the algorithm for plastic bottles is used by the BacT/ALERT® 3D 60
instrument, each bottle type must be scanned.
Note: If the barcode reader does not scan the printout, then type the bottle ID below the
barcode.
Note: Do not load any bottles.
1. From the Main screen, click the Load Bottles button.

The Load Mode screen appears.
2. Scan the first barcode shown in Figure 2-44.

After the barcode is scanned, the Accession Number field is highlighted.
3. Click the Bottle ID field to highlight.

452501-1EN1
The Bottle ID field is highlighted, and the Accession Number field is no longer
highlighted.
CAUTION: Before scanning the next barcode, ensure the Accession

Number field is no longer highlighted. The bottle ID must be scanned
into the Bottle ID field.
4. Repeat Step 2 and Step 3 for each of the eight remaining barcodes shown in
Figure 2-44.
5. Click the Check button to exit the Load Mode screen.
6. Repeat Verifying Plastic Bottle Algorithms on page 2-34 to verify that all plastic
algorithms are correct.

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Plastic SA Bottle
Plastic SN Bottle
Plastic FA Bottle
Plastic FN Bottle
Plastic PF Bottle
Plastic iAST Bottle
Plastic iNST Bottle
Plastic iLYM Bottle
Plastic MP Bottle
Plastic BPA Bottle
Plastic BPN Bottle
Plastic iFA Bottle
Plastic iFN Bottle
Plastic iPF Bottle
Figure 2-44: Plastic Barcodes

452501-1EN1
2.10.5 UPS Functional Test (APC UPS)


3. Click the Backup Management button.
Figure 2-45: Backup Management Button
The Backup Management screen overlays and disables the Setup screen.
4. Click the Manual Backup button to initiate an immediate backup.
Figure 2-46: Manual Backup Button
5. Click the Previous Screen button to return to the Main screen and verify the
backup is running.
The Backup In Progress icon will appear in the upper left corner of the Backup
Management and Main screens. The icon will disappear every 5 seconds for
half a second. Allow 15–30 minutes for the backup to complete.
Figure 2-47: Backup In Progress Icon
6. Remove AC power from the UPS by removing the UPS AC power cord from the
wall outlet. Leave the UPS connected to the instrument and leave the power
switch set to On.
7. While waiting for 1 minute, verify that the UPS emits an audible alarm.
8. Verify that the blue Abnormal Shutdown screen appears on the instrument
monitor screen.
9. Verify that the instrument powers down.
10. After the instrument powers off, restore power to the UPS.
11. Verify that the instrument retains the correct time and has no visible errors
displayed on the monitor screen.

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12. Indicate that the UPS Functional Test is complete on the BacT/ALERT® 3D 60
2.10.6 Installing the Printer

Approved printers for the BacT/ALERT® 3D 60 are the HP® 1320, Lexmark E352dn,
and Lexmark E360dn printers.
1. Unpack and set up the printer according to the printer instructions.

2. Connect the Parallel cable into the PRINTER port on the BacT/ALERT® 3D 60
system.
3. Connect the power cord to the AC power outlet. Do not plug into the UPS.
CAUTION: Do not plug the printer into the UPS. The current draw for the
heating element in the printer will overload most uninterruptible power
supplies.
4. Enable the Printer in the software. (Refer to Section 2.7.4, Configuring the
Instrument on page 2-19.)
5. Restart the BacT/ALERT® 3D 60 software to activate the printer setting.
6. Run any report to test the printer.
7. Indicate that the printer is installed on the BacT/ALERT® 3D 60 Installation

452501-1EN1

452501-1EN1
Chapter 3: Instrument Components
About this Chapter
This chapter describes the BacT/ALERT® 3D 60 and the major components.
Chapter Contents
3.1 Equipment Description • 3-3

3.2 Assembly Descriptions • 3-3
3.3 Module Components • 3-5
3.3.1 DC Power Supply • 3-5
3.3.2 Electronics Compartment • 3-6
3.3.2.1 CPU PCBA • 3-6
3.3.2.2 Quad Serial PCBA • 3-7
3.3.2.3 ModSig PCBA • 3-8
3.3.2.4 Step-5 PCBA • 3-11
3.3.2.5 Zip® Drive • 3-15
3.3.2.6 Compact Flash Disk • 3-15
3.3.2.7 Compact Flash Adapter PCBA • 3-16
3.3.3 Chassis-mounted Components • 3-17
3.3.3.1 Power Panel Assembly • 3-17
3.3.3.2 Transformer • 3-18
3.3.3.3 Heater • 3-18
3.3.3.4 Blower • 3-18
3.3.3.5 Step-5 Motor • 3-18
3.3.3.6 Fan Assembly • 3-19
3.3.3.7 Thermistor PCBA (Inlet/Outlet) • 3-19
3.3.4 Incubation Chamber • 3-20
3.3.4.1 Rack • 3-20
3.3.4.2 Cell • 3-20
3.3.4.3 Cell Flag • 3-20
3.3.4.4 Cell Indicator Lamp • 3-20
3.3.4.5 Rack Controller PCBA • 3-21
3.4 Power Supply Assembly • 3-25
3.5 Input/Output Devices • 3-28
3.5.1 56K Fax Modem (Domestic) • 3-28
3.5.2 56K Fax Modem (International) • 3-28
3.5.3 Uninterruptible Power Supply • 3-28
3.6 Display Configuration Screens • 3-30
3.6.1 Operator Panel Screens • 3-30
3.6.1.1 Configuration Screen • 3-30
3.6.1.2 Access the Configuration Screen • 3-31
3.6.2 Configuration Screen Checkboxes • 3-32
3.7 Diagnostic Test Screens, Buttons, and Values • 3-32
3.7.1 Diagnostic Buttons • 3-33
3.7.2 Diagnostic Screens Overview • 3-38
3.7.3 Incubator Diagnostic Values • 3-40

452501-1EN1
Instrument Components
3.7.3.1 Loopback Method • 3-40

3.7.3.2 Port Stats • 3-42
3.7.3.3 Message Stats • 3-43
3.7.3.4 Message Log • 3-44
3.7.3.5 Temperature Log • 3-45
3.7.3.6 Reading Log • 3-46
3.7.3.7 Flag Check • 3-47
3.7.3.8 Drawer/Heater • 3-49
3.7.3.9 LED Check • 3-49
3.7.4 Controller Module Diagnostic Values • 3-51
3.7.4.1 Zip® Drive Test • 3-51
3.7.4.2 Barcode Loopback • 3-51
3.7.4.3 Modem Loopback • 3-53
3.7.4.4 Power Event Log • 3-54
3.7.4.5 View Files • 3-55
3.7.4.6 View Files / .BID Files • 3-55
3.7.4.7 View Files / .BTF Files • 3-55
3.7.4.8 View Files / .APF Files • 3-55
3.7.4.9 View Files / .LOG Files • 3-55
3.7.4.10 Software • 3-60
3.7.4.11 Software / Debug • 3-61
3.7.4.12 Software / Software Exception Log • 3-62
3.7.4.13 Software / Operating System Exception Log • 3-62
3.7.4.14 Software / Modem Activity Log • 3-62
3.7.4.15 Software / Association Tables • 3-62
3.7.4.16 Software / Bottle Processing Tables • 3-63
3.7.4.17 Software / Audit Trail • 3-81
3.7.4.18 Software / Configuration • 3-83
3.7.5 LIS Module Diagnostic Values • 3-83
3.7.5.1 Loopback • 3-83
3.7.5.2 Port Stats • 3-85
3.7.5.3 Message Stats • 3-87
3.7.5.4 Message Log • 3-87
3.7.6 Scandisk Output • 3-88
3.8 Using the Keyboard in Place of the Mouse • 3-93
3.9 Special Function Keys • 3-94
3.10 Quick Reference Card • 3-94

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Instrument Components Equipment Description
3.1 Equipment Description
The BacT/ALERT® 3D 60 instrument is a compact and automated microbial detection

system capable of incubating, agitating, and continuously monitoring specimens
suspected of contamination from bacteremia/fungemia.
The instrument consists of a WinSystems® CPU and one 60-bottle chamber

consisting of three racks of 20 culture bottles each. An externally attached display
monitor permits the operator to control and monitor the racks. (Refer to Figure 3-1.)
Operator Control
Panel (Display)
Incubation Zip® Drive

Chamber
Barcode
Scanner
Printer
UPS
Keyboard
Figure 3-1: BacT/ALERT® 3D 60
3.2 Assembly Descriptions
This section gives a brief description of the assembly's purpose and operation.
• 3D 60 System Control
The Operator Display Monitor and the instrument internal circuitry are the
heart of the system. (Refer to Figure 3-1.) An electronics compartment
houses the internally installed WinSystems® Computer. With the attached
keyboard and barcode scanner, the operator performs all of the controlling,
programming and database management functions from the Operator Display
Monitor.
• Operator Display Monitor

This display monitor is a standard VGA monitor used for displaying diagnostic
and module setup information.
• Barcode Scanner
The barcode scanner scans bottle labels, identifying the bottles whenever
loading or unloading.

452501-1EN1
Assembly Descriptions Instrument Components
• Keyboard
This is a standard-sized 101-key keyboard. It is used as an alternative input
device to the Barcode Scanner or mouse.
• Quick Reference Card

This card identifies specific error codes and outlines instructions regarding
system operation. (Refer to Figure 3-56 and Figure 3-57.)
Note: The following information refers to the rear of the BacT/ALERT® 3D 60 and
specifically the Communications Ports. (Refer to Figure 3-2.)
• COMM Port
This port is reserved for future use.
• Printer Port
A printer connects to this port via a parallel cable and produces hard copy
reports.
Figure 3-2: Comm Ports
• Internal Speaker with External Speaker Jack

The system has a remote speaker feature with a 5mm external mini-jack to
drive two remote stereo speakers from a distance of up to 450 feet.
• Power Entry Module / On-Off Switch

The PEM contains the fuse protection for the unit when connected to main
facility AC power. The PEM also houses the main power switch for the
instrument.
• Modem Port
Used to connect the 3D 60 to an external modem.
• LIS Port
Used for connection to the facility's LIS.
• Monitor Port
Used for connection to an external VGA or SVGA monitor.

452501-1EN1
Instrument Components Module Components
• UPS Port
Used to connect an external UPS to the instrument.
• UPS Serial Port

Reserved for future use.
• Mouse Port
Used for connecting the mouse to the instrument.
• Keyboard Port
Used for connecting the keyboard to the instrument.
• Barcode Scanner Port

Used for connecting the barcode-scanning wand to the instrument.
3.3 Module Components
The BacT/ALERT® 3D 60 uses a WinSystems® internally mounted computer. It is a

small, high-performance computer system on a single board.
It has a real-time, multitasking operating system. A number of I/O options including

VGA, Compact Flash memory disk and high density parallel I/O, are integrated onto
the system. It uses four PC compatible RS-232 serial ports in addition to floppy disk,
hard disk and parallel printer interfaces.
A Zip® drive has been interfaced, allowing for factory supported software upgrades
and system backups. A 16-bit data bus has been provided for add-on peripherals.
The WinSystems® computer supports three separate user input interfaces:
• Operator Display Panel

• Standard-sized 101-key keyboard
• Barcode Scanner
The WinSystems® computer interfaces with all peripheral devices and PCBAs via the
ModSig PCBA and the PC-104 serial card (Quad Serial Interface). The ModSig PCBA
interfaces with each of the Incubation Compartment through the three Rack Controller
PCBAs over a full duplex RS-485 data bus. There are three Rack Controller PCBAs
per 3D 60 Module.
3.3.1 DC Power Supply

The BacT/ALERT® 3D 60 instrument uses a standard BTA cabinet power supply. The
Power Panel Assembly provides the AC and DC power supply voltages that are used
within the 3D 60. With the use of relays, this will also shut down incubation process
when instructed to do so by the ModSig PCBA. The power supply provides the four
separate DC voltages (±5V and ±12V) used throughout the instrument.

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Module Components Instrument Components
3.3.2 Electronics Compartment

The 3D 60 components are contained within the Electronics Compartment. (Refer to
Figure 3-3.) The Electronics Compartment is situated under the top panel of the
3D 60. The Electronics Compartment contains the internal WinSystems® computer
(CPU PCBA, Quad Serial PCBA, Compact Flash Adapter PCBA), Zip® drive, the
ModSig PCBA, and the Step-5 PCBA.
Figure 3-3: Electronics Compartment
3.3.2.1 CPU PCBA
The CPU PCBA is an off-the-shelf internally mounted WinSystems® computer that

combines a 586 (or higher) CPU with Video, Floppy, IDE, Serial and Digital I/O. The
CPU PCBA is a 586 processor with an operating clock speed of 133 MHz. This is the
heart of the system and controls all system operations. (Refer to Figure 3-4 or
Figure 3-5.)
Two different models of the CPU PCBA exist in the field. CPU PCBA (P/N 750-0070-
01) is the older model. CPU PCBA (P/N 750-0070-902) is the newer model. The
newer model functions much as the older model, with the exception of the addition of
a port for the Compact Flash Disk.

452501-1EN1
Figure 3-4: CPU PCBA (Older Model LBC-586 PLUS)
Figure 3-5: CPU PCBA (Newer Model LBC-GX500)
3.3.2.2 Quad Serial PCBA
The Quad Serial Interface (Com4) board is a daughter board that plugs into the
PC/104 bus on the WinSystems® motherboard. (Refer to Figure 3-6.)
There are four ports on the board. Com 1 is configured as a RS-485 port. Com 2, 3,
and 4 are configured as RS-232 ports. Com 1 and Com 2 are located on connector J6,

452501-1EN1
while Com 3 and Com 4 are located on connector J3. All communications ports are
software supported and operate at a 9.6K Baud data rate.
The Quad Serial is a four-channel serial (INS8250 compatible) P/C 104 module that is
based on the 16C554 UART. It is ideally suited for applications running DOS
programs or languages that require exact register compatible hardware for program
execution. Each of the channels supports RS-232, with optional RS-485 and RS-422
electrical levels to interface with a wide variety of serial communications devices.
The Quad Serial PCBA is I/O mapped. Each channel requires eight port addresses
and each is independently decoded within the I/O map. The interrupt status register
also requires one I/O port. The addresses are decoded in the PAL and are jumper-
selectable, with eight different I/O maps. The Com4 card is a 16-bit stack-through card
that supports 8-bit data transfers only.
Figure 3-6: Quad Serial Interface PCBA
3.3.2.3 ModSig PCBA
The MODSIG PCBA provides interfaces to the 3D 60 Instrument Controller section,

the Step-5 board, external peripherals and the Rack PCBAs. (Refer to Figure 3-7.) It
uses a 68HC11 microprocessor with firmware stored in the EPROM. The
microprocessor uses an external 16 MHz crystal for its clock. 32Kbytes of EPROM
and 32Kbytes of static RAM are external, with no internal ROM. There are 512 bytes
of EEPROM and 1024 bytes of RAM, both of which are internal.
A 4.5-volt reference is on the PCBA for A/D reference and a 2.5-volt reference for
temperature control. Power-fail circuitry detects if the +5VDC is out of tolerance.
LED's on the board show E Fan ON, Power-Enable ON, Blower ON, Heater ON,
Agitation ON, +5V ON for ModSig, +5V ON for Step-5 PCBA, +5V ON for Racks, Door
Switches Closed, six status indicators and RS-485 transmit and receive indicators.
Temperature sensors on the board are used for E-Fan control and to report
electronics over-temperature conditions. External input and output temperature
sensors are used by PID control firmware on the microprocessor for incubation
temperature control and are connected to JP1. Heater, blower and fan ON/OFF time

452501-1EN1
control signals connect through a connector at JP2. A 12-bit, 8-channel A to D

converter integrated circuit does conversion from analog values to digital values for
microprocessor use.
The front door has two separate interlock switches. These connect to the MODSIG
PCBA through JP11 and JP12. One switch, which the firmware cannot override,
functions as a safety interlock that disables the heater and blower if the door should
open. The second switch is for logic functions and redundancy. Both switches are
monitored by the firmware and by the Step-5 agitation motor control firmware.
Step-5
PCBA
ModSig
PCBA
Figure 3-7: ModSig PCBA
An instrument ID thumbwheel switch, normally set to 1, is available if there should be

a need to separately identify a 3D 60 at a customer's site.
A Piezo buzzer is provided as an audible alarm. A remote speaker system may be

used, by connecting to J1. The keyboard connects to JP16. A barcode reader
connects to P1 and a mouse connects to P2. A parallel port printer connects to P4. An
LIS is interfaced via P8 and a modem via P9.
CAUTION: Connection of an RS-232 Device into P1, other than a

compatible Barcode Reader, will cause damage to that device.
JP13, JP15, JP17, JP18 and JP19 connect to the Instrument Controller CPU in the
3D 60. JP29 and JP30 are used for transferring serial data signals from the Quad
Serial PCBA. The Serial UPS connector at P7 is for future use. The UPS is controlled

452501-1EN1
through the connector at P5 and must be connected for proper system operation. The
VGA display monitor is connected at P6. Five-volt power is connected to the board at
JP31 and is supplied to the Zip Drive and the Compact Flash Adapter PCBA through
JP21. Control and data signals for the racks are supplied through JP10.
CAUTION: Connection of any RS-232 device into P5, other than a

compatible UPS, will cause damage to that device.
Jumpers on the ModSig PCBA control the audio frequencies supplied to the remote
speakers. The remote speakers control volume. Volume jumpers on the board are for
future use only. Refer to Table 3-1 and Table 3-2 to identify the different jumper
settings and their effect.
Table 3-1: Audio Volume Selection at JP22
VOLUME JUMPER SETTINGS
Lowest 1&2, 5&6
Medium Low 2&3, 5&6
Medium High 1&2, 4&5
Highest 2&3, 4&5
Table 3-2: Audio Frequency Selection at JP23 through JP26
FREQUENCY JP23 JP24 JP25 JP26
600 Hz In In In In
800 Hz In In In Out
1 KHz In In Out Out
1.5 KHz In Out Out Out
3 KHz Out Out Out Out

452501-1EN1
TO Step-5 PCBA
• Door Interlock
Switches
J2 • +5 Power
• Agitate ON
32KB RAM FROM Step-5 PCBA
• Error Signal
68HC11
32KB RAM
• Blower ON
• Heater ON
Heater Inlet/Outlet
Temperature JP1 Drivers JP2 •
•
Agitate ON
E Fan ON
Sensors • Power En ON
A/D 2 Temp Instrument To and From

Drawer A (#1)
Converter Sensors ID Switch Rack PCBA
JP11 •
•
DC Power
Rack ID
Door Interlock Undervoltage/
Switches
Overvoltage
JP10 •
•
Event Request
RS-485
JP12 Detector
• Drawer ID
JP16 PS2 Keyboard

Piezo Buzzer
Oscillator P1 Barcode Port
RS-232 From Driver

CPU JP13 P2 Mouse Port
Keyboard, Parallel Printer

RS-232, Printer JP15 P4 Port
From CPU
Parallel I/O
To/From CPU
JP17 Driver P5 UPS Control
Parallel I/O
To/From CPU JP18
P6 VGA Monitor
RS-232,
RS-485 From JP29 +5V
Quad Serial JP21 Compact Flash
Zip® Drive
RS-232 From
Quad Serial PCBA
JP30
J1 Remote Speaker
+5VDC Power In JP31

P7 Serial UPS
Video From CPU JP19
P8 LIS
P9 Modem
Figure 3-8: ModSig Block Diagram
3.3.2.4 Step-5 PCBA
The Step-5 PCBA is designed to drive a five-phase stepper motor at the speed of 60
revolutions per minute. The board operates with input voltages of +5V and +12V,
drives the stepper motor directly, and provides starting and stopping functions based
on inputs received from the ModSig PCBA.

452501-1EN1
Figure 3-9: Step-5 PCBA
The Step-5 PCBA drives a Vextra 5-phase stepper motor at 1 revolution per second
(+10%) to provide rack agitation. The controller board's inputs, outputs, and features
are listed below.
• Input (DC Voltages): +5V and +12V

• Input (Control)
• Interlocks: Two door switches are used. The two door switches are
mechanical reed switches that are closed when the door is closed. The
Step-5 uses optical isolators for these inputs; when a switch is closed,
current flows through the corresponding optical isolator's LED. If either
switch is open, indicating a door open condition, motor rotation stops.
System design uses open switch position to indicate open door so that
a disconnected switch will also prevent motor operation. LED 55 & 56,
are located on the ModSig PCBA. The LED is on when a switch is
closed.
• Start/Stop signal: The start/stop signal will go high to indicate that the
Step-5 should run the agitation motor. This signal, generated by the
ModSig PCBA goes high to enable agitation. The input signal is
optically isolated on the Step-5.
• Position Sensor: A Hall-Effect sensor is located at the edge of the
Step-5 board and detects the magnet installed in the motor's drive
wheel. Both motor motion and drive wheel position tracking is
performed in the Step-5 board. Also, when the door is opened, the
sensor is used to determine how long to drive the motor so that the
racks become stationary in the correct position. If the position sensor is
not functioning a fault output will be generated. If the position sensor is
not working, the Step-5 will stop the motor when the door is opened, but
the position will be undefined.

452501-1EN1
• Outputs:
A Fault Code is sent to the ModSig PCBA if certain conditions occur. The four
conditions that initiate this code are:
• Motor over current

• Door switch (one door switch indicates open, the other indicates closed)
• Position sensor not changing state
• Safety timer not functioning (does not go high after door opened)
(Also, see Internal Output Codes.)
Motor Output: The PM589 motor is a 5-phase stepper, wired in a pentagon

configuration, 500 steps per revolution in full step mode.
Phase 1
Phase 2
Phase 3
Phase 4
Phase 5
Figure 3-10: Step-5 PCBA Motor Phases
If an over current occurs, the motor will be stopped. The fault signal is
generated by the open-collector of Q16, and goes LOW to indicate a fault. By
design, a disconnected power cable will also result in a fault indication.
• Internal Indicators:
• LED 1 Output Codes:
[1 flash]: Motor stopped OK
[2 flashes]: Motor running OK
[3 flashes]: Motor over current
[4 flashes]: Door switch (one switch open, the other closed)
[5 flashes]: Position sensor not changing state
[6 flashes]: Safety timer not functioning (does not go high after door
opened)
[7 flashes]: Motor power bad (12VDC)
Note: LED 1 on the Step-5 PCBA constantly outputs one of the above codes. To interpret
the code, count the number of longer flashes (LED on periods) after the short start
flash.
• Redundant door timer: The Step-5 includes a timer, independent of the

microcontroller. It disables the stepper motor after the door is opened
and some delay has elapsed.

452501-1EN1
The redundant door timer consists of an oscillator clocking a pair of 14-

bit counters, which are wired to result in a 28-bit binary divider. The
counters are continuously reset as long as both doors are closed. If
either door interlock opens, the timers are allowed to run. Either of two
outputs from the high-order counter may be selected by installing a
zero-ohm resistor on the board. The selected output is applied to the
PLD that drives the low-side motor transistors. When the output goes
high, the drive transistors are disabled, regardless of the state of the
microcontroller outputs.
The redundant timer is included to preclude the possibility that some
undefined failure of the microcontroller would leave the motor running
after the door is open. The timer delay is selected to insure that, under
normal conditions, the microcontroller has time to stop the motor
normally before the delay expires. Once the delay expires, the PLD
inhibits the clock to the high-order counter to prevent the delay output
from cycling. Delay values are selected as described below (output
selected is denoted as IC outputs are labeled on schematic): The door
timer output is monitored by the microcontroller, which generates a fault
output after some delay if the door is open and the timer output does
not go high.
• Motor Voltage Fault: If the motor supply voltage goes off, the microcontroller will
turn off motor drive until the motor supply is restored.
• Power Up Protection: The high side predriver transistors require that the 16C74
source current to turn them on. On power up, the I/O port pins of the 16C74
initialize inputs with no pull-ups. This prevents cross-conduction between the high
and low side MOSFETS. In addition, as part of firmware initialization, the PLD that
controls the low-side drivers does not enable any outputs until PD7 is driven high.
• Power Down Protection: The configuration bits for the 16F74 will enable the
brownout protection that resets the microcontroller if the supply drops below
approximately 4V.
• Crossover Protection: While running, the Step-5 uses a stepping sequence that
never switches a motor phase from high to low or low to high. All motor phases go
through a step where the phase is off (neither the high or low side driver is on)
between high and low transitions. If this sequence is changed (for instance, if the
board is ever used to drive a 4-phase stepper), then crossover protection will
need to be added to the firmware.
• Temperature Sensor: The printed circuit board and schematic provide for a
temperature sensor. This part is not installed in the current version of the board.
• Firmware: Firmware is developed in Microchip PIC assembly language. Firmware
performs the following functions:
• Debounce interlock switches
• Turn motor driver transistors on and off to generate motor drive
waveform
• Ramp motor up and down
• Control motor current during ramp up and ramp down using PWM duty
cycle
• Track position of motor using position sensor as 'home' position
• Monitor motor current for over current condition

452501-1EN1
• Program microcontroller hardware to generate PWM clock

• When door open, monitor safety timeout circuit for proper operation
• Stop driving motor if 12V motor supply goes off
• Generate fault outputs
The firmware defines seven states for the stepper motor:
• Stopped
• Ramping up
• Holding (constant speed)
• Seeking (waiting for position count to reach ramp down point)
• Ramping down
• Fault (over current)
• Motor power bad
Independent
Safety Timer
Interlocks
PLD
Microchip
Position PIC16C74
Sensor Drive Motor
MOSFETS
Stop/Start
Command
(From ModSig High-side
PCBA) Predrivers
DC In Fault
Output
Figure 3-11: Step-5 PCBA Block Diagram
3.3.2.5 Zip® Drive
This drive provides an internal resource for loading new operating system software
and performing system data backup. (Refer to Figure 3-1.)
3.3.2.6 Compact Flash Disk
The Compact Flash Disk is a removable mass storage device installed on the
Compact Flash Adapter PCBA or the CPU PCBA. It is a device about the size of a
matchbook and weighs about one-half ounce. Since it is a solid state device utilizing
flash memory, it contains no moving parts and requires no battery for data retention.
The Compact Flash Disk is compatible with IDE/ATAPI standards and serves as the

452501-1EN1
C drive in the BacT/ALERT® application, where it holds the operating program, bottle
records, system configurations, event log files, and miscellaneous other information
needed for BacT/ALERT® operation. (Refer to Figure 3-12.)
Figure 3-12: Compact Flash Disk (Example Only, Actual Part May Vary)
3.3.2.7 Compact Flash Adapter PCBA
The PCM-CFLASH PCBA is a PC/104 compatible adapter module designed

specifically to adapt Compact Flash Disk for use in the older LBC-586 CPU systems in
BacT/ALERT® 3D Controller Module, BacT/ALERT® 3D Combination Module, and
BacT/ALERT® 3D 60. (Refer to Figure 3-13.) The adapter provides for master/slave
selection and a visual drive status indicator.
The Compact Flash Adapter PCBA (with Compact Flash Disk installed) is mounted
near the WinSystems® motherboard. It is connected by a flat ribbon cable to the
motherboard's IDE port.
The Compact Flash Disk stores the operating system, BacT/ALERT® 3D 60 firmware,
instrument configurations, operator settings, layout of the instrument pictorial, along
with bottle record NVRAM data. On 3D 60 Modules that have been upgraded to CPU
PCBA (P/N 750-0070-902), the Compact Flash Adapter PCBA is removed and the
Compact Flash Disk is installed in a port on the underside of the CPU PCBA.

452501-1EN1
Figure 3-13: Compact Flash Adapter PCBA
3.3.3 Chassis-mounted Components
3.3.3.1 Power Panel Assembly
The BacT/ALERT® 3D 60 instrument uses a standard BTA cabinet power supply. The
Power Panel Assembly provides the AC and DC power supply voltages that are used
within the 3D 60. With the use of relays, this will also shut down incubation processes
when instructed to do so by the ModSig PCBA. The power supply provides the four
separate DC voltages (+ 5V and ±12V) used throughout the instrument. (Refer to
Figure 3-14.)
Solid State
Relays
DC Power
Supply
Transformer
Figure 3-14: Power Panel Assembly with Transformer

452501-1EN1
3.3.3.2 Transformer
The transformer isolates the instrument from facility power and is installed on the
Power Panel. (Refer to Figure 3-14.)
3.3.3.3 Heater
The heater provides the necessary heat for the incubation process of cultures. (Refer
to Figure 3-15.)
Blower
Heater Coil
Blower Motor
Capacitor
Figure 3-15: Heater/Blower Assembly
3.3.3.4 Blower
For the incubation process, the blower circulates heat (produced by the heater)
throughout the module. (Refer to Figure 3-15.) The blower stops any time the door is
opened and will start again when the door is closed.
3.3.3.5 Step-5 Motor
The Step-5 Motor provides agitation to the racks, unless the drawer has been
converted to MB. (Refer to Figure 3-16.) If all three racks are converted to MYCO
(MB), the motor is disconnected to bypass this process. (Refer to Section 6.3.)
Step-5
Motor
Figure 3-16: Agitation Motor

452501-1EN1
3.3.3.6 Fan Assembly
A fan circulates air over the electronic components within the Electronics
Compartment to help prevent overheating. (Refer to Figure 3-17.)
Fan Assembly
Figure 3-17: Internal Fan Assembly
3.3.3.7 Thermistor PCBA (Inlet/Outlet)
The Thermistor board uses an Analog device AD592BN temperature transducer to

produce a current flow proportional to temperature. The voltage source is +9VDC.
The temperature transducer has a nominal flow of 298.2µa+ 25ºC.
There are two Thermistors PCBAs in the 3D 60 instrument. The Inlet and Outlet
Thermistors measure input and output air temperature, respectively. The Inlet and
Outlet temperature readings are averaged together to comprise the Incubation
Chamber's temperature used by the temperature control logic.
Figure 3-18: Thermistor PCBA

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3.3.4 Incubation Chamber

The Incubation Chamber contains three specimen racks, rack controller PCBAs, and
the Digital Reference Thermometer. As viewed by the operator, the bottles are loaded
into the front of the 3D 60 instrument. (Refer to Figure 3-19.)
Figure 3-19: Incubation Chamber
3.3.4.1 Rack
Each rack contains 20 bottle cells. Unless the instrument is designated as an MB unit,
the racks are continuously rocked (to provide agitation for the specimen bottles). Also,
three fascia plates identify the bottle locations and are not interchangeable between
replacement racks.
3.3.4.2 Cell
There are 60 cells per instrument, with cells identified as 1 through 20 in the first (top)
rack, 21 through 40 in the middle rack and 41 through 60 in the bottom rack.
3.3.4.3 Cell Flag
The cell flag serves as a clip securing the bottles into their cells. The cell flag is also a
key component in bottle detection and cell diagnostics.
3.3.4.4 Cell Indicator Lamp
A lamp is located next to each cell and provides feedback to the operator. Depending
on the function selected by the operator, illuminated lamps identify the positions of
positive or negative bottles, cells that can be loaded, etc.

452501-1EN1
3.3.4.5 Rack Controller PCBA
The Rack Controller PCBA, using EPROM-stored software, controls the excitation
LEDs. (Refer to Figure 3-20.) The LED light illuminates and reflects on the bottle
sensors, creating emitted measurable values at the photo detectors. The Rack
Controller digitizes each cell's photo-detector output for reading by the ModSig's
Control Module and for bottle presence detection.
Cell indicator LEDs are controlled for operator information. Status and data are
communicated through an RS-485 cable from the Rack Controller to the ModSig
board. The microprocessor software also monitors the bottle rack rocking motion with
a "Hall-Effect" sensor. In addition, the software normalizes illumination readings with
cell and temperature calibration factors. Address lines from the ModSig are used to
confirm that the 3D 60's WinSystems® CPU board is addressing the correct Rack
Controller thus eliminating the need for switches on each Rack Controller. Calibration
values are stored onboard the Rack Controller PCBA in a non-volatile RAM (NVRAM).
The Rack Controller PCBA is located in the rear portion of the rack channel of the
Incubation Chamber. A fully implemented Incubation Chamber will have three Rack
Controller PCBAs.
The microprocessor is the Motorola 68HC11 and the same used on the ModSig
PCBA. This microprocessor has separate 16-bit address and 8-bit data lines defined.
This eliminates the need of having external address and data multiplexing for the
external 32KB of RAM and 32KB of EPROM included on the PCBA.
The clock speed of the 68HC11 is set at 16 MHz by an external crystal. Internally, the
microprocessor contains 512 bytes of EPROM, 1024 bytes of RAM, and no ROM.
External memory for the microprocessor is on the Rack Controller PCBA. A 16-bit free
running counter, driven by a programmable prescaler and other divider chains,
provides for a wide range of internal timing periods for software use. Included is a
watchdog timer.
The Rack Controller PCBA uses 32KB of static RAM in a surface mount package.
The software for most dynamic storage uses this memory. The Rack Controller uses
32KB of EPROM for program storage. Jumpers are included to allow the installation of
larger memory, in the event that the 27C256 microprocessor becomes obsolete.
Memory parts with less than 90ns access are required.
There are two 20-pin connector positions on the board. Power (+5 volts for each
board) is supplied through a cable from the ModSig to the JP2 connector. The other
connector, JP1, is cabled to JP2 of the next rack. No other power is required. A fuse
on the ModSig protects the set of three Rack Controllers in the Incubation Chamber.
The +5 volt input voltage produces two reference voltages. A +4.5V reference is
provided to the A-D converter. A +2.5V reference is provided for the Rack temperature
operational amplifiers as well as an accurate current control of the exciter LED's
current by an operational amplifier.

452501-1EN1
Figure 3-20: Rack Controller PCBA
Each cell has one exciter LED. Each of these LEDs is driven by an output from a
74ACT374 driver.
One indicator LED is provided for each bottle holder or cell. Each of the LEDs is driven
by an output from a 74ACT374 driver. In addition, there are four "status" LEDs for
general purpose and are explained in the firmware.

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Agitation 32 KB
Sensor RAM
Cell
68HC11 Microprocessor 32 KB
Sensors OP
w/internal RAM and EPROM RAM
Amp 1-20
Analog
Multiplexer
Drivers Cell
Constant Exciters
Rack 1-20
Temperature Current
Control
Cell
12-Bit Indicators
Reference
A-D 1-20
Voltage
Converter
Drawer ID
RS-485
RCVR/XMTR
Drawer ID Rack ID Output
Event Request
To/From To/From Next
ModSig or Rack Controller
previous Rack
Controller +5V Out
RS-485
+5V In Rack ID
RS-485 Drawer ID
Rack ID Event Request
Event Request Rack ID Out
Rack ID Out
Figure 3-21: Rack Controller Block Diagram
Each cell has an individual external sensor. The sensor outputs are multiplexed to
cascaded operational amplifiers that drive the analog input of an A-D Converter. The
cell sensor readings are sent, on request, to the instrument. The Rack Controller
firmware detects bottle presence from these photodiode sensors as well.
Circuitry is provided to develop the analog signals to the A-D Converter for the two
temperature sensors on the Rack PCBA. These sensors are part of the calibration
factors for the bottle cells.
The agitation sensor is a "Hall-Effect" sensor. The sensor detects bottle rack motion
for a change in magnetic flux from a rare-earth magnet as the rack is agitated. Each
board has a sensor; however, only one position in each drawer is utilized for
monitoring.

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The Event Request signal is a common open drain signal driven by the ModSig PCBA
and all Rack Controller PCBAs. The ModSig, Rack Controller and WinSystems® CPU
board can also read the signal. Its purpose is similar to an interrupt signal; it is to notify
the WinSystems® CPU board that an event such as a bottle removal has occurred.
For the ModSig, this signal is both an output to the WinSystems® CPU board and an
input from the Rack Controller. When the Event Request is pulled low, the Drawer ID
low signal used by the Rack Controllers is disabled. The Rack Controller drives the
Drawer ID lines to indicate which Rack Controller(s) activated the Event Request line.
The Rack Control firmware reads the Event Request line before and after reconfirming
its address, to ensure address lines are not in use.
With only one of four lines low for each drawer, the Rack Controllers can determine
which drawer they are in for each address identification for WinSystems® CPU board
commands. When the Event Request is low, this is disabled; allowing the same lines
to be used by the Rack Controllers to identify which ones activated the Event
Request. The driving circuitry and input circuitry is provided on the Rack Controller.
Firmware on the ModSig aids the WinSystems® CPU board in selecting which Rack
Controllers read status, thus expediting bottle detection state changes.
The ModSig makes only one of the three Rack ID lines low for each rack, and then
polling this line within the Rack PCBAs, the Rack Controllers can determine their
address without having individual address switches. (Refer to Figure 3-22.)
Four outputs from one of the 74ACT374-exciter LED drivers serve as the output
drivers for the Rack ID Out signals, through open-drain inverters.
The communication between the modules is over RS-485 full-duplex circuitry. The
necessary conversion between RS-485 differential signals and single-ended CMOS
compatible serial signals, for use by the software, is contained on the Rack Controller.
The actual RS-485 signals connect to all Rack Controllers through a connector on the
ModSig PCBA.

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Instrument Components Power Supply Assembly
JP10
ModSig
PCBA
+5V
+5V
16
17
18
Polling line
connects via
JP2 on each
Rack PCBA
RACK #1 RACK #2 RACK #3

JP2 JP1 JP2 JP1 JP2 JP1
16 16 16 16 16 16
17 17 17 17 17 17
18 18 18 18 18 18
Rack #1 Address Code Rack #2 Address Code Rack #3 Address Code
Input Pins 18-17-16 Input Pins 18-17-16 Input Pins 18-17-16

Binary 1-1-0 Binary 1-0-1 Binary 0-1-1
Figure 3-22: Rack Address Concept
A 12-bit A-D Converter is provided to convert the rack temperature sensor's analog
signals to the digital signals used by the Rack Controller software. The same A-D
Converter is used for converting cell sensor analog signals into digital signals.
Current for the exciter LEDs is controlled by using the +2.5 VDC reference voltage,
resistor voltage dividers, an operational amplifier, and a MOSFET. Only one exciter
LED is activated at any one time.
3.4 Power Supply Assembly
Input power for the 3D 60 is either 115 VAC or 220 VAC. (Refer to Figure 3-23.) The
installation technician sets the proper voltage selection at the Power Entry Module
(PEM). The circuitry is protected by one 6.3A time-delay 250 VAC fuse (120 VAC
version) or two 5A time-delay 250 VAC fuses (240 VAC version). AC voltage is
coupled across the isolation transformer thus insulating the instrument from facility
power for circuit protection including a 120:120VAC or a 240:120VAC (step-down)
voltage ratio.

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Power Supply Assembly Instrument Components
Facility
Power
UPS
Power
Isolation MOV
Module Transformer
Blower
TB1
Heater
Elec. Comp.
Fan
Common Logic Ground Return 3
+5 VDC DC Power E Fan

CPU PCBA
Supply Relay
-12 VDC
Heater
-12 VDC Relay
Blower
Relays
Power
Enable
ModSig PCBA
Power Panel
+5 VDC GND
Step-5 PCBA
Step-5 Motor
Figure 3-23: Power Distribution Block Diagram
Input power is routed to a metal oxide varistor (MOV) mounted between terminals 2B
and 3B of TB1. The varistor provides inline surge protection for the internal circuitry of
the system. From TB1, power is routed to the fan, DC power supply and all power-
enable relays.
The DC power supply provides the necessary DC voltages on J2 for various sub-units
throughout the 3D 60 instrument. There are three separate voltages: ±12VDC and
+5VDC, with a common DC return providing a logic ground. In addition, the DC power
supply provides a Power Fail signal that is routed to the ModSig PCBA.
The BacT/ALERT 3D 60's power supply is a quad output switcher intended for small
to medium-sized digital systems. These power supplies also contain built-in over-
voltage protection and a power fail detect signal.

452501-1EN1
Instrument Components Power Supply Assembly
Universal input voltage allows these supplies to be powered in any country of the
world without changing any jumpers or individual switch settings. The unit is capable
of supplying the high peak currents necessary to start disk drives and peripheral
devices. An integral filter reduces line-conducted noise below FCC and VDE limit B.
The over-voltage protection circuits are designed to activate at 6.25 VDC (± 0.75
VDC) for 5 VDC output. The power supply has a "Power Fail Detection" circuit that
produces a "power fail detection" (PFD) output. The PFD signal occurs within
milliseconds following an abnormal AC line condition. The delay between the
abnormal AC line condition and the PFD output varies depending on AC line variation
and power supply load.
If this condition is met, the PFD signal will go to a low state within approximately 3ms.
Once the output returns to the +4.75 VDC, the PFD signal will return to a high state in
50ms to 200ms. Table 3-3 and Table 3-4 show the power supply and pin settings.
Table 3-3: Power Supply Data
Parameter Condition Limits
Input Voltage 85–264 VAC
Input Frequency Range 47–440 Hz
Input Surge Current Cold Start, 110 VAC/220 VAC 17A maximum/ 34A maximum
Output Voltage Adjustability 5.1 VDC output (Supply Only) ± 3%
Table 3-4: Pin Chart
P1 AC Ground
J1 P2 AC Neutral
P3 AC Hot
P1 + 5.1 VDC
P2 + 5.1 VDC
P3 + 5.1 VDC
P4 Return
P5 Return
P6 Return
J2 P7 Return
P8 + 12 VDC
P9 + 12 VDC
P10 PFD
P11 - 12 VDC
P12
P13 -5 VDC

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Input/Output Devices Instrument Components
3.5 Input/Output Devices
3.5.1 56K Fax Modem (Domestic)

The fax modem serves as an interface to the 3D 60 instrument for remote access. The
remote user is able to download and upload information, including seeing what is on
the display screen that the local operator views. The Technical Support Center is able
to perform remote diagnostics and other troubleshooting of the instrument.
The modem interfaces the 3D 60 instrument through a connection to the MODEM port
on the rear of the unit. Digital signals are converted to tones by the modem for
sending to the telephone system through the telephone jack connection and to a
remote modem at the receiving end. Conversely, tones from the remote modem are
converted to digital signals and sent to the instrument through the MODEM port.
Power for the modem is supplied by a wall-mounted power supply that supplies low
voltage required by the modem. The wall-mounted power supply plugs directly into a
standard electrical outlet.
3.5.2 56K Fax Modem (International)

The international fax modem differs slightly from the domestic version, by having CE
markings and is shipped with a 220V AC adapter. It also has two additional DIP switch
settings (9 and 10). International Fax Modem DIP switch settings 9 and 10 should be
set to ON.
The fax modem serves as an interface to the 3D 60 instrument for remote access. The
remote user is able to download and upload information, including seeing what is on
the display screen that the local operator views. The Technical Support Center is able
to perform remote diagnostics and other troubleshooting of the instrument.
The modem interfaces the instrument through a connection to the MODEM port on the
rear of the unit. Digital signals are converted to tones by the modem for sending to the
telephone system through the telephone jack connection and to a remote modem at
the receiving end. Conversely, tones from the remote modem are converted to digital
signals and sent to the instrument through the MODEM port. Power for the modem is
supplied by a wall-mounted power supply that supplies low voltage required by the
modem. The wall-mounted power supply plugs directly into a standard electrical
outlet.
3.5.3 Uninterruptible Power Supply

Should facility power output exceed set voltages (high or low), the UPS will maintain
the AC power to the 3D 60 at the required voltage. If AC power is lost, the UPS
supplies power long enough for the system to perform an orderly shutdown. After the
shutdown is completed, the system signals the UPS to turn itself off.
The UPS is external to the 3D 60 and is required. (Refer to Figure 3-24.)

452501-1EN1
Instrument Components Input/Output Devices
Computer Overload
Telephone Surge Interface Protector
Protection Port
On/Off
Switch
Test
Switch
Power
On LED
Accessory Surge 120V Backup

Receptacles Receptacles
Figure 3-24: UPS Domestic Model — Front and Rear View
• On/Off Switch — Turns the UPS and BacT/ALERT® 3D 60 unit ON and OFF from
the UPS. A Power On LED is included on the On/Off Switch.
• UPS Comm Port (Computer Interface Port) — The UPS Computer Interface Port
is a standard 9-pin port used to connect a cable that monitors communication
between the UPS and the 3D 60 instrument. The port connection is shown as
Computer Interface Port in Figure 3-24.
• Overload Reset Switch — The Overload Reset switch is a reset switch (breaker)
allowing for UPS reset following a power surge or uncommon UPS shutdown. The
overload is rated 120 VAC, 12 Amp (Max) at 50/60 Hz.
• Test (Check Battery/Alarm Disable) Switch — By pressing the top of Test (toggle)
switch, the UPS battery may be checked. The UPS powers the loads from the
battery. If the UPS emits the battery exhaustion alarm, the battery is weak and
requires extended charge or replacement.
• 120V Backup Receptacles — These 120 VAC receptacles are used when devices
connected to the UPS require full battery backup to allow proper shutdown of the
equipment. A device that may require such battery backup might be the Display
Monitor, since it is required to shut down the 3D 60 instrument in a facility power-
fail situation.
CAUTION: Do not plug the printer into the UPS. The current draw for the
heating element in the printer will overload most uninterruptible power
supplies.

452501-1EN1
Display Configuration Screens Instrument Components
• Accessory Surge Receptacles — These 120V receptacles are used when devices
connected to the UPS do not require battery backup, but may require voltage
surge protection.
• AC Power Cord — The AC Power Cord is a standard three-pronged AC
(grounded) cord.
The International UPS model is very similar to the US domestic model. The voltage
rating, power cord and fuse ratings, however, are for the Interntional power
conversions. (Refer to Figure 3-25 for International UPS components.)
Computer
Interface Overload
Port Protector
On/Off
Switch
Test
Switch
Power
On LED
Accessory Surge 240V Backup

Receptacle Receptacles
Figure 3-25: UPS International Model — Front and Rear View
3.6 Display Configuration Screens
3.6.1 Operator Panel Screens

The BacT/ALERT® 3D 60 describes most of the screens displayed on the Operator
Panel. Specifically, it describes the screens used to: load/unload bottles, set the date
and time, enable/disable cells, calibrate incubation chamber temperature, perform
single cell calibration, set maximum test times, set audible alarm options and change
passwords. For detailed information on these screens, refer to Section 3.7 or the
current version of the BacT/ALERT® 3D 60 User Manual.
3.6.1.1 Configuration Screen
This screen is primarily used when an instrument is being installed. It allows the Field
Service Engineer to enter information regarding the temperature format selection,

452501-1EN1
Instrument Components Display Configuration Screens
rack configuration, and whether or not the instrument is set to MB. Refer to Figure 3-
26 for an example of the BacT/ALERT® 3D 60 Configuration screen.
Temperature
Format Rack
Selection Configuration
MB
Configuration
Figure 3-26: Configuration Screen
3.6.1.2 Access the Configuration Screen
1. At the Main screen, click the Next Screen button. This will bring up the Setup
screen. (Refer to Figure 3-27.)
Next Screen
Button
2. From the Setup screen, enter the Field Engineer password 43432121. (Refer to
Figure 3-28.)
3. Click the Key Symbol button. (Refer to Section 3.7 for Screen Diagnostics.)

452501-1EN1
Diagnostic Test Screens, Buttons, and Values Instrument Components
Keypad
Password
Buttons
Key Symbol
Button
Previous
Screen Configure
Button Screen
Button
4. Click the Configure Screen button to access the Configuration screen.
Note: To get back to the Main screen, click the Previous Screen button.
3.6.2 Configuration Screen Checkboxes

Several configuration options are represented by a graphical element called a
Checkbox. As shown in Figure 3-29, a Checkbox can appear with or without an X.
Clicking the box switches it to the opposite state.
Figure 3-29: Checkbox
3.7 Diagnostic Test Screens, Buttons, and Values
This section and its subsections contain illustrations and tables that explain the
screens, buttons, values, and other necessary information that are needed for
diagnostic testing of the BacT/ALERT® 3D 60 instrument. This section and its
subsections should be reviewed prior to performing diagnostic testing procedures.
This section and its subsections should also be used as a reference during diagnostic
testing procedures. (Refer to Chapter 7, Diagnostics and Troubleshooting Information
for instructions on how to perform diagnostic tests.)

452501-1EN1
Instrument Components Diagnostic Test Screens, Buttons, and Values
3.7.1 Diagnostic Buttons

The tables and figures shown in this section list the most common buttons used with
the BacT/ALERT® 3D 60 Diagnostic Menus. Buttons may vary, depending on the type
of BacT/ALERT® 3D system in use.
Table 3-5: Diagnostic Setup Screen Buttons
Set Date/Time Button Edit Cell Contents

Button
Enable/Disable Module, Calibrate Cell Button

Drawer, Rack, or Cell
Button
Calibrate Module View Incubation Module

Temperature Button Information Button
Set Maximum Test Time Backup Management

Button Button
Set Audible Alarm Edit Data Relationships

Options Button Button
Change Password Report Label Entry

Button Button
Select Bottle to Edit/ Report Configuration

Graph Button Button
Setup and Report Button

Configuration Button
Check Button Disabled Check Button
Cancel Button Disabled Cancel Button
Next Screen Button Setup Screen Button

(Disabled)
Scroll Up Button Scroll Down Button

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Operation Buttons: These buttons invoke operations that are common to all the
diagnostics. Refer to Table 3-6 and associated figures below for details.
Run Continuously
Pause/Run Once
Find Text
Save Output to Zip
Print Current Page
Print All Output
Cancel Print
Previous
Screen Button
Figure 3-30: Inc Module/Flag Check
Table 3-6: Operation Buttons
Button Description
Run When clicked, diagnostic runs continuously and data in the display area is updated
Continuously continuously.
Pause/Run If clicked, while the diagnostic is running continuously, the diagnostic is allowed to run
Once one more time and then it is paused. Once paused, the data in the display area
represents the data generated the last time the diagnostic was run. If clicked while the
diagnostic is already paused, the diagnostic is allowed to run one time and updates the
display data.

452501-1EN1
Table 3-6: Operation Buttons (Continued)
Button Description
Find Text This function is used to find a text string in the display data. When clicked, the following
screen appears.
Enter Text to
Search For
Press to Exit
Without Search
Press to Begin
Search
Figure 3-31: Inc Module/Temperature Log (Find Text String)

For example, if the search text entered is 1A21 and the Check button is clicked, the
original diagnostic screen appears and the display area is scrolled to the first instance of
that text. The text is highlighted in white.
Figure 3-32: Inc Module/Temperature Log (Text String Output)
To find the additional instances of the search text, press the F3 function key on your
keyboard. When the last instance is reached, searching automatically wraps back to the
first instance of the text search.

452501-1EN1
Table 3-6: Operation Buttons (Continued)
Button Description
Save Output to This function saves all of the diagnostic output to a text file on the Zip® disk. To use this
Zip function:
1. Place a Zip® disk in the instrument's Zip® drive.
2. Click the Save Output to Zip button. In response, the following screen will appear.
Figure 3-33: Inc Module/Temperature Log (Save Output to Zip)
A default file name is automatically entered for you. By default the data is saved on the
Zip® disk in a subdirectory named DIAGDUMP. The file name corresponds to the
number of the diagnostic that is currently selected. If you wish to use another filename,
click the destination filename entry box, press the SPACE bar to clear the box and
then type in the desired name.
Note: You cannot change the destination drive. It will always be the Zip® drive. Use
only 250 MB Zip® disks. To initiate the Save, click the Check button. To cancel the
save, click the Cancel button.
Operation will return to the currently selected diagnostic screen. The data is written to
the file in text. This file can be viewed using any text-editing program. For example,
Windows® Notepad. To save, click the Check button.
Print All Output Send all lines of diagnostic output to the printer.
Print Current Send just diagnostic output lines (currently displayed) to the printer.
Page
Cancel Print Button is normally disabled, yet enabled while printing is in progress. Clicking this button
cancels printing.
Exit Terminates the diagnostic, exits this screen and returns to the Diagnostic Test Selection
screen.

452501-1EN1
Display Output Area Navigation Buttons: The buttons, located just above and
below the diagnostic output display area, allow the user to scroll through the display
data.
Table 3-7: Display Output Area Navigation Buttons
Anchor display (Top/ Scroll one line Scroll one page (Up/ Go to Home or End
Bottom) (Up/Down) Down)
Positions display area
Controls whether Moves display area one Moves display area one to the first or last line of
display stays anchored line at a time (up or page (up or down). The the diagnostic output.
on the first or last line of down). The same same function can be The same function can
the diagnostic output. function can be performed by pressing be performed by
performed by pressing the Page Up or Page pressing the Home or
the Up Arrow or Down Down keys on the End keys on the
Arrow keys on the keyboard. keyboard.
keyboard.
Slide Bar: The bar, located to the left of the diagnostic output display area, allows the
user to scroll through the display data.
Table 3-8: Slide Bar Button
The raised section of the Slide bar indicates the position of the
displayed data and is relative to the amount of total display data area.
The size of the raised portion of the Slide bar is proportional to the
amount of display data in relationship to the total amount of data
(including scrollable data). For example, if there are 54 lines of total
data and only 27 lines can be displayed at a time, the raised area
would be one-half of the total size of the Slide bar.
Clicking a geographical location (top, middle, bottom, etc.) on the
Slide bar will scroll the to same relative position in the display area.
For example, if there were 2000 lines of data in the display area, and
the slide bar is clicked in the middle, the display area would scroll
approximately to line 1000.

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3.7.2 Diagnostic Screens Overview

All diagnostics screens have the same general format. The screen shown in
Figure 3-34 is the Diagnostic Test Selection screen, which is the starting point for any
diagnostic testing procedure. The screen shown in Figure 3-35 is a sample of the
screens that will be utilized by the user during diagnostic testing procedures and
indicates the fields contained in the screens. Explanations of the fields are listed in
Table 3-9. (Refer to Chapter 7, Diagnostics and Troubleshooting Information for
instructions on how to perform diagnostic tests.)
Key Symbol
Button
Main Selection
List
Sub-Selection Next Screen

List Button
Figure 3-34: Diagnostic Test Selection (Setup) Screen

452501-1EN1
Diagnostic
Name
Module, Drawer,
Rack and Cell
Identifier Code
Date and Time
Diagnostic Output
Display Area
Help Line
(if applicable)
Figure 3-35: Inc Module/Temperature Log
Table 3-9: Diagnostic Screen Fields
Field Purpose
Diagnostic Name Displays the name of the diagnostic that is

executing.
Diagnostic Output The contents of this area depend on the

Display Area particular diagnostic that is running. The
diagnostic output display area can display 27
lines at a time, but can actually hold up to
2000 lines of output data. Buttons just above
and below the screen and the slide bar
located at the left of the display area are used
to scroll the data.
Help Line Some diagnostic procedures accept keystroke

data to invoke special functions. This line
displays the key and the corresponding
function that key invokes.
Date and Time Date and time displayed is the local time. It is
displayed in day, month, year, hour, minute,
second order [DD/MM/YY HH:MM:SS],
regardless of the settings on the Set Date/
Time menu.

452501-1EN1
Table 3-9: Diagnostic Screen Fields (Continued)
Field Purpose
Module, Drawer, Information supplied in the Diagnostic Output

Rack and Cell Display Area that utilizes letters and/or
Identifier Code numbers as a code to indicate which
incubation module, drawer, rack and/or cell is
indicated.
M — Identifies an incubation module

where M is the module number (1–6).
MD — Identifies a drawer where M is

the module number, D is the drawer
letter (A–D).
MDCC-CC — Identifies a rack where

M is the module number, D is the
drawer letter, CC-CC is the cells
belonging to that rack, e.g. 1A01-20 is
the top rack in drawer A, 1B21-40 is
the middle rack in drawer B, 1D41-60
is the lower rack in drawer D.
MDCC — Identifies a cell where M is

the module number, D is the drawer
letter, and CC is the cell number (1–
60).
3.7.3 Incubator Diagnostic Values

This section will detail the normal values for diagnostic testing procedures for the
Incubation Chamber.
3.7.3.1 Loopback Method
The example screen shown in Figure 3-36 depicts the normal values to be found in
the Loopback screen.

452501-1EN1
Figure 3-36: Loopback Screen
1.1 Should increment — Number of transmit buffer empty interrupts seen by serial
hardware.
1.2 Should increment — Number of receive buffer full interrupts generated by serial
hardware.
1.3 Should remain at 0 — Number of line status interrupts generated by serial

hardware.
1.4 Should remain at 0 — Number of modem status interrupts generated by serial

hardware. (Note this interrupt is disabled as indicated on the screen.)
1.5 Total of lines 1.1 through 1.4.
2.1 Should remain at 0 — Number of overruns reported by serial hardware. An

overrun occurs if received data is not removed from the serial hardware faster than it
comes in. This value should remain at 0.
2.2 Should remain at 0 — Number of parity errors reported by serial hardware. Parity
error checking is turned off so no errors should be reported.
2.3 Should remain at 0 — Number of framing errors reported by serial hardware. A

framing error occurs if the number of serial bits between the start and stop bit are not
correct.
3.1 This value can be ignored — It is displayed for diagnosis of software activity and
indicates whether the software's transmit data FIFO is empty or not (1 or 0
respectively).

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3.2 Should remain at 0/0/0 — Displayed for the purpose of diagnosing software
activity and indicates whether there was fault storing data in the software's transmit
data FIFO and where in the code that fault occurred.
4.1 Should increment — Indicates the number of times data loopback test was run
and passed.
4.2 Should remain at 0 — Indicates the number of times loopback test was run and
failed.
4.2.1 Should remain at 0 — Indicates the number of times loopback data was
transmitted but a time-out occurred before all the data was received.
transmitted and received but the received data did not match what was transmitted.
5.1 Should remain at 0 — Indicates the state of the power fail button on the loopback
test cable, which is not used on the 3D 60.
5.2 Should remain at 0 — Indicates the state of the event request button on the
loopback connector, which is not used on the 3D 60.
3.7.3.2 Port Stats
the Port Stats screen.
Figure 3-37: Port Stats Screen
1.1 Number of transmit buffer empty interrupts seen by serial hardware.
1.2 Number of receive buffer full interrupts generated by serial hardware.

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1.3 Number of line status interrupts generated by serial hardware.
1.4 Number of modem status interrupts generated by serial hardware. (Note this
interrupt is disabled as indicated on the screen.)
2.1 Number of overruns reported by serial hardware. An overrun occurs if received

data is not removed from the serial hardware faster than it comes in. This value
should remain at 0.
2.2 Number of parity errors reported by serial hardware. Parity error checking is
turned off so no errors should be reported.
2.3 Number of framing errors reported by serial hardware. A framing error occurs if the
number of serial bits between the start and stop bit are not correct.
3.1 Indicates whether the software's transmit data FIFO is empty or not (1 or 0
respectively).
3.2 Indicates whether there was fault storing data in the software's transmit data FIFO
and where in the code that fault occurred.
3.7.3.3 Message Stats
the Message Stats screen.
Figure 3-38: Message Stats Screen
1.1 Number of times incubation module reported a power fail condition.

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1.2 Number of event requests received from the incubation module.
2.1 Number of event requests generated by the module controller. (Should be the
same as 1.2.)
2.2 Number of messages exchanged between Controller and Module Controller.
2.3 Number of messages exchanged with module controller without any problem.
2.4 Number of messages sent to module controller where the expected response did
not occur in the required time.
2.5 Number of responses from the Module Controller that had a checksum error.
2.6 Number of message exchanges with the Module Controller that fail for some
reason other than time-outs or corruption.
3.1 Number of event requests generated by the rack controller 1.
3.2 Number of messages exchanged between Control Module and rack controller 1.
3.3 Number of messages exchanged with rack controller 1 without any problem.
3.4 Number of messages sent to rack controller 1 where the expected response did
not occur in the required time.
3.5 Number of responses from the rack controller 1 that had a checksum error.
3.6 Number of message exchanges with the rack controller 1 that fail for some reason
other than time-outs or corruption.
The remaining sections duplicate the information in 3.1 through 3.6, but apply to the
racks 2 through 12 respectively.
3.7.3.4 Message Log
The Message Log screen displays the recent history of commands and responses
exchanged between the Control Module and the Incubation Module.

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T: Timestamp (shown for

reference, not actually
part of the message data)
Out: Data sent to the

Incubation Module
In: Data received from the

Incubation Module
Figure 3-39: Message Log Screen
3.7.3.5 Temperature Log
The Temperature Log screen displays the history or heater temperature data from the
sensors and sensor on the racks. Bottle testing is not affected by this diagnostic.
The Run Status runs continually and adds new temperature readings to the end of the
display as they occur.

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Time of Event in
dd/mm/yy hh:mm:ss format
Event Location
Module Controller
entry shows heater
inlet and outlet sensor
readings along with
average of the readings.
Rack Temperature entry

shows readings of two
sensors on rack, latest
module temperature
setpoint and average of
rack sensor readings.
This entry indicates that a

temperature calibration or
temperature setpoint change
occurred.
Figure 3-40: Temperature Log Screen
The Drawer open (DRW OPEN) and Close (DRW CLOS) events are also displayed,
but are not shown in the example above and events are logged when they occur.
MOD TEMP events are logged every 5 minutes. RCK TEMP events are logged
approximately once per hour per rack. TEMP SET events are logged when they
occur.
3.7.3.6 Reading Log
The Reading Log screen displays the most recent readings taken on incubation
module cells. Each line of the display identifies each cell the reading was taken from,
followed by:
• the status of the cell: LOAD, UNLOAD, OUT OF CAL

• the reading
• the number of the polynomial used to normalize the reading
The Run Status runs continually and adds new readings to the end of the display as
they occur.

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Figure 3-41: Reading Log Screen
The following reading values indicate a fault condition and you will see Fault Code
#51–57 Bottle Rack Hardware Failure reported on the operator screen.
20000: polynomial 0 used but not initialized.
-30000 or 30000: normalized reading too large.
3.7.3.7 Flag Check
The diagnostic automatically stops running once it has gathered all the required
readings and the RUN button will be in the unpressed state. Pressing the run button
restarts the diagnostic. It will gather new readings and then display the diff % data.
When first entered, or whenever the diagnostic is restarted (RUN button pressed), the
diagnostic gathers readings from the racks in the incubation module. It takes several
seconds to gather all of the data. The rack that is being processed is indicated on the
Flag Check screen. (Refer to Figure 3-42.)

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Figure 3-42: Flag Check Screen
If a rack is not installed or a drawer is not installed, they are skipped and do not
appear in the display. During the gathering phase, keyboard input is ignored.
Once all of the required data is gathered, the diff % data is displayed. (Refer to
Figure 3-43.) This screen groups the cells by the amount (Delta) that their flag reading
differs from its expected reading (i.e. the flag value when the cell was calibrated).
Cells whose
difference is greater
or equal to 1.0%
Cell location
(% diff.)
Figure 3-43: Flag Check Screen

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A given cell may appear in multiple groups. For example, a cell whose difference is
1.5% will appear in the 1.0% and 1.5% groups. Groupings are shown for percentages
of 0.5%, 1.0%, 1.5%, and so on up to 10%
No data is displayed for cells that are loaded, since a flag reading cannot be taken on
those cells. No data is displayed for cells in racks or drawers that are uninstalled.
Note that keyboard input is accepted at this point. Pressing the C key brings up the
Calibration screen. In this manner a cell can be calibrated without leaving the
diagnostic screen. When the Cancel button is pressed on the calibration screen,
operation returns to the Flag Check diagnostic screen.
Pressing 2 causes detailed data to be displayed. This data shows the current flag
reading, the expected flag reading, and the difference and percentage difference for
each cell. If a cell is loaded, the word LOAD is shown on the current reading line.
Pressing 1 returns to the diff % data.
3.7.3.8 Drawer/Heater
This diagnostic displays the state of the drawer switch and heater function in an
incubation module. Bottle testing is not affected by this diagnostic and the Run Status
runs continuously and updates the display continuously.
Average of heater inlet

and outlet sensor plus
calibration offset.
Offset determined when

temperature was last
calibrated.
Amount of heater power

currently applied to
maintain temperature.
(Note: goes to 0% if the
drawer is opened.)
Value is updated every
30 seconds.
Switch position (Switch
function) current state.
Figure 3-44: Drawer/Heater Screen
3.7.3.9 LED Check
This diagnostic provides a way to turn all cell LEDs ON and also to blink them in a
pattern to verify that they all work and that no LEDs are shorted together. Bottle
testing is not affected by this diagnostic.

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Upon initial entry to diagnostic, all LEDs are turned on and the display appears as
shown in Figure 3-45.
Figure 3-45: LED Check
After the Walking LED test is initiated, the display values appear as shown in
Figure 3-46. The displayed data indicates which LED should be on.
Figure 3-46: LED Check (Walking)

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3.7.4 Controller Module Diagnostic Values

This section will detail the normal values for diagnostic testing procedures for the
Controller Module (Instrument Controller).
3.7.4.1 Zip® Drive Test
The values listed below are the normal values to be found in the Zip Drive Test
screens.
1.1 Number of times test was run without any errors.
2.1 Number of times test was run and test file could not be opened.
2.2 Number of times test was run and an error occurred while writing.
2.3 Number of times test was run and an error occurred while reading the data or the
data did not match what was written.
2.4 Number of times an error was generated while trying to write the test data.
3.1 Last test data string written to test file on Zip® disk.
3.2 Last data read back from test file on Zip® disk.
3.7.4.2 Barcode Loopback
the Barcode Loopback screens.
Figure 3-47: Instrument Cntrl/Barcode Loopback Screen

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hardware.
hardware.

hardware.



correct.
respectively).
and passed.
failed.
4.2.3 Should remain at — Just before transmitting loopback data, the four possible
combinations or signal states are asserted on the RTS and DTS lines. The state of the
CTS line which is connected to the RTS line is monitored and if found inconsistent
with the assert RTS/DTS signals, this count is incremented.
4.2.4 Should remain at 0 — Just before transmitting loopback data, the four possible
DSR line which is connected to the DTR line is monitored and if found inconsistent

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3.7.4.3 Modem Loopback
The values listed below are the normal values to be found in the Modem Loopback
screens.
hardware.
hardware.

hardware.



correct.
respectively).
and passed.
failed.
4.2.3 Should remain at — Just before transmitting loopback data, the four possible

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3.7.4.4 Power Event Log
the Power Event Log screens.
Time of event in
dd/mm/yy hh:mm:ss
format.
Figure 3-48: Instrument Cntrl/ Power Event Log Screen
Events that appear in the log (but not necessarily shown in the example above) are:
INSTR CNTRL AC (power fault) — this is logged when AC power fails and returns as
reported by the UPS. Instrument will do a controlled shutdown.
INSTR CNTRL UPS (battery low) — this is logged when reported by the UPS.
MODULE POWER FAULT — this is logged when incubation chamber asserts its
power fault signal.
MODULE POWER UP — this is logged when incubation chamber negates its power
fault signal, or whenever the instrument software is started.
RACK POWER UP — this is logged when rack reports a power up event, or whenever
the instrument software is started.

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3.7.4.5 View Files
This function allows contents of selected files to be viewed. Bottle testing is not
affected by this diagnostic.
The Keyboard functions select the file that is to be viewed
• 2 — All the .BID files.

• 3 — All the .BTF files.
• 4 — All the .APF files.
• 5 — All the event log files (LOG\*.EVT).
• 6 — The preload data file (PLDSTORE.DAT)
The Run Status only runs once and stops.
3.7.4.6 View Files / .BID Files
For each file in the c:\btlprocs directory of the flash drive with a .BID extension, the file
name is displayed, followed by a row of dashes, followed by the contents of the file.
3.7.4.7 View Files / .BTF Files
For each file in the c:\btlprocs directory of the flash drive with a .BTF extension, the file
3.7.4.8 View Files / .APF Files
For each file in the c:\btlprocs directory of the flash drive with an .APF extension, the
file name is displayed, followed by a row of dashes, followed by the contents of the
file.
3.7.4.9 View Files / .LOG Files
For each file in the c:\btlprocs directory of the flash drive with an .LOG extension, the
file.

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FILE : EVENT1.LOG
------------------------------------------------------------
!! 139719250(06/06/01 08:04:34) 0x38(DTChg) 4294948672
!! 139719253(06/06/01 08:04:37) 0x4(ICFlt) 0
!! 139719253(06/06/01 08:04:37) 0x3(IMFlt) 1 0 0 0 0 0
!! 139719253(06/06/01 08:04:37) 0x3(IMFlt) 2 0 0 0 0 0
!! 139719253(06/06/01 08:04:37) 0x3(IMFlt) 3 0 0 0 0 0
!! 139719253(06/06/01 08:04:37) 0x3(IMFlt) 4 0 0 0 0 0
!! 139719253(06/06/01 08:04:37) 0x3(IMFlt) 5 0 0 0 0 0
!! 139719253(06/06/01 08:04:37) 0x3(IMFlt) 6 0 0 0 0 0
!! 139719258(06/06/01 08:04:42) 0x30(IMPwr) 1
!! 139719258(06/06/01 08:04:42) 0x30(IMPwr) 2
!! 139719535(06/06/01 08:09:19) 0x4(ICFlt) 12
!! 139721277(06/06/01 08:38:21) 0x38(DTChg) 4294948672
!! 139721279(06/06/01 08:38:23) 0x4(ICFlt) 0
!! 139721280(06/06/01 08:38:24) 0x3(IMFlt) 1 0 0 0 0 0
FILE : EVENT0.LOG
------------------------------------------------------------
!! 139809948(07/06/01 09:16:12) 0x38(DTChg) 4294948672
!! 139809951(07/06/01 09:16:15) 0x4(ICFlt) 0
!! 139809951(07/06/01 09:16:15) 0x3(IMFlt) 1 0 0 0 0 0
!! 139809951(07/06/01 09:16:15) 0x3(IMFlt) 2 0 0 0 0 0
!! 139809951(07/06/01 09:16:15) 0x3(IMFlt) 3 0 0 0 0 0
!! 139809951(07/06/01 09:16:15) 0x3(IMFlt) 4 0 0 0 0 0
!! 139809951(07/06/01 09:16:15) 0x3(IMFlt) 5 0 0 0 0 0
!! 139809951(07/06/01 09:16:15) 0x3(IMFlt) 6 0 0 0 0 0
!! 139809956(07/06/01 09:16:20) 0x30(IMPwr) 1
!! 139809956(07/06/01 09:16:20) 0x30(IMPwr) 2
!! 139810161(07/06/01 09:19:45) 0x4(ICFlt) 12
!! 139810363(07/06/01 09:23:07) 0x3(IMFlt) 2 0 0 74 0 0
!! 139811149(07/06/01 09:36:13) 0x4(ICFlt) 0
!! 139812682(07/06/01 10:01:46) 0x38(DTChg) 4294948672
!! 139812694(07/06/01 10:01:58) 0x4(ICFlt) 0
!! 139812695(07/06/01 10:01:59) 0x3(IMFlt) 1 0 0 0 0 0
!! 139812695(07/06/01 10:01:59) 0x3(IMFlt) 2 0 0 0 0 0
!! 139812695(07/06/01 10:01:59) 0x3(IMFlt) 3 0 0 0 0 0
!! 139812695(07/06/01 10:01:59) 0x3(IMFlt) 4 0 0 0 0 0
!! 139812695(07/06/01 10:01:59) 0x3(IMFlt) 5 0 0 0 0 0
!! 139812695(07/06/01 10:01:59) 0x3(IMFlt) 6 0 0 0 0 0
!! 139812700(07/06/01 10:02:04) 0x30(IMPwr) 2
!! 139812700(07/06/01 10:02:04) 0x30(IMPwr) 1
!! 139813009(07/06/01 10:07:13) 0x3(IMFlt) 1 0 20 0 0 0
!! 139813053(07/06/01 10:07:57) 0x3(IMFlt) 1 0 0 0 0 0
!! 139813314(07/06/01 10:12:18) 0x3(IMFlt) 1 0 99 0 0 0
!! 139813764(07/06/01 10:19:48) 0x3(IMFlt) 1 0 51 0 0 0
Figure 3-49: FILE : EVENT1.LOG and EVENT0.LOG
Each line in an event log has the same format as follows:
!! 127829789(18/01/01 13:24:00) 0x38(DTO) 82349
seconds dd/mm/yy hh:mm:ss event info
The event info content varies (depending on the kind of event) and is described in
Table 3-10.
Table 3-10: Software Exceptions
Software Exception Exception Details
0x1(SWExc) LOG,TEST,MAIN
This event occurs if there is a condition, for example a hardware problem that the software cannot handle, or
there is a design flaw in the software that results in a condition that cannot be handled. Report this information
to the 3D 60 software development team.

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Incubation Module Drawer A Drawer B Drawer C Drawer D

Module
Module Fault Fault Fault Fault Fault
Number
Fault Code Code Code Code Code
0x3(IMFlt) 3 0 41 0 0 0
This information corresponds to information displayed on the Main screen's incubation module pictorial. A fault
code of 0 means there is no fault in the module or corresponding drawer. See BacT/ALERT® 3D 60 User
Manual or Quick Reference card for the meaning of non-zero fault codes.
Controller Module Fault Fault Code
0x4(ICFlt) 10
This information corresponds to information displayed on the Main screen's Controller Module pictorial. A fault
code of 0 means there is no fault. Refer to the BacT/ALERT® 3D 60 User Manual or Quick Reference card for
the meaning of non-zero fault codes.
Module Power Up Module Number
0x30(IMPwr) 2
This event indicates that the incubation module has just powered up.
Display time offset change Offset in seconds
0x38(DTChg) 16432
Internally, the 3D 60 software maintains time in UTC time. When the operator uses the Set Date/Time screen
to enter the local time, the difference between local time and UTC is calculated and this event is logged to
record that difference. This event is an indication that the operator has changed the date or time.
Module Drawer Rack Fault

Cell QC fault Cell Number
Number Number Number Present
0x39(QCFlt) 3 2 3 12 1
This event is logged any time a cell goes out of calibration or back into calibration (presumably because the
operator has calibrated the cell). The Drawer Number value ranges from 1 to 4 and corresponds with drawers
A through D, respectively. The Rack Number ranges from 1 to 3 and corresponds with the top rack, middle
rack, and bottom rack, respectively. The Cell Number ranges from 1 to 20 and identifies the affected cell. The
cell number that the operator sees depends on the Rack Number. For example, if the Rack Number is 2 and
Cell Number is 5, the operator would see this as cell 25. If the Rack Number is 3 and the Cell Number is 10,
the operator would see this as cell 50. If the Fault present value is 1, the cell is out of calibration. If the Fault
present value is 0, then the cell has been calibrated.
Backup started
0x100(BkupStart)
This event is logged any time a backup has started.

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Backup completed
successfully
0x101(BkupOk)
This event is logged any time that a backup is completed successfully.
Backup failed
0x102(BkupFailed)
This event is logged any time that a backup has started but failed to complete successfully.
Module Drawer Rack Cell

Operator Cell Calibration Started
Number Number Number Number
0x300(CCalSt) 3 2 3 12
This event is logged any time that the operator starts a single cell calibration.
Operator Cell Calibration Module Drawer Rack Cell

Successful Number Number Number Number
0x301(CcalOK) 3 2 3 12
This event is logged any time that the operator successfully completes single cell calibration.
Controller Module Power Up
0x600(ICPwr)
This event is logged any time that the Controller Module is powered up.

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Normal Shutdown
0x200(NrmSD)
This event is logged any time that the software is shut down in the normal fashion.
Power Loss Shutdown
0x201(PwrLossSD)
This event is logged any time that the software is shut down due to a loss of power.
Abnormal Shutdown without Shutdown comment

NVRAM Save
0x202(AbNrmSD) CPU NVRAM has uninitialized data or file read error.
This event is logged any time that the software is shut down for an abnormal reason without saving the
NVRAM. For example, if during power up the software detects that the CPU NVRAM is uninitialized, the
software is abnormally shut down without saving the NVRAM.
SMX Error at Startup/Shutdown
0x203(SmxErrSD)
This event is logged any time that the software is shut down because of an SMX error detected at startup.
Abnormal Shutdown with Shutdown Comment

NVRAM Save
0x204(AbNrmSD) DEBUG MODE - immediate shutdown with NVRAM save
This event is logged any time that the software is shut down for an abnormal reason with saving the NVRAM.
For example, if the software is started with the appropriate Debug mode for immediate shutdown configuration
set, the software shuts down abnormally, but saves the NVRAM.
Remote User Requests

Shutdown
0x205(RemUserSD)
This event is logged any time that the software is shut down because of a request passed by the Remote User
software.
Module New Setpoint

Set the Setpoint Temperature
Number
0x500(MTSet) 1 37.0
This event is logged any time that the setpoint has been changed.

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Module Temperature Offset at Module Temperature Offset

Power Up Number
0x501(IMOfs) 1 -.42
This event is logged any time that the incubation module is powered up.
Module Temperature Offset Module Temperature Offset

Updated Number
0x502(IMOfs)
This event is logged any time that the incubation module's temperature is updated.
Module Current Last Stable Temperature

Module Temperature Calibrated
Number Temperature Temperature Offset
0x503(IMTCal) 1 36.00 36.86 -1.36
This event is logged any time that the incubation module's temperature is calibrated.
Remote User Software

Connection Detected
0x700(RUOn)
This event is logged any time that the software detects that the Remote User software has connected.
Remote User Software

Connection Dropped
0x701(RUOff)
This event is logged any time that the software detects that the Remote User software connection has been
dropped.
3.7.4.10 Software
The Software screen and its subcreens display data used to debug, verify and
validate Controller Module software. Also, displays logs of exception conditions
detected by the software. Bottle testing is not affected by this diagnostic.
The Keyboard functions select the file that is to be viewed.
• 1 — Software debug information

• 2 — Software exception log
• 3 — Operating system exception log
• 4 — Modem activity log
• 5 — Association tables
• 6 — Bottle processing tables

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• 7 — Audit trail log

• 8 — Scandisk output
• 9 — Other (Misc.)
Runs continually and updates display when new information needs to be displayed.
The values listed in Figure 3-50 are typical values to be found in the Software
screens. The descriptions of these values are listed below.
1.1 Percentage of time the processor is idle
1.2 Percentage of time processor is executing task code
1.3 Percentage of time processor is executing interrupts of operating system code
2.1 Amount of bytes left in heap
2.2 Number of free blocks in heap
2.3 Largest block left on heap in bytes
3.1 Approximate CMOS clock value the last time the Controller Module software was
terminated
3.2 Approximate local time the Controller Module software was terminated
Figure 3-50: Instrument Cntrl/Software Screen
3.7.4.11 Software / Debug
The Debug screen displays software debug messages intended for development
activity and is intended for the 3D 60 software development team. The format and

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content messages put in this log are determined by the software implementor and no
design specifications are imposed.
3.7.4.12 Software / Software Exception Log
The Software Exception Log screen displays software exceptions messages intended
for the 3D 60 software development team. Access this screen if a Fault Code #19
Software Exception is being displayed on the Main screen. The format and content
messages put in this log are determined by the software implementor and no design
specifications are imposed.
When a software exception is detected, a Fault Code #19 Software Exception is

displayed on the Main screen. While the software exception log is being displayed,
pressing Ctrl + R clears the Fault Code #19 Software Exception and a short beep
will be sounded on the speaker.
3.7.4.13 Software / Operating System Exception Log
The Operating System Exception Log screen displays exceptions reported by the 3D
60 operating system (SMX). The format and content messages put in this log are
determined by the operating system vendor (Micro Digital) and no design
specifications are imposed.
3.7.4.14 Software / Modem Activity Log
The Modem Activity Log screen displays software debug messages intended for
development activity and is intended for the 3D 60 software development team. The
format and content messages put in this log are determined by the software
implementor and no design specifications are imposed.
3.7.4.15 Software / Association Tables
The Association Tables screen displays current content of various dictionaries and
association tables used to keep track of bottle and pre-load data. An example of the
Association Tables screen content is shown below. Explanatory comments are shown
in italics and do not actually appear on the diagnostic screen.
--- Patient Name Dictionary --- relates a hospital ID (hid) to the patient name
17, AH3HID hash table index, hospital ID, first name, last name
18, AH4HID, AH4FIRST AH4LAST
--- HID to Acc Container --- relates hospital ID to accessions that share that hid
17, AH3HID, AH3ACC*8895AFA hash table index, hid, accession
18, AH4HID, AH4ACC*1
--- ACC to HID Dictionary --- relates accession back to its hospital ID

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83, AH3ACC*8895AFA, AH3HID hash table index, accession, hospital ID
95, AH4ACC*1, AH4HID
--- ACC to BID Container --- relates accession to bottle IDs that share that accession
83, AH3ACC*8895AFA, AH3BID1 hash table index, accession, bottle ID
95, AH4ACC*1, AH4BID1
--- BarCodeDictionary --- relates bottle ID to a bottle record, key values from that
record are displayed
[a:1003600 n:28 s:28 p:60] [r:2 s:P x:1] [loc:: a: address of bottle record
1A20 ld: 1] n: bottle record index (1-1920) s: bottle record sequence num
bid: AH3BID1 acc: AH3ACC*8895AFA p: hash table index
hid: AH3HID pn: ,
r: result code (1=pos 2=neg 3=ntd 4=near pos)
[a:1003800 n:29 s:29 p:61] [r:3 s:I x:1] [loc:: s: status (P=prelim, I= incomplete, F=final) x: significant test result if
1A40 ld: 1] ld: 0=unloaded 1=loaded
bid: AH4BID1 acc: AH4ACC*1 loc: if "ld: 1", cell where bottle is loaded;
hid: AH4HID pn: AH4LAST, AH4FIRST if "ld: 0", cell where bottle was last loaded
bid: bottle ID
acc: accession number
hid: hospital ID
pn: last, first parts of patient
--- ACC to ACC Container --- relates a base accession to accessions with same base
3, AH3ACC, AH3ACC*8895AFA hash table index, base accession, accession with suffix
4, AH4ACC, AH4ACC*1
--- PRELOAD: ACC to RecNums Container --- relates a base accession to all record numbers in the
preload file that have that accession
2, ACC*1, 11 hash table index, accession, preload file rec num
14, ACC43, 6
--- PRELOAD: BID to RecNum Dictionary --- relates a bottle ID to the one record number in the preload
file that has that bottle ID
171, AH2BIDA, 12 hash table index, bottle ID, preload file rec num
--- PRELOAD: ACC to RecNum Dictionary --- release an accession to the one record number in the
preload file that has that accession
191, AH4ACC*1, 2 hash table index, accession, preload file rec num
275, AH3ACC*8895AFA, 1
3.7.4.16 Software / Bottle Processing Tables
The Bottle Processing Tables screen displays the current content of the tables that
drive the way the 3D processes bottles. See the following example.
*** Bottle Processing Tables Log ***

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------------ Bottle IDs Table (76 entries) ----------
Prefix, Min, Max, BottleType, Container Type
ZINHI, 5, 15, 23, 2
ZBLYM, 5, 8, 16, 2
ZPPC, 5, 15, 29, 2
ZPDC, 5, 15, 28, 2
ZEMB, 5, 15, 25, 2
ZSTR, 5, 15, 24, 2
ZINH, 5, 15, 22, 2
ZRIF, 5, 15, 21, 2
ZPZA, 5, 15, 20, 2
ZBMB, 5, 8, 18, 2
ZBMP, 5, 8, 17, 2
ZBPF, 5, 8, 15, 2
ZBFN, 5, 8, 14, 2
ZBFA, 5, 8, 13, 2
ZBSN, 5, 15, 12, 2
ZBSA, 5, 8, 11, 2
ZPC, 5, 15, 27, 2
ZDC, 5, 15, 26, 2
ZGD, 5, 15, 19, 2
ZMB, 5, 15, 9, 1

ZMS, 5, 15, 8, 1
ZPN, 5, 15, 7, 1
ZPA, 5, 15, 6, 1
ZFN, 5, 15, 5, 1
ZFA, 5, 15, 4, 1
@O, 8, 8, 29, 2
@A, 8, 8, 28, 2
@C, 8, 8, 27, 2
@D, 8, 8, 26, 2
@E, 8, 8, 25, 2
@S, 8, 8, 24, 2
@I, 8, 8, 22, 2
@Z, 8, 8, 23, 2
@R, 8, 8, 21, 2
@P, 8, 8, 20, 2
!B, 8, 8, 18, 2
!M, 8, 8, 17, 2

452501-1EN1
!L, 8, 8, 16, 2
!P, 8, 8, 15, 2
!G, 8, 8, 14, 2
!F, 8, 8, 13, 2
!N, 8, 8, 12, 2
!A, 8, 8, 11, 2
SB, 8, 8, 18, 3
SM, 8, 8, 17, 3
SL, 8, 8, 16, 3
SP, 8, 8, 15, 3
SG, 8, 8, 14, 3
SF, 8, 8, 13, 3
SN, 8, 8, 12, 3
SA, 8, 8, 11, 3
MB, 0, 0, 8, 1
MS, 10, 10, 8, 1

PN, 10, 10, 7, 1
PE, 10, 10, 6, 1
FN, 10, 10, 5, 1

FA, 10, 10, 4, 1
ZN, 5, 15, 3, 1
ZA, 5, 8, 2, 1
IA, 8, 8, 50, 2
IN, 8, 8, 51, 2
IL, 8, 8, 52, 2
9, 0, 0, 0, 0
8, 0, 0, 0, 0
7, 0, 0, 0, 0
6, 0, 0, 0, 0
5, 0, 0, 0, 0
4, 0, 0, 0, 0
3, 0, 0, 0, 0
2, 0, 0, 0, 0
1, 0, 0, 0, 0
0, 0, 0, 0, 0
G, 0, 0, 0, 0
U, 0, 0, 1, 0
H, 9, 9, 3, 1
D, 9, 9, 2, 1

452501-1EN1
------------ Bottle Types Table (100 entries) ----------
Type, Name, UTT, Disp, Drw, Cnt, Disk, LES/Glass, LES/Plas.
0, GENERIC, G, 1, 3, 0, 10, 5, 11
1, UNKNOWN, U, 1, 5, 0, 10, 5, 11
2, AEROBIC, A, 1, 2, 1, 10, 10, 10
3, ANAEROBIC, N, 1, 2, 1, 10, 10, 10
4, FAN AEROBIC, FA, 1, 2, 1, 10, 10, 10
5, FAN ANAEROBIC, FN, 1, 2, 1, 10, 10, 10
6, PEDI-BACT, PE, 1, 2, 1, 10, 10, 10
7, LYM-BACT, PN, 1, 2, 1, 4, 4, 4
8, MB/BACT, MS, 1, 1, 1, 2, 2, 2
9, MB/BACT BLOOD, MB, 1, 4, 1, 3, 3, 3
10, BACT/ALERT SV, BA, 0, 2, 0, 5, 5, 11

11, BACT/ALERT SA, BA, 0, 2, 0, 5, 5, 11
12, BACT/ALERT SN, BN, 0, 2, 0, 5, 5, 11
13, BACT/ALERT FA, BFA, 0, 2, 0, 6, 6, 12
14, BACT/ALERT FN, BFN, 0, 2, 0, 5, 5, 11
15, BACT/ALERT PF, BPE, 0, 2, 0, 5, 5, 11
16, BACT/ALERT LYM, BLYM, 0, 2, 0, 9, 9, 15
17, BACT/ALERT MP, BMS, 0, 1, 0, 7, 16, 13
18, BACT/ALERT MB, BMB, 0, 4, 0, 8, 17, 14
19, GENERIC DRUG, GD, 0, 1, 4, 3, 17, 17

20, PYRAZINAMIDE, PZA, 0, 1, 4, 2, 16, 16
21, RIFAMPIN, RIF, 0, 1, 4, 3, 17, 17
22, ISONIAZID, INH, 0, 1, 4, 3, 17, 17

23, ISONIAZID HI, INHI, 0, 1, 4, 3, 17, 17
24, STREPTOMYCIN, STR, 0, 1, 4, 3, 17, 17
25, ETHAMBUTOL, EMB, 0, 1, 4, 3, 17, 17
26, DIRECT CONTROL, DC, 0, 1, 4, 3, 17, 17
27, PROP CONTROL, PC, 0, 1, 4, 3, 17, 17
28, PZA DIRECT CONTROL, PDC, 0, 1, 4, 2, 16, 16
29, PZA PROP CONTROL, PPC, 0, 1, 4, 2, 16, 16
30, Q30, Q30, 0, 3, 0, 10, 5, 11
31, Q31, Q31, 0, 3, 0, 10, 5, 11
32, Q32, Q32, 0, 3, 0, 10, 5, 11
33, Q33, Q33, 0, 3, 0, 10, 5, 11
34, Q34, Q34, 0, 3, 0, 10, 5, 11
35, Q35, Q35, 0, 3, 0, 10, 5, 11
36, Q36, Q36, 0, 3, 0, 10, 5, 11

452501-1EN1
37, Q37, Q37, 0, 3, 0, 10, 5, 11
38, Q38, Q38, 0, 3, 0, 10, 5, 11
39, Q39, Q39, 0, 3, 0, 10, 5, 11
40, Q40, Q40, 0, 3, 0, 10, 5, 11
41, Q41, Q41, 0, 3, 0, 10, 5, 11
42, Q42, Q42, 0, 3, 0, 10, 5, 11
43, Q43, Q43, 0, 3, 0, 10, 5, 11
44, Q44, Q44, 0, 3, 0, 10, 5, 11
45, Q45, Q45, 0, 3, 0, 10, 5, 11
46, Q46, Q46, 0, 3, 0, 10, 5, 11
47, Q47, Q47, 0, 3, 0, 10, 5, 11
48, Q48, Q48, 0, 3, 0, 10, 5, 11
49, Q49, Q49, 0, 3, 0, 10, 5, 11
50, BTA-I AST, ISA, 0, 2, 0, 5, 5, 11
51, BTA-I NST, ISN, 0, 2, 0, 5, 5, 11
52, BTA-I LYM, ILYM, 0, 2, 0, 9, 9, 15

53, Q53, Q53, 0, 3, 0, 10, 5, 11
54, Q54, Q54, 0, 3, 0, 10, 5, 11
55, Q55, Q55, 0, 3, 0, 10, 5, 11

56, Q56, Q56, 0, 3, 0, 10, 5, 11
57, Q57, Q57, 0, 3, 0, 10, 5, 11
58, Q58, Q58, 0, 3, 0, 10, 5, 11
59, Q59, Q59, 0, 3, 0, 10, 5, 11
60, Q60, Q60, 0, 3, 0, 10, 5, 11

61, Q61, Q61, 0, 3, 0, 10, 5, 11
62, Q62, Q62, 0, 3, 0, 10, 5, 11
63, Q63, Q63, 0, 3, 0, 10, 5, 11
64, Q64, Q64, 0, 3, 0, 10, 5, 11
65, Q65, Q65, 0, 3, 0, 10, 5, 11
66, Q66, Q66, 0, 3, 0, 10, 5, 11

67, Q67, Q67, 0, 3, 0, 10, 5, 11
68, Q68, Q68, 0, 3, 0, 10, 5, 11
69, Q69, Q69, 0, 3, 0, 10, 5, 11

70, Q70, Q70, 0, 3, 0, 10, 5, 11
71, Q71, Q71, 0, 3, 0, 10, 5, 11
72, Q72, Q72, 0, 3, 0, 10, 5, 11
73, Q73, Q73, 0, 3, 0, 10, 5, 11
74, Q74, Q74, 0, 3, 0, 10, 5, 11
75, Q75, Q75, 0, 3, 0, 10, 5, 11

452501-1EN1
76, Q76, Q76, 0, 3, 0, 10, 5, 11
77, Q77, Q77, 0, 3, 0, 10, 5, 11
78, Q78, Q78, 0, 3, 0, 10, 5, 11
79, Q79, Q79, 0, 3, 0, 10, 5, 11
80, Q80, Q80, 0, 3, 0, 10, 5, 11
81, Q81, Q81, 0, 3, 0, 10, 5, 11
82, Q82, Q82, 0, 3, 0, 10, 5, 11
83, Q83, Q83, 0, 3, 0, 10, 5, 11
84, Q84, Q84, 0, 3, 0, 10, 5, 11
85, Q85, Q85, 0, 3, 0, 10, 5, 11
86, Q86, Q86, 0, 3, 0, 10, 5, 11
87, Q87, Q87, 0, 3, 0, 10, 5, 11
88, Q88, Q88, 0, 3, 0, 10, 5, 11
89, Q89, Q89, 0, 3, 0, 10, 5, 11
90, Q90, Q90, 0, 3, 0, 10, 5, 11
91, Q91, Q91, 0, 3, 0, 10, 5, 11

92, Q92, Q92, 0, 3, 0, 10, 5, 11
93, Q93, Q93, 0, 3, 0, 10, 5, 11
94, Q94, Q94, 0, 3, 0, 10, 5, 11

95, Q95, Q95, 0, 3, 0, 10, 5, 11
96, Q96, Q96, 0, 3, 0, 10, 5, 11
97, Q97, Q97, 0, 3, 0, 10, 5, 11
98, Q98, Q98, 0, 3, 0, 10, 5, 11
99, Q99, Q99, 0, 3, 0, 10, 5, 11
------- Algorithm Parameter Tables (100 entries) ----------
0 ID(H2) BltFact(0.1E1) Resv(1320) AdjThres(70) AdjLim(4)
StupPts(5) StupSumx(15) StupDenom(50)
FastPts(17) FastSumx(153) FastDenom(6936)
InitThres(3300) FastStupThres(6) SlopStupThres(0.1E1)
FastCntrThres(12) FastBcktThres(0.105E2) FastBcktInc(1)
FastRateThres(32) FastRateInc(3) FastDgdr(0.93E0)

FastSlopProp(0.825E0) FastMayThres(3) SlowStupThres(12)
SlowCntrThres(16) SlowBcktThres(15) SlowBcktInc(1)
SlowDgdr(0.98E0) SlowSlopProp(0.9083E0)
MinSkipPts(6)
1 ID(E2) BltFact(0.1E1) Resv(1320) AdjThres(70) AdjLim(4)

452501-1EN1
2 ID(G2) BltFact(0.1E1) Resv(1320)
MinSkipPts(216) MinAvgPts(24) MinAvgMed(1)
SlopProp(0.1E0) SlowSlopProp(0.2E-1)
FastDgdr(0.75E0) SlowDgdr(0.9E0)
AcelSlopThres(20) SlowSlopThres(10)
PosDlyThres(1) DltThres(100) NumAlg2Pts(576)
PosSlopDly(720) DltDgdr(0.995E0)
--- Embedded E2 Parms ---
ID(E2) BltFact(0.1E1) Resv(1320) AdjThres(70) AdjLim(4)


PosSlopDly(720) DltDgdr(<1.0E-32)



452501-1EN1
InitThres(3300) FastStupThres(6) SlopStupThres(-0.1E5)
MinSkipPts(6)
MinSkipPts(6)


MinSkipPts(6)

452501-1EN1



MinSkipPts(6)


MinSkipPts(6)

452501-1EN1
MinSkipPts(6)

MinSkipPts(6)

--- Embedded H2 Parms ---
ID(H2) BltFact(0.231E1) Resv(1320) AdjThres(70) AdjLim(4)


MinSkipPts(6)

452501-1EN1
MinSkipPts(6)


MinSkipPts(6)



452501-1EN1
MinSkipPts(6)

MinSkipPts(6)
18 not used
19 not used
20 not used
21 not used
22 not used
23 not used
24 not used
25 not used
26 not used
27 not used
28 not used
29 not used
30 not used
31 not used
32 not used
33 not used
34 not used
35 not used
36 not used
37 not used
38 not used

452501-1EN1
39 not used
40 not used
41 not used
42 not used
43 not used
44 not used
45 not used
46 not used
47 not used
48 not used
49 not used
50 not used
51 not used
52 not used
53 not used
54 not used
55 not used
56 not used
57 not used
58 not used
59 not used
60 not used
61 not used
62 not used
63 not used
64 not used
65 not used
66 not used
67 not used
68 not used
69 not used
70 not used
71 not used
72 not used
73 not used
74 not used
75 not used
76 not used
77 not used
78 not used
79 not used

452501-1EN1
80 not used
81 not used
82 not used
83 not used
84 not used
85 not used
86 not used
87 not used
88 not used
89 not used
90 not used
91 not used
92 not used
93 not used
94 not used
95 not used
96 not used
97 not used
98 not used
99 not used
------------ Default Maximum Test Times ----------
7.0 days ( 604800 secs.) Type = GENERIC (0)
7.0 days ( 604800 secs.) Type = UNKNOWN (1)

7.0 days ( 604800 secs.) Type = AEROBIC (2)
7.0 days ( 604800 secs.) Type = ANAEROBIC (3)
7.0 days ( 604800 secs.) Type = FAN AEROBIC (4)

7.0 days ( 604800 secs.) Type = FAN ANAEROBIC (5)
7.0 days ( 604800 secs.) Type = PEDI-BACT (6)
7.0 days ( 604800 secs.) Type = LYM-BACT (7)
42.0 days ( 3628800 secs.) Type = MB/BACT (8)
42.0 days ( 3628800 secs.) Type = MB/BACT BLOOD (9)
7.0 days ( 604800 secs.) Type = BACT/ALERT SV (10)

7.0 days ( 604800 secs.) Type = BACT/ALERT SA (11)
7.0 days ( 604800 secs.) Type = BACT/ALERT SN (12)
7.0 days ( 604800 secs.) Type = BACT/ALERT FA (13)
7.0 days ( 604800 secs.) Type = BACT/ALERT FN (14)
7.0 days ( 604800 secs.) Type = BACT/ALERT PF (15)
7.0 days ( 604800 secs.) Type = BACT/ALERT LYM (16)
42.0 days ( 3628800 secs.) Type = BACT/ALERT MP (17)
42.0 days ( 3628800 secs.) Type = BACT/ALERT MB (18)

452501-1EN1
15.0 days ( 1296000 secs.) Type = GENERIC DRUG (19)
30.0 days ( 2592000 secs.) Type = PYRAZINAMIDE (20)
15.0 days ( 1296000 secs.) Type = RIFAMPIN (21)
15.0 days ( 1296000 secs.) Type = ISONIAZID (22)
15.0 days ( 1296000 secs.) Type = ISONIAZID HI (23)
15.0 days ( 1296000 secs.) Type = STREPTOMYCIN (24)
15.0 days ( 1296000 secs.) Type = ETHAMBUTOL (25)
15.0 days ( 1296000 secs.) Type = DIRECT CONTROL (26)
15.0 days ( 1296000 secs.) Type = PROP CONTROL (27)
30.0 days ( 2592000 secs.) Type = PZA DIRECT CONTROL (28)
30.0 days ( 2592000 secs.) Type = PZA PROP CONTROL (29)
7.0 days ( 604800 secs.) Type = Q30 (30)
7.0 days ( 604800 secs.) Type = Q31 (31)
7.0 days ( 604800 secs.) Type = Q32 (32)
7.0 days ( 604800 secs.) Type = Q33 (33)
7.0 days ( 604800 secs.) Type = Q34 (34)
7.0 days ( 604800 secs.) Type = Q35 (35)

7.0 days ( 604800 secs.) Type = Q36 (36)
7.0 days ( 604800 secs.) Type = Q37 (37)
7.0 days ( 604800 secs.) Type = Q38 (38)

7.0 days ( 604800 secs.) Type = Q39 (39)
7.0 days ( 604800 secs.) Type = Q40 (40)
7.0 days ( 604800 secs.) Type = Q41 (41)
7.0 days ( 604800 secs.) Type = Q42 (42)
7.0 days ( 604800 secs.) Type = Q43 (43)
7.0 days ( 604800 secs.) Type = Q44 (44)

7.0 days ( 604800 secs.) Type = Q45 (45)
7.0 days ( 604800 secs.) Type = Q46 (46)
7.0 days ( 604800 secs.) Type = Q47 (47)
7.0 days ( 604800 secs.) Type = Q48 (48)
7.0 days ( 604800 secs.) Type = Q49 (49)
7.0 days ( 604800 secs.) Type = BTA-I AST (50)

7.0 days ( 604800 secs.) Type = BTA-I NST (51)
7.0 days ( 604800 secs.) Type = BTA-I LYM (52)
7.0 days ( 604800 secs.) Type = Q53 (53)

7.0 days ( 604800 secs.) Type = Q54 (54)
7.0 days ( 604800 secs.) Type = Q55 (55)
7.0 days ( 604800 secs.) Type = Q56 (56)
7.0 days ( 604800 secs.) Type = Q57 (57)
7.0 days ( 604800 secs.) Type = Q58 (58)
7.0 days ( 604800 secs.) Type = Q59 (59)

452501-1EN1
7.0 days ( 604800 secs.) Type = Q60 (60)
7.0 days ( 604800 secs.) Type = Q61 (61)
7.0 days ( 604800 secs.) Type = Q62 (62)
7.0 days ( 604800 secs.) Type = Q63 (63)
7.0 days ( 604800 secs.) Type = Q64 (64)
7.0 days ( 604800 secs.) Type = Q65 (65)
7.0 days ( 604800 secs.) Type = Q66 (66)
7.0 days ( 604800 secs.) Type = Q67 (67)
7.0 days ( 604800 secs.) Type = Q68 (68)
7.0 days ( 604800 secs.) Type = Q69 (69)
7.0 days ( 604800 secs.) Type = Q70 (70)
7.0 days ( 604800 secs.) Type = Q71 (71)
7.0 days ( 604800 secs.) Type = Q72 (72)
7.0 days ( 604800 secs.) Type = Q73 (73)
7.0 days ( 604800 secs.) Type = Q74 (74)
7.0 days ( 604800 secs.) Type = Q75 (75)
7.0 days ( 604800 secs.) Type = Q76 (76)

7.0 days ( 604800 secs.) Type = Q77 (77)
7.0 days ( 604800 secs.) Type = Q78 (78)
7.0 days ( 604800 secs.) Type = Q79 (79)

7.0 days ( 604800 secs.) Type = Q80 (80)
7.0 days ( 604800 secs.) Type = Q81 (81)
7.0 days ( 604800 secs.) Type = Q82 (82)
7.0 days ( 604800 secs.) Type = Q83 (83)
7.0 days ( 604800 secs.) Type = Q84 (84)
7.0 days ( 604800 secs.) Type = Q85 (85)

7.0 days ( 604800 secs.) Type = Q86 (86)
7.0 days ( 604800 secs.) Type = Q87 (87)
7.0 days ( 604800 secs.) Type = Q88 (88)
7.0 days ( 604800 secs.) Type = Q89 (89)
7.0 days ( 604800 secs.) Type = Q90 (90)
7.0 days ( 604800 secs.) Type = Q91 (91)

7.0 days ( 604800 secs.) Type = Q92 (92)
7.0 days ( 604800 secs.) Type = Q93 (93)
7.0 days ( 604800 secs.) Type = Q94 (94)

7.0 days ( 604800 secs.) Type = Q95 (95)
7.0 days ( 604800 secs.) Type = Q96 (96)
7.0 days ( 604800 secs.) Type = Q97 (97)
7.0 days ( 604800 secs.) Type = Q98 (98)
7.0 days ( 604800 secs.) Type = Q99 (99)

452501-1EN1
------------ Bottle Types Tracking Data ----------
0 LES/Glass (0x6000) Display GENERIC
1 LES/Glass (0x6000) Display UNKNOWN
2 LES/Glass (0x2000) Display AEROBIC

3 LES/Glass (0x2000) Display ANAEROBIC
4 LES/Glass (0x2000) Display FAN AEROBIC
5 LES/Glass (0x2000) Display FAN ANAEROBIC
6 LES/Glass (0x2000) Display PEDI-BACT
7 LES/Glass (0x2000) Display LYM-BACT
8 LES/Glass (0x4000) Display MB/BACT
9 LES/Glass (0x6000) Display MB/BACT BLOOD
10 LES/Glass (0x2000)
11 LES/Glass (0x2000) Display BACT/ALERT SA

12 LES/Glass (0x2000) Display BACT/ALERT SN
13 LES/Glass (0x2000) Display BACT/ALERT FA
14 LES/Glass (0x2000) Display BACT/ALERT FN
15 LES/Plastic (0x2001) Display BACT/ALERT PF
16 LES/Glass (0x2000) Display BACT/ALERT LYM
17 LES/Glass (0x4000) Display BACT/ALERT MP
18 LES/Glass (0x6000) Display BACT/ALERT MB

452501-1EN1

452501-1EN1
3.7.4.17 Software / Audit Trail
The Audit Trail screen displays activities and other related information. Each audit trail
entry consists of an event and the time and date the event occurred. Refer to
Table 3-11 for a list of events recorded in the Audit Trail.
Note: Some recorded events may occur while the user is logged out, such as firmware
upgrades, and will not have an associated User ID. In these cases, the user is listed
as Unknown.
Note: The Audit Trail is available on all BacT/ALERT® 3D 60 software configurations,

regardless of 21 CFR Part 11 status.
Table 3-11: Audit Trail Events
Event Event Parameters
User Log In Time, Date, User ID
User Log Out Time, Date, User ID
Anonymous Bottle First Loaded Time, Date, User ID, Cell Location, Max Test Time,
Sequence Number

452501-1EN1
Table 3-11: Audit Trail Events (Continued)
Identified Bottle First Loaded Time, Date, User ID, Cell Location, Bottle Type,
Max Test Time, Bottle ID, Accession Number,
Sequence Number
Bottle Identified Time, Date, User ID, Cell Location, Bottle Type,
Max Test Time, Bottle ID, Accession Number,
Sequence Number
Bottle Moved Time, Date, User ID, Original Cell, Destination Cell,
Sequence Number
Bottle Unloaded Time, Date, User ID, Cell Location, Sequence

Number
Bottle Record Changed Time, Date, User ID or LIS, Cell Location, Action
(Bottle Type Changed, Loaded Status Changed,
Max Test Time Per Bottle Changed, Test Result
Manually Changed, Bottle ID Changed, Accession
Number Changed), Sequence Number, Bottle
Type, Loaded Status, Max Test Time, Test Result,
How Determined, Bottle ID, Accession Number
Note: The Bottle Type, Loaded Status, Max Test

Time, Test Result, How Determined, and
Accession Number are recorded in the Audit Trail
when they change.
Temperature Calibration Time, Date, User ID, Module ID, New Temperature
Setpoint
Cell Calibration Time, Date, User ID, Cell Location
Display Time Changed Time, Date, User ID, Amount of Change Relative to
UTC (Universal Coordinated Time)
Firmware Updated Time, Date, Device, Firmware Revision
Note: User ID is not recorded.
Module, Drawer, Rack, or Cell Time, Date, User ID, Location, Action (enable or
Enabled or Disabled disable), Device
Note: This event is recorded only from the Enable/

Disable Module, Drawer, Rack, or Cell screen.
Maximum Test Time for Bottle Time, Date, User ID, Bottle Type, Max Test Time
Type Changed
Positive Alarm Setting Changed Time, Date, User ID, Action (enable or disable)
Instrument Alarm Setting Time, Date, User ID, Action (enable or disable)
Changed
Operation Error Alarm Setting Time, Date, User ID, Action (enable or disable)
Changed
System Password Changed Time, Date, User ID

452501-1EN1
Table 3-11: Audit Trail Events (Continued)
21 CFR Part 11 Mode Changed Time, Date, User ID, Action (enable or disable)
Note: User ID is recorded only for disable.
User Account Changed Time, Date, User ID, Action (user added, user
deleted, password changed or cleared)
Patient Name Changed Time, Date, User ID, Hospital ID, First Name, Last
Name
Hospital ID Changed Time, Date, User ID, Accession Number, Hospital

ID
Cell Gap Detection Faults Time, Date, User ID, Number of Bottles Cleared
Cleared
3.7.4.18 Software / Configuration
Refer to Section 2.7.5 to view or configure user preferences.
3.7.5 LIS Module Diagnostic Values

This section will detail the normal values for diagnostic testing procedures for the LIS.
3.7.5.1 Loopback
the Loopback screens.

452501-1EN1
Figure 3-51: LIS/Loopback Screen
hardware.
hardware.

hardware.



correct.
respectively).

452501-1EN1
indicates whether Controller Module is waiting to receive data from the DBMS, or is
transmitting data to the DBMS.
3.0 Should remain at 0 — Displayed for the purpose of diagnosing software activity
and indicates whether there was a fault storing data in the software's receive data
FIFO.
and passed.
failed.
3.7.5.2 Port Stats
the Port Stats screens.

452501-1EN1
Figure 3-52: LIS/Port Stats Screen
1.1 Number of transmit buffer empty interrupts seen by serial hardware.
1.2 Number of receive buffer full interrupts generated by serial hardware.
1.3 Number of line status interrupts generated by serial hardware.
1.4 Number of modem status interrupts generated by serial hardware. (Note this
interrupt is disabled as indicated on the screen.)
2.1 Number of overruns reported by serial hardware. An overrun occurs if received

data is not removed from the serial hardware faster than it comes in. This value
should remain at 0.
2.2 Number of parity errors reported by serial hardware. Parity error checking is
turned off so no errors should be reported.
2.3 Number of framing errors reported by serial hardware. A framing error occurs if the
number of serial bits between the start and stop bit are not correct.
3.0 Indicates whether there was fault storing data in the software's receive data FIFO.

452501-1EN1
3.7.5.3 Message Stats
This screen displays statistics related to messages exchanged between the

instrument and LIS. The example screen shown in Figure 3-53 depicts the normal
values to be found in the Message Stats screens.
Figure 3-53: LIS/Message Stats Screen
3.7.5.4 Message Log
This screen displays recent history of message data exchanged between Controller
Module and LIS. The example screen shown in Figure 3-54 depicts the normal values
to be found in the Message Log screens.

452501-1EN1
Figure 3-54: LIS/Message Log Screen
3.7.6 Scandisk Output

Scandisk, as its name implies, is a function that runs periodically to checks the
integrity of the C and D drives. For the C drive, an additional set of checks is made to
verify the size of the fixed size files associated with the 3D application. This is not
done for the D drive.

452501-1EN1
The output of this operation is displayed on the screen. Following is an example of

that output.
*** ScanDisk Log ***
********************************************************
DRIVE INFO for C:

OEMName = MSDOS5.0
Bytes/Sec = 512
Secs/Cluster = 4
Rsvd Secs =1
Num of FATS = 2
Root Ent Cnt = 512
TotSec16 =0
Media = 0xF8
FATSz16 = 245
Secs/Trk = 32
Num of Heads = 8
Hidden Secs = 32
TotSec32 = 250336
DrvTypeNum = 128
Reserved1 = 0x0
BootSig = 0x29
VolID = 981014277
Vol Label = NO NAME
FileSysType = FAT16
--- Computed data ---
FAT Type = 16
FAT Size = 245

452501-1EN1
Total Secs = 250336

Bytes/FATEnt = 2
RootDirSector= 491
RootDirSectrs= 32
DataSector = 523
ClusterSector= 523
EOCMark >= 0xFFF8
BADSectorMark= 0xFFF7
Cluster 2 sector = 523
********************************************************
********************************************************
SCANDISK C:
Time = 10/12/01 09:14:28
----------------------------
CHECK DIRECTORY STRUCTURES
----------------------------
File IO.SYS
File MSDOS.SYS
Directory DOS
File COMMAND.COM
File AUTOEXEC.BAT
File CONFIG.SYS
File PME16.EXE
File BTA3D.INI
Total Entries 7
Deleted Entries 0
Directories 1
Cluster count 1
Traverse subdirectory DOS
Directory .
Directory ..
File ATTRIB.EXE
File CHKDSK.EXE
File COUNTRY.SYS
Total Entries 5
Deleted Entries 0
Directories 2
Cluster count 1
----------------------------
CHECK FILE STRUCTURES
----------------------------
Check file IO.SYS

452501-1EN1
Check file MSDOS.SYS
Check file COMMAND.COM
Check file AUTOEXEC.BAT
Check file CONFIG.SYS
Check file PME16.EXE
Traverse subdirectory DOS
Check file ATTRIB.EXE
Check file CHKDSK.EXE
Check file COUNTRY.SYS
----------------------------
CHECK FREE SPACE
----------------------------
Check free space for clusters 2 to 62454
********************************************************
SCANDISK PASSED for drive C:

Time = 10/12/01 09:14:29
********************************************************
********************************************************
CHECK FIXED SIZED FILES
********************************************************
C:\CPUNVRAM.BIN expected / actual size 524288 / 524288

C:\CPUNVR2.BIN expected / actual size 524288 / 524288
C:\SSDNVRAM.BIN expected / actual size 2097152 / 2097152
C:\SSDNVR2.BIN expected / actual size 2097152 / 2097152
C:\READDATA\READINGS.DAT expected / actual size 70656512 / 70656512
********************************************************
FILE SIZE CHECK PASSED
********************************************************
********************************************************
DRIVE INFO for D:

OEMName = *KBxeIHC
Bytes/Sec = 512
Secs/Cluster = 8
Rsvd Secs =1
Num of FATS = 2
Root Ent Cnt = 512
TotSec16 =0
Media = 0xF8
FATSz16 = 239
Secs/Trk = 32
Num of Heads = 64
Hidden Secs = 32
TotSec32 = 489440

452501-1EN1
DrvTypeNum = 128
Reserved1 = 0x0
BootSig = 0x29
VolID = 365958411
Vol Label = ZIP250
FileSysType = FAT16
--- Computed data ---
FAT Type = 16
FAT Size = 239
Total Secs = 489440
Bytes/FATEnt = 2
RootDirSector= 479
RootDirSectrs= 32
DataSector = 511
ClusterSector= 511
EOCMark >= 0xFFF8
BADSectorMark= 0xFFF7
Cluster 2 sector = 511
********************************************************
********************************************************
SCANDISK D:
Time = 10/12/01 09:14:32

----------------------------
CHECK DIRECTORY STRUCTURES
----------------------------
File ZIP250
File 100-1D.RKP
File 100-1E.RKP
File 100-1F.RKP
Directory MTOUCH62
Total Entries 5
Deleted Entries 0
Directories 1
Cluster count 1
Traverse subdirectory MTOUCH62
Directory .
Directory ..
File MCAL.BAT
File MCAL.OVL
Total Entries 4
Deleted Entries 0
Directories 2
Cluster count 1
----------------------------

452501-1EN1
Instrument Components Using the Keyboard in Place of the Mouse
CHECK FILE STRUCTURES
----------------------------
Check file 100-1D.RKP
Check file 100-1E.RKP
Check file 100-1F.RKP
Traverse subdirectory MTOUCH62
Check file MCAL.BAT
Check file MCAL.OVL
----------------------------
CHECK FREE SPACE
----------------------------
Check free space for clusters 2 to 61117
********************************************************
SCANDISK PASSED for drive D:
Time = 10/12/01 09:14:34
********************************************************
3.8 Using the Keyboard in Place of the Mouse
Normally, the mouse is used to make selections and enter data. The keyboard is an
alternate method and backup means of inputting data. Items on a screen are selected
by using the Tab key. A box or color change indicates which item is selected.
Pressing Enter will initiate the function of the selected item. For menus that require
entry of a numeric password, the numeric keys can be used instead of clicking the
mouse. The number keys (1–4) are used to enter the password value. The 5 is used
instead of clicking the Key Symbol button. Up/Down Scroll buttons are selected by
using the Tab key. Use > for next, and < for the previous item. Function keys can be
used to invoke the following commands:
• Ctrl + F1 – activates a special Unload mode. This identifies bottles that are
loaded in cells that are disabled or out of calibration. The green drawer LED
illuminates on drawers containing such bottles. When the drawer is opened, the
cell indicators will light for those bottles. Cells with rapidly flashing LEDs are
disabled or unusable. In this mode, bottles can be removed from the indicated
cells one at a time and moved to usable cells whose LED is off.
• Ctrl + F2 – activates a special Unload mode. This identifies cells out of
calibration. All such cells are identified whether they are loaded or not. When the
drawer is opened, the cell indicators will light for cells out of calibration.
• Ctrl + F3 – activates a special Unload mode. This identifies all bottles declared
positive by Fault Code #80 Reading Gap Detected.
• Ctrl + F10 – activates a special Unload mode. This identifies all currently loaded
bottles regardless of their test status. The green drawer indicator is lit on drawers
with such bottles. When the drawer is opened, the cell indicators will light for the
loaded cells.

452501-1EN1
Special Function Keys Instrument Components
Note: These special Unload modes function like the regular Unload modes. Bottles can be
removed and identified as they are removed. Bottles can even be moved to a different
cell if so desired.
Note: Anonymous bottles cannot be relocated to another cell until a bottle ID has been
entered for the bottle.
3.9 Special Function Keys
• Left Shift Key at bootup – boots the system up to DOS.

• Ctrl + Alt + Shift + 2 – enables an emergency exit to DOS.
• Alt + 5 – clears the Fault Code #80 Reading Gap Detected for all bottles.
• Ctrl + R – while in the Diagnostic screen, clears the Fault Code #19 Software
Exception.
• Ctrl + P – prints a copy of the BacT/ALERT® 3D 60 software screen.
• Ctrl + D – opens the Controller Module Software Diagnostic Test screen.
3.10 Quick Reference Card
The quick reference card is simply that, a quick reference. (Refer to Figure 3-56 and
Figure 3-57.) The card contains references to errors and fault codes that may appear
on the BacT/ALERT® 3D 60 during operation. The card's purpose is to aid the
operator in determining what may have caused a particular problem. It does not
contain corrective action measures. Refer to Chapter 7, Diagnostics and
Troubleshooting Information of this manual for possible solutions.

452501-1EN1
452501-1EN1
BacT/ALERT® 3D Quick Reference Card P/N 514432-2EN1 (95091)

OPERATOR ERROR CODES
BacT/ALERT® 3D 60 Service Manual

Refer to User Manual for detailed error description and troubleshooting instructions.
Code Description Code Description
901 CORRUPTED BOTTLE RECORD HAS BEEN SELECTED BOTTLE ID SCANNED MATCHES THAT OF A PREVIOUSLY
932
902 REQUIRED DATA MISSING UNLOADED BOTTLE
909 INVALID CELL LOAD – CELL QC IN PROCESS 940 BOTTLE DETAIL NOT FOUND
910 INVALID CELL LOAD BOTTLE ID ENTERED MATCHES THAT OF A BOTTLE THAT
941
911 INVALID CELL UNLOAD IS CURRENTLY LOADED IN A DIFFERENT CELL
BOTTLE TYPE CHANGE REQUIRES DIFFERENT
912 INVALID CELL RELOAD 942
ALGORITHM
BOTTLE ID JUST SCANNED MATCHES THAT OF A 943 IDENTIFIED BOTTLE CHANGED TO ANONYMOUS
913
CURRENTLY LOADED BOTTLE 944 MANUAL UNLOAD OF ANONYMOUS BOTTLE
921 BARCODE SCAN NOT ALLOWED IN THIS MODE BOTTLE ID ENTERED MATCHES THAT OF A PREVIOUSLY
945
923 INVALID BARCODE ENTRY UNLOADED BOTTLE
INCORRECT OR UNEXPECTED BARCODE SCANNED 960 DUPLICATE ENTRIES
930
AFTER UNLOADING A BOTTLE 961 INVALID BLANK FIELD
931 DETECTION ALGORITHM HAS BEEN CHANGED
Figure 3-56: Quick Reference Card (Front Side)

[02] SEE REVERSE FOR INSTRUMENT FAULT CODES
3-95
Quick Reference Card
3-96
Quick Reference Card
BacT/ALERT® 3D Quick Reference Card P/N 514432-2EN1 (95091)

INSTRUMENT FAULT AND STATUS CODES
Refer to User Manual for detailed error description and troubleshooting instructions.
Code Description Code Description
1 POWER FAULT IN INCUBATION MODULE 62 ERRONEOUS CELL LOAD STATUS REPORTED
2 COMMUNICATION LOST WITH INCUBATION MODULE 71 INVALID TIME STAMP
3 INCUBATION MODULE TEMPERATURE IS TOO HIGH 72 INVALID CALCULATION DATA
4 INCUBATION MODULE TEMPERATURE IS TOO LOW 73 INVALID METHOD DATA
5 INCORRECT INCUBATION MODULE CONNECTION 74 ALGORITHM CHANGE
6 INCUBATION MODULE STEPPER MOTOR FAULT 75 BOTTLE DATA CORRUPTED
10 CONTROLLER MODULE POWER FAULT 77 READING POLYNOMIAL CHANGE
11 INSUFFICIENT CHARGE IN UPS 78 INCOMPLETE TEST DATA
12 LIS COMMUNICATION FAULT 79 BOTTLE RELOADED VIA WRONG CONTROLLER
14 SYSTEM AUTOMATICALLY REBOOTED 80 READING GAP DETECTED
19 SOFTWARE EXCEPTION 81 BOTTLE LOADED IN CELL DURING QC
20 DRAWER OPEN FOR TOO LONG 99 BOTTLE LOADED IN A NON-OPERATIONAL CELL
21 DRAWER AGITATION FAILURE INCUBATION MODULE TEMPORARILY UNAVAILABLE WHILE
710
22 UNEXPECTED DRAWER AGITATION POWER UP INITIALIZATION TAKES PLACE
39 RACK TEMPERATURE FAULT 800 PRINTER FAULT
41-47 RACK(S) NOT RESPONDING 810 BACKUP FAILED
Figure 3-57: Quick Reference Card (Rear Side)

51-57 RACK HARDWARE FAILURE 820 ZIP® (IOMEGA) DISK MISSING OR ZIP DRIVE FAULT
60 CELL FAILED QC
SEE REVERSE FOR OPERATOR ERROR CODES
452501-1EN1

Chapter 4: Operating Procedures
About this Chapter
The intention of this chapter is to provide Field Service Engineers with the basic
operating procedures. These procedures may already be included in the
BacT/ALERT® 3D 60 User Manual.
Chapter Contents
4.1 Power Up/Down Sequence • 4-2

4.1.1 Power Down • 4-2
4.1.2 Power Up • 4-2
4.2 Compact Flash Disk Data Backup • 4-2
4.3 Compact Flash Disk Data Backup Restore • 4-5
4.4 3D 60 Module Data Backup • 4-11
4.5 3D 60 Module Data Backup Restore • 4-13
4.6 DOS Controller Module Backup • 4-13
4.7 Incubator Temperature Verification • 4-14
4.8 Digital Reference Thermometer Operation • 4-14
4.9 Configuring Users — 21 CFR Part 11 Mode • 4-15
4.9.1 Add Users • 4-15
4.9.2 Delete Users • 4-18
4.9.3 Clear User Passwords • 4-22

452501-1EN1
Power Up/Down Sequence Operating Procedures
4.1 Power Up/Down Sequence
The following procedure is designed to properly bring the system power up and down
gracefully.
4.1.1 Power Down

1. Press Esc, then type yes to exit from the operating system. The monitor will
display the screen titled Software Exception Debug screen.
Note: If an error occurs, press Esc, then type yes to restart the sequence.
2. Press Enter. A blue screen appears and the following will be displayed:
Normal shutdown in progress
Saving non-volatile memory
Shutdown complete
3. After the DOS prompt appears, turn the Main Power switch located on the
Power Entry Module (PEM) to Off.
4. Press the On/Off switch to turn the UPS off.
5. If performing work on the interior of the module, disconnect the power cord from
the PEM.
4.1.2 Power Up
1. Reconnect the power cord to the PEM if it had been previously disconnected.
2. Turn Main Power switch to On, providing AC power to the UPS.
3. Push the On/Off switch on the UPS.
Note: The system should restart on its own when power is reapplied to the instrument.
4.2 Compact Flash Disk Data Backup
1. Press Esc, then type yes to exit the software.

2. Insert a blank disk into the Zip® drive.
3. At the C:\ > prompt, type FORMAT D: and press Enter.
4. Verify the following message appears:
*
* Formatting Zip Disk
*
Insert New diskette for drive D:
And press ENTER when ready...
Note: It is recommended that the Zip® disk be formatted. If the backup fails to perform,
replace the Zip® disk with a new Zip® disk.

452501-1EN1
Operating Procedures Compact Flash Disk Data Backup
5. Press Enter to format the Zip® disk.

6. Verify the following message appears:
Formatting 2xx.xxM
Format complete
7. When asked to format another disk, press N, then press Enter.
8. Verify the system returns to the C:\ > prompt.
9. Press Ctrl + Alt + Delete to restart the BacT/ALERT® 3D 60 software.
10. Perform a backup of the software. (Refer to Section 4.4.)
11. Return to the Main screen.
12. Record the numbers shown on the Bottle Status table on the Main screen.
Note: The contents of the Bottle Status table will be used as a reference after the restore
procedure is completed. It will be used to assure that no bottle status has changed.
13. Record the version of the software shown on the Main screen. (Refer to
Figure 4-1.)
Note: Screens will vary depending on software configurations.
Bottle Status
Table
Software Version
Number
Next Screen
Button
14. Click the Next Screen button to access the Setup screen.
15. Enter the password 43432121.

17. Click the Edit Cell Contents button to access the Edit Cell Contents screen.

452501-1EN1
Compact Flash Disk Data Backup Operating Procedures
Figure 4-2: Edit Cell Contents Button
18. Click a cell with a dark circle around it and an asterisk (*) inside the circle.
Dark Circle
with Asterisk (*)
Previous Screen
Button
Figure 4-3: Edit Cell Contents Screen
19. Verify the Edit Bottle Detail screen appears. (Refer to Figure 4-4.)
Cancel Button
Figure 4-4: Edit Bottle Detail Screen
20. Print Figure 4-33 on page 4-26.

452501-1EN1
Operating Procedures Compact Flash Disk Data Backup Restore
21. Record the bottle data in the blank fields of Figure 4-33 for one bottle in the
Incubation Chamber.
22. Click the Cancel button to return to the Edit Cell Contents screen.
23. Click the Previous Screen button to return to the Main screen.
IMPORTANT: Ensure that the 3D 60 software backup has completed prior to exiting the
software.
25. At the C:\ > prompt, type xcopy*.Dat D:\backup /v and press Enter.
Note: DOS will ask you if you wish to overwrite the files with the .DAT extension. Press A to
overwrite all files. If asked to create a new file or directory, the backup performed
earlier did not complete properly. Return to Step 10 and begin the procedure again.
26. At the C:\ > prompt, type xcopy*.Bak D:\backup /v and press Enter.
Note: DOS will ask you if you wish to overwrite the files with the .Bak extension. Press A to
overwrite all files. If asked to create a new file or directory, the backup performed
earlier did not complete properly. Return to Step 10 and begin the procedure again.
27. At the C:\ > prompt, type D: and press Enter to verify the backup completed
without errors.
28. At the D:\ > prompt, type DIR/w and press Enter.
29. Verify BACKUP<DIR> appears.
Note: If BACKUP $$$ also appears, the backup failed. Return to Step 10 and begin the
procedure again.
30. At the D:\ > prompt, type CD BACKUP and press Enter.
31. At the D:\Backup> prompt, type DIR/w and press Enter.
Note: The B.25 software will list 20 or more files and folders in the directory. The last file
listed in the backup is BACKUP.OK with 0 bytes. This file is created when the backup
completes without errors and indicates that the backup was successful.
32. Eject the Zip® disk from the drive.
4.3 Compact Flash Disk Data Backup Restore
1. Insert the appropriate software version (B.25 or most current) of BTA 3D

Installation and Utilities Disk.

452501-1EN1
Compact Flash Disk Data Backup Restore Operating Procedures
CAUTION: To ensure proper software settings and compatibility, the 3D

disk should be labeled with the same version that the customer had
been using. The software version must match the software version
recorded in Step 13 of Section 4.2.
2. At the C:\ > prompt, type D:INSTALL and press Enter.

3. When the software installation is complete, remove the BTA 3D Installation and
Utilities Disk.
4. Once the installation is complete, press Ctrl + Alt + Delete simultaneously to
reboot the instrument. Verify that the 3D 60 software starts up and the Main
screen appears.
5. Insert the Zip® disk that was created in Section 4.2.
Note: If a backup was not performed, proceed to Step 13.
6. At the C:\ > prompt, type RESTORE and press Enter.
Note: The restore should take 5–10 minutes to perform. If the message RESTORE FAILED
appears (Figure 4-5), remove the new Compact Flash Disk and install the old
Compact Flash Disk. After installation of the old Compact Flash Adapter PCBA is
complete, perform Section 4.2 from the beginning.
Figure 4-5: Restore Failed
7. Remove the Zip® disk when the RESTORE COMPLETE message appears.
Figure 4-6: Restore Complete

452501-1EN1
8. Verify the C:\ > prompt appears to indicate that the restore is complete.
WARNING
If the Compact Flash Disk Data Backup Restore procedure cannot be
performed, all previous bottle data has been lost. The customer must
be advised to remove all bottles using the Ctrl + F10 function and
subculture the bottles. Failure to comply may result in invalid test
results.
IMPORTANT: If the Compact Flash Disk Data Backup Restore procedure cannot be
performed, the system’s site configuration must be restored to reflect the
current requirements of the site. This includes bottle test time, LIS parameters,
temperature, user preferences, instrument configurations, etc.
IMPORTANT: If the Compact Flash Disk Data Backup Restore procedure cannot be
performed, the bottle barcodes for i FA, i FN, and i PF must be activated. (Refer
to the BacT/ALERT® 3D i FA, BacT/ALERT® 3D i FN, and BacT/ALERT® 3D i PF
Bottle Barcode Activation Instructions.)
10. From the Main screen, verify the numbers shown on the Bottle Status table on
the Main screen are the same as recorded in Step 12 of Section 4.2. (Refer to
Figure 4-7.)
Note: Screens will vary depending on software configurations.
Bottle Status
Table
Software Version
Number
Load Bottles
Button

452501-1EN1
11. Verify the version of the software shown on the Main screen is the same as
recorded in Step 13 of Section 4.2. (Refer to Figure 4-7.)
12. Verify the bottle information is the same as recorded in Step 21 of Section 4.2.
13. Scan the Plastic SA Bottle barcode. (Refer to Figure 4-8.)
Note: To ensure that the algorithm for plastic bottles are used by the BacT/ALERT® 3D 60
instrument, each bottle type must be scanned. If the barcode reader does not scan the
barcodes shown in Figure 4-8, type the bottle ID below the barcode in the Bottle ID
field.
WARNING
If BPA/BPN or iFA/iFN/iPF barcodes are entered from the keyboard,
the bottle type in the Bottle Type field must be BPA/BPN or iFA/iFN/
iPF, as applicable. If the generic bottle type is shown in the Bottle
Type field after entering BPA/BPN or iFA/iFN/iPF barcodes from the
keyboard, then BPA/BPN or iFA/iFN/iPF bottle types have not been
activated. If this occurs, you must perform the BPA/BPN or iFA/iFN/
iPF activation, as applicable.
A continuous beep during keyboard input of BPA/BPN or iFA/iFN/iPF

barcodes indicates incorrect plastic bottle activation. If this occurs,
you must perform the BPA/BPN or iFA/iFN/iPF activation, as
applicable.
Note: After the barcode is scanned, the Accession Number field is highlighted.
14. Click the Bottle ID field to highlight it.

15. Repeat Step 13 and Step 14 until all barcodes from Figure 4-8 have been
scanned.
CAUTION: Before scanning the next barcode, ensure the Accession

Number field is no longer highlighted. The bottle ID must be scanned
into the Bottle ID field.
Note: Plastic BPA/BPN Bottle or Plastic iFA/iFN/iPF Bottle barcodes will only work after
the BPA/BPN or iFA/iFN/iPF activation, as applicable. If you receive an Instrument
Status Code #923 Invalid Barcode Entry when scanning BPA, BPN, iFA, iFN, or
iPF barcodes, you must activate the BPA/BPN or iFA/iFN/iPF barcodes, as
applicable.
16. Click the Check button to exit the Load Mode screen.

452501-1EN1
Plastic SA Bottle
Plastic SN Bottle
Plastic FA Bottle
Plastic FN Bottle
Plastic PF Bottle
Plastic iAST Bottle
Plastic iNST Bottle
Plastic iLYM Bottle
Plastic MP Bottle
Plastic BPA Bottle
Plastic BPN Bottle
Plastic iFA Bottle
Plastic iFN Bottle
Plastic iPF Bottle
Figure 4-8: Barcodes for Plastic Bottles

452501-1EN1
17. Press Ctrl + D.

18. Verify the Software screen appears. (Refer to Figure 4-9.)
Figure 4-9: Software Screen
19. Type 6 to access the Software Bottle Tables screen. (Refer to Figure 4-10.)
Line Scroll
Up Button
Figure 4-10: Software Bottle Tables Screen

452501-1EN1
Operating Procedures 3D 60 Module Data Backup
20. Click the Line Scroll Up button to view the algorithms listed in Table 4-1.
Table 4-1: Plastic Bottle Algorithms
Algorithm Sensor Bottle Type Verify
10 N/A N/A N/A
11 LES/Plastic BacT/ALERT SA
12 LES/Plastic BacT/ALERT SN
13 LES/Plastic BacT/ALERT FA
14 LES/Plastic BacT/ALERT FN
15 LES/Plastic BacT/ALERT PF
16 N/A N/A N/A
17 LES/Plastic BacT/ALERT MP
18 N/A N/A N/A
50 LES/Plastic BacT/ALERT iAST
51 LES/Plastic BacT/ALERT iNST
52 LES/Plastic BacT/ALERT iLYM
53 LES/Plastic BacT/ALERT BPA
54 LES/Plastic BacT/ALERT BPN
55 LES/Plastic BacT/ALERT iFA
56 LES/Plastic BacT/ALERT iFN
57 LES/Plastic BacT/ALERT iPF
21. Verify that the algorithms are set to plastic.

22. Check off the Verify column in Table 4-1 as each algorithm is verified.
23. Repeat Step 13 through Step 22 for any bottle types that are not present in the
table or are not set to LES/Plastic.
24. After all algorithms have been verified and all appropriate steps have been
completed, return the system to operation.
4.4 3D 60 Module Data Backup
1. From the Main screen, click the Next Screen button.


4. Insert the backup disk into the Zip® drive.

452501-1EN1
3D 60 Module Data Backup Operating Procedures
Note: Only 250 Megabyte Zip® disks should be used as the backup media with B.25
software.
5. Click the Backup Management button to start the backup process.
Figure 4-11: Backup Management Icon
6. Click the Previous Screen button until the Main screen appears.
7. Verify the Backup in Process icon is flashing in the upper left corner of the
screen.
Note: The backup will take between 15–30 minutes to complete.
Note: When the backup is finished, the Backup in Process icon will stop flashing.
8. Press Esc and type yes to exit the software.

9. At the C:\ > prompt, type D: and press Enter.
10. Type DIR and press Enter.
Note: If the backup was successful, BACKUP <DIR> will appear. If the backup failed,
BACKUP $$$ will be displayed.
11. If the backup failed:

a. Type FORMAT D: and press Enter.
b. Verify the following message appears:
*
* Formatting Zip Disk
*
Insert New diskette for drive D:
And press ENTER when ready...
c. Press Enter to format the Zip® disk.
d. Verify the following message appears:
Formatting 2xx.xxM
Format complete
e. When asked to format another disk, press N, then press Enter.
f. Verify the system returns to the C:\ > prompt.
g. Press Ctrl + Alt + Delete to restart the BacT/ALERT® 3D 60 software.
h. Begin the Backup procedure at Step 1, omitting Step 4.
Note: If the backup fails to perform again, replace the Zip® disk with a new Zip® disk and
perform the procedure again.
12. Type CD BACKUP and press Enter.

452501-1EN1
Operating Procedures 3D 60 Module Data Backup Restore
13. Type DIR and press Enter.

14. Ensure that the B.25 lists 22–25 files and that the BACKUP OK file is the last
one listed.
15. Eject the Zip® disk.
Note: The backup can be used to restore the data if the system crashes during the UPS test
of the 3D 60.
4.5 3D 60 Module Data Backup Restore
1. Insert the Zip® disk that has the backup data copied to it.
3. At the C:\ > prompt, type RESTORE and press Enter.
Note: When the program has completed restoration successfully, a message will appear
indicating that the restore was complete.
4.6 DOS Controller Module Backup
This function is equivalent to performing a backup within the BacT/ALERT® 3D 60

application, except that the backup time is much shorter when it is executed from the
DOS prompt.
IMPORTANT: Bottle readings are not taken when operating from the DOS level.
Note: The DOS Controller Module Backup is only available on systems with the new B.25.23
software version or higher.

2. Insert a blank disk into the Zip® drive.
3. At the D:\ > prompt, type FORMAT and press Enter.
4. At the C:\ > prompt, type BACKUP and press Enter.
5. At the D:\ > prompt, type DIR and press Enter to verify that the backup was
successful.
a. Backup <DIR> = Successful backup
b. Backup $$$ = Unsuccessful backup. Perform backup again.
Note: It is recommended that the Zip® disk be formatted. If the backup fails to perform,
replace the Zip® disk with a new Zip® disk and repeat Step 2 through Step 5.
6. Eject the Zip® disk.

452501-1EN1
Incubator Temperature Verification Operating Procedures
4.7 Incubator Temperature Verification
Note: Ensure all drawers have been closed for a minimum of 30 minutes before continuing.
1. Ensure the thermometer is switched ON and is set to TEST, and remove the
probe cover.
2. Open the door and tape or lay the Digital thermometer next to the thermometer
in the Incubation Chamber.
3. Place the probe as close to the unit’s thermometer as possible.
4. Close the door and allow the temperature to stabilize for 20 minutes.
5. Open the door and switch thermometer to the HOLD position and remove.
6. Close the door and measure the incubator temperature.
7. Adjust the incubator temperature if the difference between the measured
temperature and the set point temperature of the incubator exceeds ±0.5 °C.
Continue verifying additional incubation modules as required.
8. Inform the customer of the difference between the measured temperature and
the internal thermometer. Note in comments section on the PM Check List who
was informed.
4.8 Digital Reference Thermometer Operation
1. Open the door.

2. Move the Reference Thermometer ON/OFF switch to ON.
3. Move the HOLD/TEST switch to TEST.
4. Close the door and allow 30 minutes for the temperature to stabilize.
5. To take readings with the Reference Thermometer:
Note: Time required for action is about 30 seconds.
a. Open the door about 1/3 of the way.

b. Move the HOLD/TEST switch, located at the bottom of the Reference
Thermometer LCD display, to HOLD to freeze the current reading.
c. Look at the display or remove the Reference Thermometer to observe the
current reading.
d. Record the reading per policy.
e. Install the Reference Thermometer, if necessary.
f. Move the HOLD/TEST switch to TEST to allow continuous readings.
g. Move the ON/OFF switch to OFF.
h. Close the door.

452501-1EN1
Operating Procedures Configuring Users — 21 CFR Part 11 Mode
4.9 Configuring Users — 21 CFR Part 11 Mode
4.9.1 Add Users

1. From the Main screen, click the Login button.
User Name
Password Check
Button
Cancel
Button
Change
Password
Previous Button
Screen
Button
Figure 4-13: User Login Screen
biomerieux3d. The User Name service is always valid. Do not provide the service

452501-1EN1
Configuring Users — 21 CFR Part 11 Mode Operating Procedures
Next Screen
Button
Key Symbol
Button
Configure
Users
Button


452501-1EN1
Add User
Previous
Screen Check
Button Button

12. Verify the Add User screen appears.
User Name
Field
Add User
Button User
List
Previous
Screen Check
Button Button
Figure 4-17: Add User Screen
13. Enter the user name in the User Name field.

16. Verify the user name appears in the user list.

452501-1EN1
Add User
Button User
List
Previous
Screen Check
Button Button
Figure 4-18: Add User Screen with User Name Added
17. Repeat Step 11 through Step 16 to add additional users.

18. When all users have been added, click the Previous Screen button until the
Main screen appears.
4.9.2 Delete Users


452501-1EN1
User Name
Password Check
Button
Cancel
Button
Change
Password
Previous Button
Screen
Button
Next Screen
Button

452501-1EN1
Key Symbol
Button
Configure
Users
Button

Delete User
Button
Previous
Screen Check
Button Button

452501-1EN1
11. Click the Delete User button.

12. Verify the Delete User screen appears.
Delete User
Button User
List
Previous
Screen Check
Button Button
Figure 4-24: Delete User Screen
13. Select the user name(s) to delete in the user list.
Note: More than one user name may be selected. If the wrong user name is selected, click
the name again to deselect it.
Delete User
Button Highlighted
Users
Previous
Screen Check
Button Button
Figure 4-25: Delete User Screen with User Names Highlighted
14. Click the Delete User button.

16. Verify the user name(s) does not appear in the user list.

452501-1EN1
17. When all desired users have been deleted, click the Previous Screen button
until the Main screen appears.
4.9.3 Clear User Passwords

User Name
Password Check
Button
Cancel
Button
Change
Password
Previous Button
Screen
Button

452501-1EN1
Next Screen
Button
Key Symbol
Button
Configure
Users
Button


452501-1EN1
Clear User
Password
Button
Previous
Screen Check
Button Button
11. Click the Clear User Password button.

12. Verify the Clear User Password screen appears.
Clear User
Password
Button User
List
Previous
Screen Check
Button Button
Figure 4-31: Clear User Password Screen
13. Select the user name(s) associated with the passwords to clear from the user
list.
Note: More than one user name may be selected. If the wrong user name is selected, click
the name again to deselect it.
Note: When you clear a user password, the password is reset to the blank setting. The user
will then have to recreate a password the next time they try to log in.

452501-1EN1
Clear User
Password
Button Highlighted
Users
Previous
Screen Check
Button Button
Figure 4-32: Clear User Password Screen with User Names Highlighted
14. Click the Clear User Password button.

16. When all desired passwords have been cleared, click the Previous Screen
button until the Main screen appears.

452501-1EN1
Figure 4-33: Blank Edit Bottle Detail Screen

452501-1EN1
Chapter 5: Component Replacement
About this Chapter
This chapter provides the steps necessary to perform the remove and replace actions
of the Lowest Replaceable Unit (LRU). This chapter explains the common field repair
procedures for replacing defective components of the BacT/ALERT® 3D 60.
This chapter also provides procedures that may be utilized to facilitate higher
maintenance. Replacement sections are divided into removal and installation
procedures for that purpose.
IMPORTANT: If you are replacing a component, it is extremely important that you complete all
procedures within the replacment section.
IMPORTANT: Before you perform any of the repair/replacement procedures in this chapter,
use the troubleshooting procedures in Chapter 7, Diagnostics and
Troubleshooting Information to isolate and diagnose instrument problems.
For a list of available spare parts, contact your local bioMérieux subsidiary or refer to
the most recent spare parts database.
Before beginning a procedure to replace a component, read the procedure

completely. Due to design improvements on the instrument, there may be more than
one part number for a component. Ensure that you are using the correct procedure to
replace the component prior to starting the procedure.
Chapter Contents
5.1 Important Information • 5-5

5.2 Components Covered • 5-5
5.2.1 Electronics • 5-5
5.2.2 Power Supply • 5-6
5.2.3 Incubation Chamber • 5-6
5.2.4 Agitation • 5-6
5.2.5 Operator Input Components • 5-6
5.2.6 External Components • 5-6
5.3 CPU PCBA (P/N 750-0070-902) Replacement • 5-7
5.3.1 CPU PCBA (P/N 750-0070-902) Initial Checks • 5-7
5.3.2 CPU PCBA (P/N 750-0070-902) Removal • 5-8
5.3.3 CPU PCBA (P/N 750-0070-902) Installation • 5-10
5.3.4 Restore CPU Configuration Data • 5-13
5.3.5 Re-enter Configuration and Operation Option Data • 5-13
5.3.6 CPU PCBA (P/N 750-0070-902) Final Checks • 5-15
5.4 CPU PCBA (P/N 750-0070-01) Replacement • 5-16
5.4.1 CPU PCBA (P/N 750-0070-01) Initial Checks • 5-16
5.4.2 CPU PCBA (P/N 750-0070-01) Removal • 5-18
5.4.3 CPU PCBA (P/N 750-0070-01) Installation • 5-20

452501-1EN1
Component Replacement
5.4.4 Restore CPU Configuration Data • 5-22

5.5 CPU BIOS Battery Replacement • 5-23
5.5.1 CPU BIOS Battery Removal • 5-23
5.5.2 CPU BIOS Battery Installation • 5-26
5.6 Quad Serial PCBA Replacement • 5-27
5.6.1 Quad Serial PCBA Removal • 5-27
5.6.2 Quad Serial PCBA Installation • 5-29
5.7 Compact Flash Disk Replacement • 5-29
5.7.1 Compact Flash Disk Removal • 5-29
5.7.2 Compact Flash Disk Installation • 5-32
5.8 Compact Flash Adapter PCBA Replacement • 5-33
5.8.1 Compact Flash Adapter PCBA Removal • 5-33
5.8.2 Compact Flash Adapter PCBA Installation • 5-35
5.9 ModSig PCBA Replacement • 5-36
5.9.1 ModSig PCBA Removal • 5-36
5.9.2 ModSig PCBA Installation • 5-39
5.10 ModSig PCBA Fuse(s) Replacement • 5-41
5.10.1 ModSig PCBA Fuse(s) Removal • 5-41
5.10.2 ModSig PCBA Fuse(s) Installation • 5-42
5.11 Step-5 PCBA Replacement • 5-43
5.11.1 Step-5 PCBA Removal • 5-43
5.11.2 Step-5 PCBA Installation • 5-45
5.12 Step-5 Motor Replacement • 5-45
5.12.1 Step-5 Motor Removal • 5-45
5.12.2 Step-5 Motor Installation • 5-49
5.13 Outlet Thermistor PCBA Replacement • 5-50
5.13.1 Outlet Thermistor PCBA Removal • 5-50
5.13.2 Outlet Thermistor PCBA Installation • 5-52
5.14 Inlet Thermistor PCBA Replacement • 5-52
5.14.1 Inlet Thermistor PCBA Removal • 5-52
5.14.2 Inlet Thermistor PCBA Installation • 5-54
5.15 Zip® Drive Replacement • 5-55
5.15.1 Zip® Drive Removal • 5-55
5.15.2 Zip® Drive Installation • 5-59
5.16 System Power Panel Assembly Replacement • 5-60
5.16.1 System Power Panel Assembly Removal • 5-60
5.16.2 System Power Panel Assembly Installation • 5-62
5.17 Power Supply Transformer Replacement • 5-62
5.17.1 Power Supply Transformer Removal • 5-63
5.17.2 Power Supply Transformer Installation • 5-64
5.18 Power Supply Metal Oxide Varistor (MOV) Replacement • 5-65
5.18.1 Power Supply Metal Oxide Varistor (MOV) Removal • 5-65
5.18.2 Power Supply Metal Oxide Varistor (MOV) Installation • 5-66
5.19 Power Supply Solid State Relay(s) Replacement • 5-67

452501-1EN1
5.19.1 Power Panel Solid State Relays Removal • 5-67

5.19.2 Power Panel Solid State Relays Installation • 5-69
5.20 DC Power Supply Replacement • 5-70
5.20.1 DC Power Supply Removal • 5-70
5.20.2 DC Power Supply Installation • 5-71
5.21 Power Entry Module Replacement • 5-72
5.21.1 Power Entry Module Removal • 5-72
5.21.2 Power Supply Transformer Removal • 5-72
5.21.3 Power Entry Module Installation • 5-73
5.22 Power Entry Module Fuse(s) Replacement • 5-74
5.22.1 Power Entry Module Fuse(s) Removal • 5-74
5.22.2 Power Entry Module Fuse(s) Installation • 5-75
5.23 Fan Replacement • 5-76
5.23.1 Fan Removal • 5-76
5.23.2 Fan Installation • 5-79
5.24 Heater Replacement • 5-80
5.24.1 Heater Removal • 5-80
5.24.2 Heater Installation • 5-82
5.25 Thermal Switch Replacement • 5-82
5.25.1 Thermal Switch Removal • 5-82
5.25.2 Thermal Switch Installation • 5-84
5.26 Blower Assembly Replacement • 5-84
5.26.1 Blower Assembly Removal • 5-84
5.26.2 Blower Assembly Installation • 5-86
5.27 Blower Motor Capacitor Replacement • 5-86
5.27.1 Blower Motor Capacitor Removal • 5-86
5.27.2 Blower Motor Capacitor Installation • 5-88
5.28 Digital Reference Thermometer Replacement • 5-88
5.28.1 Digital Reference Thermometer Removal • 5-88
5.28.2 Digital Reference Thermometer Installation • 5-89
5.29 Digital Reference Thermometer Battery Replacement • 5-89
5.29.1 Digital Reference Thermometer Battery Removal • 5-89
5.29.2 Digital Reference Thermometer Battery Installation • 5-90
5.30 Rack Assembly Replacement • 5-90
5.30.1 Rack Assembly Removal • 5-90
5.30.2 Rack Assembly Installation • 5-94
5.31 Bottle Holder Cover Replacement • 5-95
5.31.1 Bottle Holder Cover Removal • 5-95
5.31.2 Bottle Holder Cover Installation • 5-96
5.32 Link Assembly Replacement • 5-97
5.32.1 Link Assembly Removal • 5-97
5.32.2 Link Assembly Installation • 5-99
5.33 Step-5 Drive Agitation Linkage Assembly Replacement • 5-100
5.33.1 Step-5 Drive Agitation Linkage Assembly Removal • 5-100

452501-1EN1
5.33.2 Step-5 Drive Agitation Linkage Assembly Installation • 5-103

5.34 Gas Spring Assembly Replacement • 5-105
5.34.1 Gas Spring Assembly Removal • 5-105
5.34.2 Gas Spring Assembly Installation • 5-106
5.35 Magnetic Door Switches Replacement • 5-107
5.35.1 Magnetic Door Switches Removal • 5-107
5.35.2 Magnetic Door Switches Installation • 5-109
5.36 Keyboard Replacement • 5-109
5.36.1 Keyboard Removal • 5-109
5.36.2 Keyboard Installation • 5-110
5.37 Barcode Scanner Replacement • 5-110
5.37.1 Barcode Scanner Removal • 5-110
5.37.2 Barcode Scanner Installation • 5-111
5.38 Fax Modem Replacement • 5-111
5.38.1 Fax Modem Removal • 5-111
5.38.2 Fax Modem Installation • 5-112
5.39 UPS Replacement • 5-112
5.39.1 UPS Removal • 5-112
5.39.2 UPS Installation • 5-113
5.40 UPS Battery Replacement • 5-114
5.40.1 UPS Battery Removal • 5-114
5.40.2 UPS Battery Installation • 5-116
5.41 Reflective Standard Discs Replacement • 5-116
5.41.1 Reflective Standard Discs Removal • 5-117
5.41.2 Reflective Standard Discs Installation • 5-117
5.42 Post Service Validation • 5-124
5.42.1 Required Materials • 5-124
5.42.2 Procedures • 5-124

452501-1EN1
Component Replacement Important Information
5.1 Important Information
WARNING
Potential Biohazardous Material! Instrument surfaces and
contaminated bottles are potentially biohazardous and should be
handled according to good laboratory practices. Observe universal
precautions when operating the instrument and when performing
maintenance or troubleshooting.
WARNING
The customer could have a subculture event present if the 3D 60 is
shut down for more than an hour. The B.25 software monitors for a
gap in the readings. If an hour gap is detected, the software will flag
all bottles affected with a Fault Code #80 Reading Gap Detected.
Failure to follow the procedures in this chapter or failure to attend to
fault conditions reported by the instrument within 1 hour may lead to
invalid test results and the need to subculture bottles.
CAUTION: Proper ESD precautions must be observed when working on

or around any PCBA. (Refer to Appendix F, Electrostatic Discharge
(ESD).)
IMPORTANT: Before you perform maintenance or troubleshooting procedures, perform the

Decontamination procedure. (Refer to Appendix B, Decontamination
Procedures.)
5.2 Components Covered
5.2.1 Electronics
• CPU PCBA (P/N 750-0070-01 / 902)
• Quad Serial PCBA
• Compact Flash Adapter PCBA
• ModSig PCBA
• ModSig PCBA Fuses
• Step-5 PCBA
• Step-5 Motor

452501-1EN1
Components Covered Component Replacement
• Outlet Thermistor PCBA

• Inlet Thermistor PCBA
• Zip® Drive
5.2.2 Power Supply

• System Power Panel
• Power Supply Transformer
• Power Supply Metal Oxide Varistor (MOV)
• Power Panel Solid State Relays
• DC Power Supply
• Power Entry Module Fuses
5.2.3 Incubation Chamber

• Digital Reference Thermometer
• Rack Assembly
• Magnetic Door Switches
• Gas Spring Assembly
5.2.4 Agitation
• Fan
• Heater
• Blower Assembly
• Blower Motor Capacitor
• Step-5 Drive Agitation Linkage Assembly
5.2.5 Operator Input Components

• Keyboard
• Barcode Scanner
5.2.6 External Components

• Fax Modem
• UPS

452501-1EN1
Component Replacement CPU PCBA (P/N 750-0070-902) Replacement
5.3 CPU PCBA (P/N 750-0070-902) Replacement
This section is for the replacement of CPU PCBA (P/N 750-0070-902). CPU PCBA
(P/N 750-0070-01) is no longer manufactured. Replacement of CPU PCBA (P/N 750-
0070-01) will require an instrument upgrade to CPU PCBA (P/N 750-0070-902). Refer
to Section E.1 in Appendix E, Instrument Improvements for instructions on this
upgrade.
Set Point
Temperature
Software
Version
Figure 5-1: Instrument Icon Pictorial
5.3.1 CPU PCBA (P/N 750-0070-902) Initial Checks

If the CPU is being removed for reasons other than being faulty (i.e. CPU upgrade),
perform these initial checks. Otherwise, proceed to Step 2.
1. If the BacT/ALERT® 3D 60 software is executing, perform the following:

a. Print a copy of Table 5-8 and Table 5-9 on page 5-125.
Note: Table 5-9 will be used later in this procedure.
b. Record the bottle counts and software version from the Main screen in
Table 5-8.
c. Press Esc and type yes to exit the program. Wait for the C:\ > prompt to
appear.
Note: If the CPU is faulty to the point that access to the C:\ > prompt is impossible, go
directly to Section 5.3.2 and Section 5.3.3 to replace the CPU PCBA.
2. Simultaneously, press Ctrl + Alt + Delete. The screen will go blank and then
text will appear.
3. Press F1 at the bioMérieux splash screen to enter the CMOS Setup screen.
4. Record both the local date and time and CMOS date and time in Table 5-9 that
was printed out earlier.

452501-1EN1
CPU PCBA (P/N 750-0070-902) Replacement Component Replacement
5.3.2 CPU PCBA (P/N 750-0070-902) Removal

1. Refer to Section 4.1.1 and perform the Power Down procedure.

(ESD).)
2. Open the door and remove two screws securing the top panel. (Refer to
Figure 5-2.)
Top Panel
Screw Top Panel
Screw
Figure 5-2: Top Panel Screws
3. Lift the top panel to the OPEN position.

4. Close the door.
5. Remove two screws securing the Quad Serial PCBA to the CPU PCBA. (Refer
to Figure 5-3.)
Note: The replacement procedure is simplified if the Quad Serial PCBA cables are not
disconnected.

452501-1EN1
Screws
Figure 5-3: Quad Serial PCBA
6. Tag and disconnect the cable assemblies from the CPU PCBA. (Refer to
Figure 5-4.)
IMPORTANT: Take special care not to damage the plastic bulkhead connectors when
disconnecting the connectors.
J14 J7
J2
J12
J19
J26
J46 J47 J43
Figure 5-4: CPU PCBA Jumper Locations
7. Remove six screws securing the CPU PCBA to the support standoffs.

452501-1EN1
8. Remove the CPU PCBA and set it aside.

9. Remove the random access memory (RAM) (P/N 186201-1) from the SODIMM
socket located at J103 on the back of the CPU PCBA. (Refer to Figure 5-5.)
10. Remove the Compact Flash Disk from the slot on the back of the CPU PCBA.
RAM CPU PCBA
Compact Flash Disk
Figure 5-5: CPU PCBA (Back View)
5.3.3 CPU PCBA (P/N 750-0070-902) Installation

(ESD).)
1. Install the RAM (P/N 186201-1) into the SODIMM socket located at J103 on the
back of the CPU PCBA. (Refer to Figure 5-5.)
Note: The new CPU PCBA may already have the RAM installed when shipped. If the RAM
was installed in the new CPU PCBA when shipped, disregard Step 1.
2. Install the Compact Flash Disk into the slot on the back of the CPU PCBA.
3. Position the new CPU PCBA on the top panel.
4. Install the screws and standoffs to secure the CPU PCBA to the top panel.

452501-1EN1
5. Connect the cable assemblies to the CPU PCBA. (Refer to Figure 5-6 and
Table 5-1 for cable and component placement.)
Note: Do not remove the existing jumpers from J31 on the CPU PCBA.
J14 J7
J2
J12
J19
J26
J31
J46 J47 J43
Figure 5-6: CPU PCBA Jumper Locations
Note: The old connection locations are also given in Table 5-1 to aid in reconnection of the
cables to the new CPU PCBA, as some of the cables may still have the older
connections listed on them.
Table 5-1: CPU PCBA Connector Locations
New Old Description

Connector Connector
Location Location
J2 J4 Digital I/O Cable
J7 J22 COMM Cable (Ethernet)
J14 N/A CPU BIOS Clock Battery (if installed)
J19 J2 COM 3/COM 4 Cable
J26 J3 Multi I/O Cable
J43 J7 DC Power Supply Cable

452501-1EN1
Table 5-1: CPU PCBA Connector Locations (Continued)
New Old Description

Connector Connector
Location Location
J46 J27 CRT (P27) Cable
J47 J18 IDE (Signal) Cable
J103 N/A Random Access Memory (RAM)
J105 N/A Compact Flash Disk
6. Carefully align the pins for the Quad Serial PCBA and plug into the CPU PCBA.
7. Install two screws to secure the Quad Serial PCBA to the CPU PCBA. (Refer to
Figure 5-3.)
8. Apply power to the instrument and turn on the UPS.
9. Return the top panel to the CLOSED position.
10. Open the door and install two screws to secure the top panel. (Refer to
Figure 5-7.)
Top Panel
Screw Top Panel
Screw
11. Close the door.

12. Refer to Section 5.42 and perform the Post Service Validation procedure.
13. Record the procedure in the Service Log per local procedures.
14. Return the system to operation.

452501-1EN1
5.3.4 Restore CPU Configuration Data

1. Refer to Section 4.1.2 and perform the Power Up procedure.
2. Press F1 at the bioMérieux splash screen to enter the CMOS Setup screen.
3. Print a copy of Table 5-10 on page 5-125.
4. To determine the time spent on the CPU PCBA replacement and new CMOS
time:
a. Enter the Local Time from Table 5-9 in the Time column next to the Local
Time at Start in Table 5-10.
Note: Information was recorded in Table 5-9 during the Initial Checks procedure in
Section 5.3.1.
b. Enter the current Local Time in the Time column next to the Local Time at
Finish in Table 5-10.
c. Subtract the Local Time at Finish from Local Time at Start and enter the
information in the Time column next to Time Spent Replacing CPU PCBA
in Table 5-10.
d. Enter the CMOS Time from Table 5-9 in the Time column next to the
CMOS Time at Start in Table 5-10.
e. Enter the information from the Time column next to Time Spent Replacing
CPU PCBA in Table 5-10 in the Time column next to Time Spent
Replacing CPU PCBA in Table 5-10.
f. Subtract the Time Spent Replacing CPU PCBA from CMOS Time at Start
in Table 5-10.
Note: If the CMOS date and time were not noted in Table 5-9 due to a down system, set the
CMOS date and time to Coordinated Universal Time (UTC).
Note: The current UTC may be obtained from the National Technical Information Services
WWV radio station by calling 1-303-499-7111, or by accessing the Internet USNO
Master Clock at the following web address: http://tycho.usno.navy.mil/cgi-bin/timer.pl.
5. Highlight A. Time and press Enter.

6. Enter the determined CMOS Date and Time from Table 5-10 and press Enter.
Note: Note 24 hour format.
system.
5.3.5 Re-enter Configuration and Operation Option Data

1. Verify that the correct version of 3D 60 software is displayed on the bottom of
the Main screen.

452501-1EN1

5. Click the Setup and Configuration button to access the Configuration screen.
6. Using the Configuration screen, perform the following:
a. Set the pictorial to reflect the setup of the 3D 60.
b. Set the configuration for the 3D 60.
CAUTION: Ensure all entries are correct. Bottle testing could be

adversely affected if the configuration information is incorrect.
7. Click the Previous Screen button until the Main screen appears.
8. At the Main screen confirm the following:
a. That the display clock is running.
b. The 3D 60 appears on the pictorial as expected. If not, refer to Step 6b
and reenter configuration data.
9. Turn off the power to the 3D 60.
10. Verify that the 3D 60 continues to run for about 1½ minutes and then powers
down automatically.
11. Turn the power back on to the 3D 60, and verify that the 3D program starts up
and the Main screen appears.

15. Set the display time to the local date and time:
a. Click the Set Date/Time button to access the Set Date and Time screen.
b. Reset the format to the operators preference.
c. Click the Check button to save changes and return to the Setup screen.
16. Verify test times are accurate:
a. Click the Set Maximum Test Time button to access the Set Maximum
Test Time screen.
b. Insure the test time for each bottle type is the same as recorded.
c. If the test time for each bottle type is not the same as recorded, adjust the
times as needed.
d. Click the Check button to save changes and return to the Setup screen.

452501-1EN1
17. If any cells or racks were disabled:

a. Click the Enable/Disable Module, Drawer, Rack, or Cell button to
access the Enable/Disable Module, Drawer, Rack, or Cell screen.
Note: Only the rack and cells will be able to be enabled or disabled on the 3D 60.
b. Adjust the component settings as needed.

18. If the password was changed from the default:
a. Click the Change Password button to access the Change Password
screen.
b. Enter the correct password.
19. Set the audible alarms:
a. Click the Set Audible Alarms Options button to access the Set Audible
Alarms screen.
b. Adjust the alarms options as required.
20. Click the Previous Screen button to return to the Main screen.
5.3.6 CPU PCBA (P/N 750-0070-902) Final Checks
Note: The steps listed here ensures that the 3D 60 functions as expected.
1. Verify the bottle counts are the same as those recorded in the initial checks.
2. Verify the optimal temperature settings.
3. At the Main screen, click the Load Bottles button. Without loading any bottles,
verify the following:
a. The Load Bottles screen appears.
b. Upon opening the door to the Incubation Chamber, verify that the yellow
LED illuminates as well as the cell indicator lights for available cells.
Verify that the yellow LED extinguishes when the door to the Incubation
Chamber is closed.
4. Click the Check button to exit the Load Bottles screen.

452501-1EN1
5.4 CPU PCBA (P/N 750-0070-01) Replacement
This section is for the replacement of CPU PCBA (LBC-586 PLUS Board, P/N 750-
0070-01). Although CPU PCBA (P/N 750-0070-01) is no longer manufactured,
refurbished boards may be available. If refurbished boards are not available,
replacement of CPU PCBA (P/N 750-0070-01) will require an instrument upgrade to
CPU PCBA (P/N 750-0070-902). Refer to Section E.1 in Appendix E, Instrument
Improvements for instructions on this upgrade.
5.4.1 CPU PCBA (P/N 750-0070-01) Initial Checks

If the CPU is being removed for reasons other than being faulty, (i.e.: CPU upgrade,)
perform these initial checks. Otherwise, proceed to Step 2.
1. If the BacT/ALERT® 3D 60 software is executing, perform the following:

a. Print a copy of Table 5-8 and Table 5-9 on page 5-125.
Note: Table 5-9 will be used later in this procedure.
b. Record the bottle counts and software version from the Main screen in
Table 5-8.
c. Write down the Controller Module ID value displayed. (Refer to
Figure 5-1.)
d. Press Esc and type yes to exit the program. Wait for the C:\ > prompt to
appear.
Note: If the CPU is faulty to the point that access to the C:\ > prompt is impossible, go
directly to Section 5.4.2 and Section 5.4.3 to replace the CPU PCBA.
2. Simultaneously, press Ctrl + Alt + Delete. The screen will go blank and then
text will appear.
3. While the system is rebooting, press the Delete key to enter the CMOS SETUP
menu.
4. Ensure the CMOS SETUP menu appears. (Refer to Figure 5-8.)

452501-1EN1
Figure 5-8: CMOS Setup Screen
5. Select STANDARD CMOS SETUP and press the Enter key.

6. Verify the CMOS Setup Utility screen appears. (Refer to Figure 5-9.)
Figure 5-9: CMOS Setup Utility Screen
7. Record both the local date and time and CMOS date and time in Table 5-9 that
was previously printed out.
8. Press the Esc key to exit the CMOS Setup Utility screen.
9. Press F10 + Y and press Enter to save and exit the BIOS Main screen.
Note: The software will boot to the Main screen.

452501-1EN1
5.4.2 CPU PCBA (P/N 750-0070-01) Removal


(ESD).)
Figure 5-10.)
Top Panel
Screw Top Panel
Screw

4. Close the door.
to Figure 5-11.)
disconnected.

452501-1EN1
Screws
6. Remove the Quad Serial PCBA and lay it aside.
Note: Connectors should be removed from the CPU PCBA in the order they are given.
7. Tag and disconnect WinJ3 from connector J3.

8. Tag and disconnect WinP2 from J2.
9. Tag and disconnect WinP7 from J7.
10. Tag and disconnect P18 from connector J18.
11. Tag and disconnect P27 from connector J27.
12. Tag and disconnect J5 from connector J5.
13. Tag and disconnect J4 from connector J4.
14. Remove six screws securing the CPU PCBA to the support standoffs. (Refer to
Figure 5-12.)
Screws
Screws
Figure 5-12: CPU PCBA

452501-1EN1
5.4.3 CPU PCBA (P/N 750-0070-01) Installation

(ESD).)
1. Position the CPU PCBA on the drawer frame.

2. Install the screws and standoffs to secure the CPU PCBA to the drawer frame.
3. Remove the existing jumpers from J31 on the CPU PCBA. (Refer to
Figure 5-13.)
J2 J3
D1
J3
J1
D2
C2
J2
C3 C4
J4
C1
+
J6
C6
R2
R3
R1
R4
C5
R5
J4 J7
C7
U6
U4
U7
J9
J8
C8
J11
J10
U10
J18
J5
Y2
U9
R16
U8
J18
J17
U15
U3
U5
U1
U2
Y1
J12
U14
U11
LITHIUM
KEEPER
II
LTC-3PN
J14
J15
J16
J5
J13
J13
J20
U16
T1
J19
J21
J19
U18
J27
U17
J23
J24
J25
J22
J26
J22
J27
J41
J28
J31
J23
J21
J30
U19
U20
LS1
U22
J33
T2
J31
C9
D6 D5 D4 D3
U21
+ +
C11
C10
+
J37
J35
J34 Y3
U25 U26
U24
J38
U23
U28
U29
U27
J39
SIM1
J40
Figure 5-13: CPU PCBA Connector Locations

452501-1EN1
4. Connect the cable assemblies to the CPU PCBA. (Refer to Table 5-2 for cable
and component placement.)
Table 5-2: CPU PCBA Connector Locations
Connector Description
Location
J2 COM 3/COM 4 Cable
J3 Multi I/O Cable
J4 Digital I/O Cable
J7 DC Power Supply Cable
J18 IDE (Signal) Cable
J22 COMM Cable (Ethernet)
J27 CRT (P27) Cable
J13, J19, 9-Pin Connector from CPU BIOS Clock Battery (if
J23 installed)
5. Position the Quad Serial PCBA in place.

6. Install two screws to secure the Quad Serial PCBA to the CPU PCBA.
Figure 5-14.)
Top Panel
Screw Top Panel
Screw

452501-1EN1
10. Close the door.
5.4.4 Restore CPU Configuration Data

menu.
3. Print a copy of Table 5-11 on page 5-125.
time:
a. Enter the Local Time from Table 5-9 in the Time column next to the Local
Time at Start in Table 5-10.
Note: Information was recorded in Table 5-9 during the Initial Checks procedure in
Section 5.4.1.
Finish in Table 5-10.
in Table 5-11.
d. Enter the CMOS Time from Table 5-9 in the Time column next to the
CMOS Time at Start in Table 5-11.
CPU PCBA in Table 5-10 in the Time column next to Time Spent
Replacing CPU PCBA in Table 5-11.
in Table 5-10.
Note: If the CMOS date and time were not noted in Table 5-9 due to a down system, set the
5. To change the date or time settings, press Up or Down Arrow key on the
keyboard to highlight the value you want to change.
6. Enter the determined time and/or date from New CMOS Date and Time in
Table 5-11 and press Enter.
7. If no changes were made, press the Esc key, select Y, and press Enter to exit
the BIOS.

452501-1EN1
Component Replacement CPU BIOS Battery Replacement
8. If changes were made, press F10, select Y, and press Enter to save to CMOS
and exit the BIOS.
9. Verify the system functions normally and that there are not any Fault Codes
present.
10. If Fault Code #71 Invalid Time Stamp or #80 Reading Gap Detected occurs,
verify that the CMOS date and time are correct.
11. Refer to Section 5.3.5 and perform the Re-enter Configuration and Operation
Option Date.
12. Refer to Section 5.3.6 and perform the CPU PCBA Final Checks procedure.
5.5 CPU BIOS Battery Replacement
Note: The CPU BIOS batteries should be replaced 10 years after their manufacture date.
The CPU BIOS battery has the part number and date code printed on it with the date
format of MMYYYY.
5.5.1 CPU BIOS Battery Removal


(ESD).)
Figure 5-15.)

452501-1EN1
CPU BIOS Battery Replacement Component Replacement
Top Panel
Screw Top Panel
Screw

4. Close the door.
to Figure 5-16.)
Screws
disconnected.
6. Unplug the Quad Serial PCBA.

452501-1EN1
Component Replacement CPU BIOS Battery Replacement
7. Remove the Quad Serial PCBA and lay it to the side.
Note: If the CPU BIOS Clock Battery is installed on an older model CPU PCBA, proceed to
Step 8. If the CPU BIOS Clock Battery is installed on a newer model CPU PCBA,
proceed to Step 9.
8. Disconnect the 9-pin connector of the battery assembly from J23, J19, and J13.
9-Pin Connector
Figure 5-17: 9-Pin Connector Placement
9. Disconnect the 3-pin connector from J14 on the CPU PCBA. (Refer to
Figure 5-18.)
J14
J17
Figure 5-18: Jumper and Connector Locations
10. Remove the cabling from the cable tie.

11. Remove the CPU BIOS Clock Battery from the CPU PCBA and set it aside.

452501-1EN1
CPU BIOS Battery Replacement Component Replacement
CPU BIOS
Clock Battery
Figure 5-19: CPU BIOS Clock Battery
5.5.2 CPU BIOS Battery Installation

(ESD).)
1. Position the CPU BIOS Clock Battery on the Velcro® dot on the CPU PCBA.
Note: Only perform Step 2 if the CPU BIOS Clock Battery is being installed on an older
model CPU PCBA. Only perform Step 3 and Step 4 if the CPU BIOS Clock Battery is
being installed on a newer model CPU PCBA. The caution statement below Step 4
only applies to the newer model CPU PCBA.
2. Connect the 9-pin connector of battery assembly to J23, J19, and J13. (Refer to
Figure 5-17.)
3. Connect the 3-pin connector to J14 on the CPU PCBA. (Refer to Figure 5-18.)
4. Ensure the jumper at J17 has been removed.
CAUTION: Failure to remove the jumper at J17 will shorten the battery
life.
5. Secure the cables with the cable tie.


452501-1EN1
Component Replacement Quad Serial PCBA Replacement
Figure 5-16.)
9. Connect the two cable assemblies to the Quad Serial PCBA.
Figure 5-15.)
12. Close the door.
5.6 Quad Serial PCBA Replacement
5.6.1 Quad Serial PCBA Removal


(ESD).)
Figure 5-20.)

452501-1EN1
Quad Serial PCBA Replacement Component Replacement
Top Panel
Screw Top Panel
Screw

4. Close the door.
5. Disconnect the two cable assemblies from the Quad Serial PCBA.
to Figure 5-21.)
Screws
7. Remove the Quad Serial PCBA and set it aside.

452501-1EN1
Component Replacement Compact Flash Disk Replacement
5.6.2 Quad Serial PCBA Installation


(ESD).)
Figure 5-21.)
4. Connect the two cable assemblies to the Quad Serial PCBA.
Figure 5-20.)
7. Close the door.
5.7 Compact Flash Disk Replacement
This procedure is for the replacement of the Compact Flash Disk. The type of CPU
PCBA in use will determine the location of the Compact Flash Disk. In Controller
Modules that still have the older version of the CPU PCBA (P/N 750-0070-01), the
Compact Flash Disk is located in the Compact Flash Adapter PCBA. If the Controller
Module has the newer version of the CPU PCBA (P/N 750-0070-902), the Compact
Flash Adapter PCBA has been removed and the Compact Flash Disk is located on the
CPU PCBA.
Replacing the Compact Flash Disk or loading firmware without performing proper data
backup and restore procedures can, under certain circumstances, result in an
incorrect algorithm being applied to plastic bottles. If problems are encountered after
installation of the Compact Flash Disk, refer to Chapter 7, Diagnostics and
Troubleshooting Information to troubleshoot the problem.
5.7.1 Compact Flash Disk Removal

1. Refer to Section 4.4 and perform the 3D 60 Module Data Backup procedure.
Note: If you are removing the Compact Flash Disk as part of another maintenance
procedure and not as part of the replacement procedure for the Compact Flash Disk

452501-1EN1
Compact Flash Disk Replacement Component Replacement
(i.e. to facilitate higher maintenance), it is not required that you perform the Compact
Flash Disk Data Backup procedure; however, it is recommended.

3. Shut down the UPS and disconnect the AC power from the system.

(ESD).)
Figure 5-22.)
Top Panel
Screw Top Panel
Screw

6. Close the door.
7. If the older version of the CPU PCBA is in use, remove the Compact Flash Disk
from the Compact Flash Adapter PCBA by pressing the black release plunger
and set the Compact Flash Disk aside. (Refer to Figure 5-23.)

452501-1EN1
Component Replacement Compact Flash Disk Replacement
Compact Flash
Disk
Black Plunger
8. If the newer version of the CPU PCBA is in use, remove the Compact Flash
Disk from the CPU PCBA. (Refer to Figure 5-24.)

452501-1EN1
Compact Flash Disk Replacement Component Replacement
CPU PCBA Compact Flash Disk
Figure 5-24: CPU PCBA (Back View)
5.7.2 Compact Flash Disk Installation

1. Install the Compact Flash Disk in the CPU PCBA if the newer version of the
CPU PCBA is in use. (Refer to Figure 5-24.)
2. Install the Compact Flash Disk in the Compact Flash Adapter PCBA if the older
version of the CPU PCBA is still in use. (Refer to Figure 5-23.)
3. Turn on the UPS and connect the AC power to the system.
Figure 5-22.)
6. Close the door.
8. Refer to Section 4.5 and perform the 3D 60 Module Data Backup Restore
procedure.
IMPORTANT: If you are installing the Compact Flash Disk as part of another maintenance
procedure and not as part of the replacement procedure for the Compact Flash
Disk (i.e. to facilitate higher maintenance), and you did not perform the 3D 60
Module Data Backup during removal of the Compact Flash Disk, do not perform
the 3D 60 Module Data Backup Restore procedure.

452501-1EN1
Component Replacement Compact Flash Adapter PCBA Replacement
5.8 Compact Flash Adapter PCBA Replacement
This replacement procedure is only for 3D 60 Modules that still have the older version
of the CPU PCBA (P/N 750-0070-01). If the 3D 60 Module has the newer version of
the CPU PCBA (P/N 750-0070-902), the Compact Flash Adapter PCBA has been
removed and the Compact Flash Disk is located on the CPU PCBA. Refer to
Section E.1 to ensure that all upgrades associated with the CPU PCBA have been
completed.
5.8.1 Compact Flash Adapter PCBA Removal

2. Shut down the UPS and disconnect the AC power from the system.

(ESD).)
Figure 5-25.)
Top Panel
Screw Top Panel
Screw

5. Close the door.

452501-1EN1
Compact Flash Adapter PCBA Replacement Component Replacement
6. Remove the Compact Flash Disk from the Compact Flash Adapter PCBA by
pressing the black release plunger and set the Compact Flash Disk aside.
Compact Flash
Disk
Black Plunger
Screws
7. Disconnect the J7 power cable from the Compact Flash Adapter PCBA. (Refer
to Figure 5-27.)

452501-1EN1
Component Replacement Compact Flash Adapter PCBA Replacement
J3
J7
Figure 5-27: Compact Flash Adapter Connector Locations
8. Remove four screws securing the Compact Flash Adapter PCBA to the support
standoffs. (Refer to Figure 5-26.)
9. Disconnect the J3 cable from the Compact Flash Adapter PCBA. (Refer to
Figure 5-27.)
10. Remove the Compact Flash Adapter PCBA.
5.8.2 Compact Flash Adapter PCBA Installation

(ESD).)
1. Connect the J3 cable to the Compact Flash Adapter PCBA. (Refer to

Figure 5-27.)
2. Position the Compact Flash Adapter PCBA in place.
Note: Ensure the J7 power cable is routed around the right side and on top of the Compact
Flash Adapter PCBA before installing the mounting screws.
3. Install four screws to secure the Compact Flash Adapter PCBA to the support
standoffs. (Refer to Figure 5-26.)
4. Connect the J7 power cable to the Compact Flash Adapter PCBA. (Refer to
Figure 5-27.)

452501-1EN1
ModSig PCBA Replacement Component Replacement
5. Install the Compact Flash Disk in the Compact Flash Adapter PCBA. (Refer to
Figure 5-26.)
6. Ensure that the Compact Flash Disk is locked in place.
Note: A soft click will be heard when the Compact Flash Disk locks in place.

Figure 5-25.)
9. Close the door.
10. Connect the AC power to the system and power up the UPS.
5.9 ModSig PCBA Replacement
5.9.1 ModSig PCBA Removal


(ESD).)
Figure 5-28.)

452501-1EN1
Component Replacement ModSig PCBA Replacement
Top Panel
Screw Top Panel
Screw

4. Close the door.
5. Disconnect the cable assembly from MSJ2. (Refer to Figure 5-29.)
Note: The connector at MSJ2 is keyed with a tab lock.
6. Disconnect the cable assembly from MSJP2.

7. Disconnect the cable assembly from JP10/P1.
Note: JP4 and JP28 connectors do not have any cables connected to them.

452501-1EN1
Step-5
PCBA
ModSig
PCBA
Figure 5-29: ModSig PCBA Connector Locations
8. Cut the tie wraps around the bundled cables on the ModSig PCBA.
Note: The cables in Step 9 through Step 19 should be disconnected in the exact order
listed.
9. Disconnect the cable assembly MS-JP30 from connector JP30.

16. Disconnect the cable assembly at JP21.
17. Disconnect the cable assemblies MS-JP11 and MS-JP12.
18. Disconnect the cable assembly MS-JP31.
19. Disconnect the cable assembly MS-JP1.
20. Remove two screws from the rear panel. (Refer to Figure 5-30.)

452501-1EN1
Component Replacement ModSig PCBA Replacement
Screws
Nuts Nuts
Figure 5-30: Rear Panel
21. Remove eight screws securing the ModSig PCBA to the support standoffs.
22. Disconnect the MCJ4 cable from the J4 connector on the Step-5 PCBA. (Refer
to Figure 5-29.)
23. Remove the ModSig PCBA from the standoffs.
24. Remove two screws securing the ModSig PCBA to the rear bulkhead.
25. Remove two hex nuts from the LIS port on the rear bulkhead. (Refer to
Figure 5-30.)
26. Remove two hex nuts from the MOUSE port on the rear bulkhead.
27. Remove two hex nuts from the BARCODE port on the rear bulkhead.
28. Remove the knurled nut from the EXT SPKR port on the rear bulkhead.
29. Remove the ModSig PCBA from the rear bulkhead and set it aside.
5.9.2 ModSig PCBA Installation

(ESD).)
1. Align the rear bulkhead to the mounting holes and peripheral ports on the
ModSig PCBA.
2. Install two screws to secure the ModSig PCBA to the rear bulkhead.
3. Install the knurled nut on the EXT SPKR port on the rear bulkhead. (Refer to
Figure 5-30.)
4. Install two hex nuts on the BARCODE port on the rear bulkhead.

452501-1EN1
5. Install two hex nuts on the MOUSE port on the rear bulkhead.
6. Install two hex nuts on the LIS port on the rear bulkhead.
7. Position the ModSig PCBA on the support standoffs.
Note: Ensure that there are not any cables under the ModSig PCBA.
8. Loosely install two screws in the rear panel to allow for proper alignment of the
ModSig PCBA.
9. Loosely install eight screws to align the ModSig PCBA on the support standoffs.
10. Ensure ModSig PCBA is aligned correctly.
11. Tighten eight screws to secure the ModSig PCBA to the support standoffs.
12. Tighten two screws in the rear panel.
13. Connect the MCJ4 cable to the J4 connector on the Step-5 PCBA. (Refer to
Figure 5-29.)
Note: The cables in Step 14 through Step 24 should be connected in the exact order listed.
14. Connect the cable assembly MS-JP1.

15. Connect the cable assembly MS-JP31.
16. Connect the cable assemblies MS-JP11 and MS-JP12.
17. Connect the cable assembly at JP21.
18. Connect the cable assembly MS-JP19 to connector JP19.
25. Connect the cable assembly to JP10/P1.
26. Connect the cable assembly to MSJP2.
27. Connect the cable assembly to MSJ2. (Refer to Figure 5-29.)
Note: The connector at MSJ2 is keyed with a tab lock.

Figure 5-28.)
30. Close the door.

452501-1EN1
Component Replacement ModSig PCBA Fuse(s) Replacement
5.10 ModSig PCBA Fuse(s) Replacement
The ModSig PCBA contains seven fuses identified as F1, F2, F3, F4, F5, F6, and F7.
F1 and F6 are 3.15-Amp 5x20mm type FST Time Lag fuses
(P/N 870-0008-22). F2, F3, F4, and F7 are 1-Amp 5x20mm type FST Time Lag fuses
(P/N 870-0008-17). Fuse F5 is a 0.5-Amp 5x20mm type FST Time Lag fuse (P/N 870-
0008-14).
5.10.1 ModSig PCBA Fuse(s) Removal


(ESD).)
Figure 5-31.)
Top Panel
Screw Top Panel
Screw

4. Close the door.

452501-1EN1
ModSig PCBA Fuse(s) Replacement Component Replacement
5. Determine which fuse requires replacement. (Refer to Figure 5-32.)

6. Remove the fuse from the retaining clip.
F2
F7
F3
F5
F6
F4 F1
Figure 5-32: ModSig PCBA Fuse Locations
5.10.2 ModSig PCBA Fuse(s) Installation

(ESD).)
CAUTION: The new fuse must be the same amperage and voltage rating
as the removed fuse. Overfusing could damage the equipment and
create a potential fire hazard.
1. Install the fuse in the retaining clip. (Refer to Table 5-3 for fuse information and
Figure 5-32 for fuse location.)
Table 5-3: ModSig PCBA Fuses
Fuse Rating Controls Fuse P/N
F1 3.15 Amp Drawer Communications 870-0008-22
F2 1 Amp Barcode Scanner 870-0008-17
F3 1 Amp Keyboard 870-0008-17
F4 1 Amp Remote Speaker 870-0008-17

452501-1EN1
Component Replacement Step-5 PCBA Replacement
Table 5-3: ModSig PCBA Fuses (Continued)
F5 0.5 Amp Audible Alarms 870-0008-14
F6 3.15 Amp 5VDC 870-0008-22
F7 1 Amp Step-5 PCBA 870-0008-17

Figure 5-31.)
4. Close the door.
5.11 Step-5 PCBA Replacement
5.11.1 Step-5 PCBA Removal


(ESD).)
Figure 5-33.)

452501-1EN1
Step-5 PCBA Replacement Component Replacement
Top Panel
Screw Top Panel
Screw

4. Close the door.
5. Disconnect the MCJ4 cable from the J4 connector. (Refer to Figure 5-34.)
Figure 5-34: Step-5 PCBA Connector Locations

452501-1EN1
Component Replacement Step-5 Motor Replacement
6. Disconnect the MCJ3 cable from the J3 connector.

7. Disconnect the MCJ1 cable from the J1 connector.
8. Remove six screws securing the Step-5 PCBA to the support standoffs.
9. Remove the Step-5 PCBA and set it aside.
5.11.2 Step-5 PCBA Installation

(ESD).)
1. Position the Step-5 PCBA on the support standoffs.

2. Install six screws to secure the Step-5 PCBA to the support standoffs. (Refer to
Figure 5-34.)
3. Connect the MCJ1 cable to the J1 connector.
4. Route the MCJ3 cable between the inside standoffs of the ModSig and Step-5
PCBAs.
Note: Feed the MCJ3 cable underneath the Step-5 PCBA and plug it in.

Figure 5-33.)
9. Close the door.
5.12 Step-5 Motor Replacement
5.12.1 Step-5 Motor Removal


452501-1EN1
Step-5 Motor Replacement Component Replacement

(ESD).)
Figure 5-35.)
Top Panel
Screw Top Panel
Screw

4. Close the door.
5. Disconnect the MCJ3 cable from the J3 connector. (Refer to Figure 5-36.)

452501-1EN1
MCJ3
Figure 5-36: Step-5 PCBA MCJ3 Connector
6. Remove the left side panel by lifting from the top edge of the panel.
7. Locate the setscrew points on the Motor Offset Round. (Refer to Figure 5-37.)
Motor Offset
Round
Drive Agitation
Linkage
Setscrew
Points
Figure 5-37: Motor Offset Round Setscrew Location
8. Remove the first setscrew.
Note: Use a 3/32 in. Allen wrench to remove setscrews.

452501-1EN1
Step-5 Motor Replacement Component Replacement
9. Rotate the Drive Agitation Linkage 90 degrees clockwise and remove the
second setscrew.
10. Remove four motor mounting screws from the pressed nuts. (Refer to
Figure 5-38.)
Motor
Mounting
Screws
Figure 5-38: Motor Mounting Screw Location
11. Pull the Step-5 Motor out and to the right in the direction shown in Figure 5-39.
Step-5
Motor
Figure 5-39: Step-5 Motor Removal
12. Remove four nuts and washers securing the motor mounting plate to the Step-5
Motor.
13. Set the Step-5 Motor aside.

452501-1EN1
5.12.2 Step-5 Motor Installation

1. Install four nuts and washers to secure the motor mounting plate to the Step-5
Motor.
2. Position the Step-5 Motor in place and align with the motor mounting screw
holes.
3. Push the four motor mounting screws up to the pressed nuts and tighten
slightly.
Note: Do not tighten the motor mounting screws all the way.
4. Tighten the motor mounting screws in an X pattern until all screws are
completely tightened. Tighten the upper left screw first, the lower right screw
second, the upper right screw third, and the the lower left screw fourth. (Refer to
Figure 5-40 for the tightening sequence.)
First
Third
Fourth Second
Figure 5-40: Motor Mounting Screw Tightening Sequence
5. Position the motor offset round in place with proper orientation to the motor
shaft flats.
Note: Support the opposite end of the Step-5 Motor when pushing the motor offset round on
the Motor Shaft to prevent pushing the isolation grommets from their locations in the
chassis holes.
6. Install the first setscrew in the motor offset round. (Refer to Figure 5-37.)
7. Rotate the drive agitation linkage 90 degrees clockwise and install the second
setscrew.
8. Ensure that the motor offset round and the drive agitation linkage are in the
correct position.
9. Insert paper cardstock over the wide foam at the top of the door.

452501-1EN1
Outlet Thermistor PCBA Replacement Component Replacement
Note: The paper cardstock will prevent damage to the foam when installing the left side
panel.
10. Install the left side panel.

11. Remove the paper cardstock.

(ESD).)
12. Connect the MCJ3 cable to the J3 connector. (Refer to Figure 5-36.)
Figure 5-35.)
15. Close the door.
5.13 Outlet Thermistor PCBA Replacement
5.13.1 Outlet Thermistor PCBA Removal


(ESD).)
Figure 5-41.)

452501-1EN1
Component Replacement Outlet Thermistor PCBA Replacement
Top Panel
Screw Top Panel
Screw

4. Close the door.
6. Disconnect the cable from the J3 connector on the Outlet Thermistor PCBA.
Screws
J3 Connector
Figure 5-42: Outlet Thermistor PCBA

452501-1EN1
Inlet Thermistor PCBA Replacement Component Replacement
7. Remove two screws securing the Outlet Thermistor PCBA to the panel.
8. Remove the Outlet Thermistor PCBA and set it aside.
5.13.2 Outlet Thermistor PCBA Installation

(ESD).)
1. Position the Outlet Thermistor PCBA on the panel.
Note: The Outlet Thermistor PCBA should be positioned so that the writing on the PCBA is
upside down. Refer to Figure 5-42 for the proper orientation.
2. Install two screws to secure the Outlet Thermistor PCBA to the panel. (Refer to
Figure 5-42.)
3. Connect the cable to the J3 connector on the Outlet Thermistor PCBA.
panel.

Figure 5-41.)
9. Close the door.
5.14 Inlet Thermistor PCBA Replacement
5.14.1 Inlet Thermistor PCBA Removal


452501-1EN1
Component Replacement Inlet Thermistor PCBA Replacement

(ESD).)
Figure 5-43.)
Top Panel
Screw Top Panel
Screw

4. Close the door.
5. Remove the right side panel by lifting from the top edge of the panel.
6. Disconnect the cable from the J3 connector on the Inlet Thermistor PCBA.

452501-1EN1
Inlet Thermistor PCBA Replacement Component Replacement
Screws
J3 Connector
Figure 5-44: Inlet Thermistor PCBA
7. Remove two screws securing the Inlet Thermistor PCBA to the panel.
8. Remove the Inlet Thermistor PCBA and set it aside.
5.14.2 Inlet Thermistor PCBA Installation

(ESD).)
1. Position the Inlet Thermistor PCBA on the panel.

2. Install two screws to secure the Inlet Thermistor PCBA to the panel. (Refer to
Figure 5-44.)
3. Connect the cable to the J3 connector on the Inlet Thermistor PCBA.
Note: The paper cardstock will prevent damage to the foam when installing the right side
panel.
5. Install the right side panel.

Figure 5-43.)

452501-1EN1
Component Replacement Zip® Drive Replacement
9. Close the door.

5.15 Zip® Drive Replacement
WARNING
Do not insert any object, other than a Zip® disk, into the Zip® drive
under any circumstances.
CAUTION: Do not forcibly remove the Zip® disk from the instrument.
Forcibly removing the Zip® disk may cause damage to the Zip® disk or
Zip® drive and may cause the system to lock up.
5.15.1 Zip® Drive Removal


(ESD).)
Figure 5-45.)

452501-1EN1
Zip® Drive Replacement Component Replacement
Top Panel
Screw Top Panel
Screw

4. Close the door.
Note: Only perform Step 5 if the Compact Flash Adapter PCBA is installed. If the Compact
Flash Adapter PCBA is not installed, proceed to Step 6.
5. Remove four screws securing the Compact Flash Adapter PCBA to the chassis.
Note: Do not remove the connections to the Compact Flash Adapter PCBA. Allow the
Compact Flash Adapter PCBA to hang down.

452501-1EN1
Screws
6. Disconnect the IDE cable from the Zip® Drive. (Refer to Figure 5-47.)
IDE Cable
Main Power
Connector
Figure 5-47: Zip® Drive Cable Removal
7. Disconnect the main power connector from the Zip® Drive.
Note: The main power connector is a connector with blue and black wires. Do not pull on the
wires to disconnect the connector.
8. Remove four screws securing the Zip® Drive to the instrument. (Refer to
Figure 5-48.)
IMPORTANT: Hold on to the Zip® Drive as you remove the last screw securing the Zip® Drive
to the chassis. The Zip® Drive can fall and be damaged when the last screw is
removed.

452501-1EN1
Zip® Drive Replacement Component Replacement
Screws
Figure 5-48: Zip® Drive Screw Location
9. Lower the top panel about half way.

10. From the bottom of the Zip® Drive, push the Zip® Drive through the cutout in the
top panel. (Refer to Figure 5-49.)
Top Panel
Cutout
Figure 5-49: Zip® Drive Cutout
11. Set the Zip® Drive down on a clean surface.

12. Remove the screws securing the Zip® Drive to the mounting bracket.
Note: There are typically four to six screws securing the Zip® Drive to the mounting bracket.
The number of screws will depend on where the screws are located. The screws may
be installed from the side, with three on each side of the mounting bracket, or on the
bottom of the mounting bracket. Refer to Figure 5-50.

452501-1EN1
Screws
Screws
(3 ea. Side)
Side Installation Bottom Installation
Figure 5-50: Zip® Drive Mounting Bracket Screw Locations
13. Remove the Zip® Drive from the mounting bracket and set it aside.
5.15.2 Zip® Drive Installation

1. Position the Zip® Drive in the mounting bracket.
2. Install the screws to secure the the Zip® Drive to the mounting bracket.
Note: There are typically four to six screws securing the Zip® Drive to the mounting bracket.
The number of screws will depend on where the screws are located. The screws may
be installed from the side, with three on each side of the mounting bracket, or on the
bottom of the mounting bracket. Refer to Figure 5-50.
3. Lower the top panel about half way.

4. From the bezel of the Zip® Drive, push the Zip® Drive through the cutout in the
top panel. (Refer to Figure 5-49.)
5. Install four screws to secure the Zip® Drive to the chassis. (Refer to
Figure 5-48.)
IMPORTANT: Hold onto the Zip® Drive until at least one screw has been installed.
6. Connect the main power connector to the Zip® Drive. (Refer to Figure 5-47.)
7. Disconnect the IDE cable from the Zip® Drive.
Note: Only perform Step 8 and Step 9 if the Compact Flash Adapter PCBA is installed. If the
Compact Flash Adapter PCBA is not installed, proceed to Step 10.
8. Position the Compact Flash Adapter PCBA in place.

9. Install four screws to secure the Compact Flash Adapter PCBA to the chassis.
Figure 5-45.)

452501-1EN1
System Power Panel Assembly Replacement Component Replacement
12. Close the door.

5.16 System Power Panel Assembly Replacement
5.16.1 System Power Panel Assembly Removal


(ESD).)
Figure 5-51.)
Top Panel
Screw Top Panel
Screw

4. Close the door.

452501-1EN1
Component Replacement System Power Panel Assembly Replacement
6. Disconnect the HBJ1/JBP1 wiring connector coming from the Heater and
Blower to TB1 and Relays. (Refer to Figure 5-52.)
BHP1
Connector
HBJ1/HBP1
Connector
Figure 5-52: Power Panel Assembly Connector Locations
7. Disconnect the BHP1 wiring connector coming from the electronics

compartment to the power supply.
8. Remove two screws securing the Power Panel Assembly to the chassis. (Refer
to Figure 5-53.)
Screws
Figure 5-53: Chassis Rear Panel
9. Lift the Power Panel Assembly up and out of the instrument through the top
panel and set it aside.

452501-1EN1
Power Supply Transformer Replacement Component Replacement
Note: The top panel may have to be pushed beyond the normal locked position of the Gas
Spring Assembly in order to clear the Power Panel Assembly from the instrument.
5.16.2 System Power Panel Assembly Installation

(ESD).)
1. Lower the Power Panel Assembly down and into the instrument through the top
panel.
Note: The top panel may have to be pushed beyond the normal locked position of the Gas
Spring Assembly in order to place the Power Panel Assembly in the instrument.
2. Install two screws to secure the Power Panel Assembly to the chassis. (Refer to
Figure 5-53.)
3. Connect the BHP1 wiring connector coming to the electronics compartment to
the power supply. (Refer to Figure 5-52.)
4. Connect the HBJ1/JBP1 wiring connector coming from the Heater and Blower
to TB1 and Relays.
panel.

Figure 5-51.)
10. Close the door.
5.17 Power Supply Transformer Replacement
Note: Individual power supply subassembly components are not repaired or replaced in
Domestic 3D 60s. Individual components are spared as parts and replaced in
International 3D 60s only.

452501-1EN1
Component Replacement Power Supply Transformer Replacement
5.17.1 Power Supply Transformer Removal

1. Refer to Section 5.16.1 and perform the System Power Panel Assembly
Removal procedure.

(ESD).)
2. Disconnect the four Transformer wires from the PEM. (Refer to Table 5-4 and
Figure 5-54.)
Table 5-4: Transformer to PEM Wires
Color Name
Brown PWRSWA
Orange PWRSWB
Red PWRSWC
Yellow PWRSWD
TB1-4B
TB1-1B
PEM
Figure 5-54: PEM Wiring
3. Remove the bolt securing the Transformer to the Power Panel Assembly
chassis. (Refer to Figure 5-55.)

452501-1EN1
Power Supply Transformer Replacement Component Replacement
Bolt
Figure 5-55: Transformer
4. Remove the screws from Terminal Block TB1-1B and TB1-4B. (Refer to
Figure 5-54.)
5. Disconnect the Green and Brown wires from TB1-4B.
6. Disconnect the Red and Blue wires from TB1-1B.
7. Remove the Transformer and set it aside.
5.17.2 Power Supply Transformer Installation

(ESD).)
1. Position the Transformer in place.

2. Connect the Red and Blue wires to TB1-1B. (Refer to Figure 5-54.)
3. Connect the Green and Brown wires to TB1-4B.
4. Install the screws in Terminal Block TB1-1B and TB1-4B.
5. Install the bolt to secure the transformer to the Power Panel Assembly chassis.
6. Connect the four Transformer wires to the PEM. (Refer to Table 5-4 and
Figure 5-54.)
Installation procedure.

452501-1EN1
Component Replacement Power Supply Metal Oxide Varistor (MOV) Replacement
5.18 Power Supply Metal Oxide Varistor (MOV) Replacement
5.18.1 Power Supply Metal Oxide Varistor (MOV) Removal


(ESD).)
Figure 5-56.)
Top Panel
Screw Top Panel
Screw

4. Close the door.

452501-1EN1
Power Supply Metal Oxide Varistor (MOV) Replacement Component Replacement
Bolt
7. Pull the Transformer out of the instrument far enough to easily access the
Terminal Board (TB1).
Note: It is not necessary to disconnect the Transformer wires.
8. Remove the screws from TB1-2B and TB1-3B. (Refer to Figure 5-58.)
TB1-3B
TB1-2B
MOV
Figure 5-58: Terminal Board 1 Wiring
9. Remove the MOV and set it aside.
5.18.2 Power Supply Metal Oxide Varistor (MOV) Installation

(ESD).)
1. Position the MOV on Terminal Board 1 (TB1).

2. Install the screws on TB1-2B and TB1-3B. (Refer to Figure 5-58.)
3. Postion the Transformer in place. (Refer to Figure 5-57.)

452501-1EN1
Component Replacement Power Supply Solid State Relay(s) Replacement
4. Install the bolt to secure the Transformer to the Power Panel Assembly chassis.
panel.

Figure 5-56.)
10. Close the door.
5.19 Power Supply Solid State Relay(s) Replacement
5.19.1 Power Panel Solid State Relays Removal


(ESD).)
Figure 5-59.)

452501-1EN1
Power Supply Solid State Relay(s) Replacement Component Replacement
Top Panel
Screw Top Panel
Screw

4. Close the door.
6. Determine which relay is defective.
7. Remove the lock nut from the defective relay. (Refer to Figure 5-60.)
Screws
Lock Nut
Cable
Connectors
K1 K2 K3 K4
Figure 5-60: Solid State Relays
8. Gently pull the solid state relay off of the studs, taking care not to damage the
wires attached to the terminals.

452501-1EN1
Component Replacement Power Supply Solid State Relay(s) Replacement
9. Remove four slotted screws securing the cable (lug) connectors to the defective
solid state relay.
10. Tag and disconnect the cable connections from the solid state relay.
11. Remove the solid state relay from the Power Panel assembly and set it aside.
5.19.2 Power Panel Solid State Relays Installation

(ESD).)
1. Position cable connections on the solid state relay as previously tagged. (Refer
to Figure 5-60.)
2. Install four slotted screws to secure the cable (lug) connectors to the solid state
relay.
3. Position the solid state relay on the Power Panel assembly.
Note: The solid state relays mount inverted with terminals 3 and 4 at the top. (Refer to
Figure 5-60.)
4. Install the lock nut to secure the solid state relay to the Power Panel assembly.
panel.

Figure 5-59.)
10. Close the door.

452501-1EN1
DC Power Supply Replacement Component Replacement
5.20 DC Power Supply Replacement
5.20.1 DC Power Supply Removal

Removal procedure.

(ESD).)
2. Disconnect J1 and J2 connectors from the DC Power Supply PCBA. (Refer to

Figure 5-61.)
J2 Connector
J1 Connector
Figure 5-61: DC Power Supply
3. Remove four mounting screws from the rear of the Power Panel Assembly.
IMPORTANT: Hold on to the DC Power Supply as you remove the last screw securing the DC
Power Supply to the Power Panel Assembly. The DC Power Supply can fall and
be damaged when the last screw is removed.

452501-1EN1
Component Replacement DC Power Supply Replacement
Screws
Figure 5-62: Power Panel Assembly — Rear View
4. Remove the DC Power Panel and set it aside.
5.20.2 DC Power Supply Installation

(ESD).)
1. Position the DC Power Supply on the Power Panel Assembly.

2. Install four mounting screws through the rear of the Power Panel Assembly to
secure the DC Power Supply to the Power Panel Assembly. (Refer to
Figure 5-62.)
IMPORTANT: Hold on to the DC Power Supply until at least one screw is installed to secure
the DC Power Supply to the Power Panel Assembly. The DC Power Supply can
fall and be damaged until at least one screw is installed.
3. Connect J1 and J2 connectors to the DC Power Supply PCBA. (Refer to

Figure 5-61.)

452501-1EN1
Power Entry Module Replacement Component Replacement
5.21 Power Entry Module Replacement
5.21.1 Power Entry Module Removal
5.21.2 Power Supply Transformer Removal

Removal procedure.

(ESD).)
2. Disconnect the ground wire lug from the PEM. (Refer to Figure 5-63.)
PEM
Ground
Wire Lug
Figure 5-63: PEM Ground Wire Lug
3. Disconnect four AC input cable lugs from the PEM. (Refer to Figure 5-64.)

452501-1EN1
Component Replacement Power Entry Module Replacement
AC Input
Cable Lugs
Figure 5-64: PEM Wiring
4. Release the tabs securing the PEM to the System Power Panel Assembly.
5. Remove the PEM and set it aside.
5.21.3 Power Entry Module Installation

1. Position the PEM on the System Power Panel Assembly. (Refer to Figure 5-64.)
2. Push the PEM until it snaps into place on the rear panel.
3. Connect four AC input cable lugs to the PEM. (Refer to Table 5-5.)
Table 5-5: Power Entry Module Connector Locations
Location
A Brown Isolation Transformer Connector
B Orange Isolation Transformer Connector
C Red Isolation Transformer Connector
D Yellow Isolation Transformer Connector
4. Connect the ground wire lug to the PEM. (Refer to Figure 5-63.)
6. Installation procedure.

452501-1EN1
Power Entry Module Fuse(s) Replacement Component Replacement
5.22 Power Entry Module Fuse(s) Replacement
The Power Entry Module (P/N 805-0017-02) is located in the rear of the Power Panel
Assembly. (Refer to Figure 5-62.) When configured for 115 VAC, the PEM has one
6.3 Amp 250 V slow-blow fuse (P/N 870-0008-25). In addition, a conversion clip is
located across the neutral line in the fuse holder. (Refer to Figure 5-67.) When
configured for 230 VAC, the PEM has two 5.0 Amp 250 V slow-blow fuses (P/N 870-
0008-24). (Refer to Figure 5-68.)
5.22.1 Power Entry Module Fuse(s) Removal

Note the fuse orientation
to the rear of the fuse
holder
Figure 5-65: Power Entry Module with Fuse Holder Removed
Figure 5-66: Fuse Holder
2. Disconnect the main power cable.

3. Open the PEM cover using a flat blade screwdriver.

452501-1EN1
Component Replacement Power Entry Module Fuse(s) Replacement
4. Slide out the fuse holder. (Refer to Figure 5-65.)

5. Remove the defective fuse(s). (Refer to Figure 5-67 or Figure 5-68.)
5.22.2 Power Entry Module Fuse(s) Installation

1. Install the fuse(s) in the fuse holder. (Refer to Figure 5-67 or Figure 5-68 and
Table 5-6.)
CAUTION: The new fuse MUST be the same size rating as the removed
fuse. Over fusing could damage the equipment and create a fire hazard.
Table 5-6: Facility Power Rating and Fuse Conversion Chart
Facility Power Rating Figure to Use
100 Volts AC Figure 5-67

Note: Failure to properly install the spring clip will result in no power to the unit. (Refer to
Figure 5-66.)
2. Install the fuse holder. (Refer to Figure 5-65.)

3. Close the PEM cover.
4. Connect the main power cable.
Note: Steps for replacing fuses in the 230 VAC version are the same as the steps taken with
the 115 VAC version, with the exception of the fuse size and the 115 V conversion clip
(which is not used). Remove and dispose of the clip if one is present. Refer to
Figure 5-68 for 230 VAC version.
CAUTION: Installation of the 115 V conversion clip (Figure 5-67) in the

230 VAC version WILL RESULT IN DAMAGE to the unit. (Refer to
Figure 5-68.)

452501-1EN1
Fan Replacement Component Replacement
Conversion Clip
6.3A 250V
Slow-blow Fuse
5.0A 250V
Slow-blow Fuse
(2 Required)
5.23 Fan Replacement
5.23.1 Fan Removal


(ESD).)
Figure 5-69.)

452501-1EN1
Component Replacement Fan Replacement
Top Panel
Screw Top Panel
Screw

4. Close the door.
Bolt
7. Pull the Transformer out of the instrument far enough to easily access the
Terminal Board (TB1).
Note: It is not necessary to disconnect the Transformer wires.

452501-1EN1
Fan Replacement Component Replacement
8. Remove the screws from TB1-2A and TB1-4A. (Refer to Figure 5-71.)
TB1-4A
TB1-2A
Figure 5-71: Terminal Board 1 Wiring
9. Tag and disconnect the wires from TB1-4A.

10. Tag and disconnect the wires from TB1-2A.
11. Pull the fan power wires up and out of the Power Supply chassis.
12. Make a note of the direction of the fan blades prior to removal of the fan.
13. Remove four screws, nuts, and washers and two wire clamps securing the fan
to the Power Panel Assembly. (Refer to Figure 5-72.)
Note: There are two wire clamps on the two bottom screws that hold wiring in place.
Note: Hold on to the washers as the nuts and screws are removed, as the washers can fall
into the chassis.

452501-1EN1
Component Replacement Fan Replacement
Nuts
Wire Clamps
Washers
Screws
Figure 5-72: Fan Assembly
14. Remove the fan from the chassis and set it aside.
5.23.2 Fan Installation

1. Install four screws through the back side of the Power Panel. (Refer to
Figure 5-72.)
2. Position the fan on the chassis over the screws.
3. Ensure the fan blades are in the same direction as noted during removal.
4. Push two wire clamps on the bottom two screws.
5. Install four washers and nuts to secure the fan to the chassis.
6. Route the fan power wires underneath the relays.
7. Position the wires on TB1-4A as previously tagged. (Refer to Figure 5-71.)

452501-1EN1
Heater Replacement Component Replacement
8. Position the wires on TB1-2A as previously tagged.

9. Install the screws on TB1-2A and TB1-4A.
10. Ensure that all wire connections are properly made.
11. Postion the Transformer in place. (Refer to Figure 5-70.)
12. Install the bolt to secure the Transformer to the Power Panel Assembly chassis.
panel.

Figure 5-69.)
18. Close the door.
5.24 Heater Replacement
5.24.1 Heater Removal

Figure 5-73.)

452501-1EN1
Component Replacement Heater Replacement
Top Panel
Screw Top Panel
Screw

4. Close the door.
6. Remove the nuts from the HTR-1 and HTR-2 terminals. (Refer to Figure 5-74.)
HTR-2
HTR-2 Terminal
Terminal Connector
Mounting
Support
Tab
HTR-1
Terminal
HTR-1 Locking Heater Mounting

Terminal Tab Support
Connector Tab
Figure 5-74: Heater
7. Disconnect the connectors from the HTR-1 and HTR-2 terminals.

452501-1EN1
Thermal Switch Replacement Component Replacement
8. Gently pull down on the locking tab and remove the Heater by pulling outward
from the bottom of both ends.
CAUTION: Do not pull down on the locking tab too hard. The locking tab
can be damaged, losing its ability to lock the heater in place.
5.24.2 Heater Installation

1. Position the Heater in place by aligning the mounting support tabs with the top
holes in the Heater. (Refer to Figure 5-74.)
2. Push the bottom of both ends of the Heater inward until the locking tab locks the
heater in place.
3. Connect the connectors to the HTR-1 and HTR-2 terminals.
4. Install the nuts on the HTR-1 and HTR-2 terminals.
panel.

Figure 5-73.)
10. Close the door.
5.25 Thermal Switch Replacement
5.25.1 Thermal Switch Removal

Figure 5-75.)

452501-1EN1
Component Replacement Thermal Switch Replacement
Top Panel
Screw Top Panel
Screw

4. Close the door.
6. Disconnect the TC0-1 and TC0-2 connectors from the Thermal Switch. (Refer to
Figure 5-76.)
7. Remove two screws and lock washers securing the Thermal Switch to the
thermal switch mounting bracket.
Screw
TC0-2
Thermal
Switch Connector
TC0-1
Connector Screw
Thermal Switch
Mounting Bracket
Figure 5-76: Thermal Switch

452501-1EN1
Blower Assembly Replacement Component Replacement
8. Remove the Thermal Switch from the thermal switch mounting bracket and set
aside.
5.25.2 Thermal Switch Installation

1. Position the Thermal Switch on the thermal switch mounting bracket.
IMPORTANT: Ensure that the Thermal Switch is not touching the Heater coil.
2. Install two screws and lock washers to secure the Thermal Switch to the thermal
switch mounting bracket. (Refer to Figure 5-76.)
3. Connect the TC0-1 and TC0-2 connectors to the Thermal Switch.
panel.

Figure 5-75.)
9. Close the door.
5.26 Blower Assembly Replacement
5.26.1 Blower Assembly Removal

Figure 5-77.)

452501-1EN1
Component Replacement Blower Assembly Replacement
Top Panel
Screw Top Panel
Screw

4. Close the door.
6. Disconnect the Blower’s power cable at BLP1/BLJ1. (Refer to Figure 5-78.)
Blower
Mounting
Nuts
BLP1/BLJ1
Figure 5-78: Blower Assembly
7. Remove four mounting nuts securing the Blower in place.

8. Remove the Blower and set it aside.

452501-1EN1
Blower Motor Capacitor Replacement Component Replacement
5.26.2 Blower Assembly Installation

1. Position the Blower in place.
2. Install four mounting nuts to secure the Blower in place. (Refer to Figure 5-78.)
3. Connect the Blower’s power cable at BLP1/BLJ1.
panel.

Figure 5-77.)
9. Close the door.
5.27 Blower Motor Capacitor Replacement
5.27.1 Blower Motor Capacitor Removal

Removal procedure.

(ESD).)
2. Remove the boot from the Blower Motor Capacitor. (Refer to Figure 5-79.)

452501-1EN1
Component Replacement Blower Motor Capacitor Replacement
Boot
Figure 5-79: Blower Motor Capacitor
3. Make a note of the color and location of the cable (lug) connectors on the
Blower Motor Capacitor.
4. Disconnect the cable (lug) connectors from the Blower Motor Capacitor. (Refer
to Figure 5-80.)
Cable (Lug)
Connectors
Lock Nut
Figure 5-80: Blower Motor Capacitor — Boot Removed

452501-1EN1
Digital Reference Thermometer Replacement Component Replacement
5. Remove the lock nut from the Blower Motor Capacitor retaining clamp.
6. Slide the Blower Motor Capacitor out of the retaining clamp and set it aside.
5.27.2 Blower Motor Capacitor Installation

1. Slide the Blower Motor Capacitor into the retaining clamp.
2. Install the lock nut on the Blower Motor Capacitor retaining clamp.
3. Connect the cable (lug) connectors to the Blower Motor Capacitor in
accordance with the notes taken during removal. (Refer to Figure 5-80.)

(ESD).)
4. Install the boot on the Blower Motor Capacitor. (Refer to Figure 5-79.)
5.28 Digital Reference Thermometer Replacement
5.28.1 Digital Reference Thermometer Removal

1. Open the door to the Incubation Chamber.
2. Remove the Reference Thermometer from the top-left side of the Incubation
Chamber. (Refer to Figure 5-81.)

452501-1EN1
Component Replacement Digital Reference Thermometer Battery Replacement
Reference
Thermometer
Figure 5-81: Digital Reference Thermometer
5.28.2 Digital Reference Thermometer Installation

1. Install the Reference Thermometer from the top-left side of the Incubation
2. Close the door to the Incubation Chamber.
5.29 Digital Reference Thermometer Battery Replacement
5.29.1 Digital Reference Thermometer Battery Removal

2. Remove the Reference Thermometer from the top-left side of the Incubation

452501-1EN1
Rack Assembly Replacement Component Replacement
Reference
Thermometer
Figure 5-82: Digital Reference Thermometer
3. Using a flat blade screwdriver, rotate the battery cap counterclockwise and
remove the battery cap.
4. Remove the battery from the Reference Thermometer.
5.29.2 Digital Reference Thermometer Battery Installation

1. Install the battery in the Reference Thermometer with the positive side facing
up.
2. Position the battery cap over the battery.
3. Using a flat blade screwdriver, rotate the battery cap clockwise to secure.
4. Install the Reference Thermometer from the top-left side of the Incubation
5.30 Rack Assembly Replacement
5.30.1 Rack Assembly Removal


452501-1EN1
Component Replacement Rack Assembly Replacement
2. Remove bottles by using CTRL + F10 function or unload all of the bottles from
the defective rack.

(ESD).)
Figure 5-83.)
Top Panel
Screw Top Panel
Screw

6. Close the door.
7. Remove two screws securing the rack cable cover to the chassis. (Refer to
Figure 5-84.)

452501-1EN1
Screws
Rack Cable Cover
Figure 5-84: Rack Cable Cover
8. Remove the rack cable cover from the chassis.

9. Remove two screws securing the rack cable clamp of the rack being removed.
Rack
Cable
Clamp
Screws
Figure 5-85: Rack Cable Clamp

452501-1EN1
Component Replacement Rack Assembly Replacement

(ESD).)
10. Disconnect the cables from the Rack Controller PCBA. (Refer to Figure 5-86.)
Connections
Figure 5-86: Rack Controller PCBA Connections
11. Loosen two captive screws located at either end of the rack being removed.

452501-1EN1
Captive Screws
Figure 5-87: Rack Assembly Removal
12. Slide the Rack Assembly out of the instrument.
Note: Step 13 through Step 15 should only be performed if removing the Rack Assembly for
replacement. Step 13 through Step 15 should not be performed if removing the Rack
Assembly to facilitate higher maintenance.
13. Remove two screws from the rack cable clamp of the new Rack Assembly.
14. Remove the ground cable from the old rack cable clamp.
Note: Retain the old parts and return them with the defective Rack Assembly.
15. Disconnect the Rack cable connectors (daisy-chained cables) from the Rack
Interface PCBA connectors.
5.30.2 Rack Assembly Installation

(ESD).)

452501-1EN1
Component Replacement Bottle Holder Cover Replacement
Note: Step 1 through Step 3 should only be performed if installing a new Rack Assembly.
Step 1 through Step 3 should not be performed if installing the Rack Assembly after
removing the Rack Assembly to facilitate higher maintenance.
1. Install ground cables on the new rack cable clamp.

2. If replacing a rack with cells 1 through 20 or 21 through 40, remove the plug
from P1 on the Rack Interface PCBA.
Note: Retain these parts and return them with the defective Rack Assembly.
3. Connect the Rack cable connectors (daisy-chained cables) to the Rack

Interface PCBA connectors.
4. Slide the Rack Assembly into the instrument.
5. Tighten two captive screws located at either end of the rack. (Refer to
Figure 5-87.)
6. Connect the cables to the Rack Controller PCBA. (Refer to Figure 5-86.)
7. Install two screws to secure the rack cable clamp of the rack being installed.
8. Position the rack cable cover on the chassis.
9. Install two screws to secure the rack cable cover to the chassis. (Refer to
Figure 5-84.)
Figure 5-83.)
12. Close the door.
5.31 Bottle Holder Cover Replacement
5.31.1 Bottle Holder Cover Removal

2. Remove bottles by using CTRL + F10 function or unload all of the bottles from
the defective rack.

452501-1EN1
Bottle Holder Cover Replacement Component Replacement
4. Remove five screws securing the Bottle Holder Cover to the Rack Assembly.
Note: Older configurations of the Rack Assembly may have six screws.
Rack Assembly
Screws
Bottle Holder Cover
Figure 5-88: Bottle Holder Cover
5. Remove the Bottle Holder Cover from the Rack Assembly and set it aside.
5.31.2 Bottle Holder Cover Installation

1. Position the Bottle Holder Cover on the Rack Assembly.
2. Install five screws to secure the Bottle Holder Cover to the Rack Assembly.
Note: Older configurations of the Rack Assembly may have six screws.


452501-1EN1
Component Replacement Link Assembly Replacement
5.32 Link Assembly Replacement
5.32.1 Link Assembly Removal

1. Remove the rack assemblies. (Refer to Section 5.30.)
2. To remove the left side Link Assemblies:
a. Remove the left side panel by lifting from the top edge of the panel.
b. Determine which Link Assembly needs to removed.
c. Insert a screwdriver into the head of the interior bushing screw. (Refer to
Figure 5-89.)
Link Assembly
Exterior Bushing
Screw
Interior Bushing
Screw
Figure 5-89: Left Link Assembly Bushing Screws
d. Grasp the interior nut with a wrench and turn the screwdriver
counterclockwise to remove the nut securing the Link Assembly to the link
cover. (Refer to Figure 5-90.)

452501-1EN1
Link Assembly Replacement Component Replacement
Exterior Nut
Interior Nut
Link Cover
Figure 5-90: Instrument Left Side
e. Insert a screwdriver into the head of the exterior bushing screw. (Refer to
Figure 5-89.)
f. Grasp the exterior nut with a wrench and turn the screwdriver
counterclockwise to remove the nut securing the Link Assembly to the
chassis.
g. Remove the Link Assembly from the chassis.
3. To remove the right side Link Assemblies:
a. Remove the right side panel by lifting from the top edge of the panel.
b. Determine which Link Assembly needs to removed.
c. Insert a screwdriver into the head of the bushing screw. (Refer to
Figure 5-91.)

452501-1EN1
Component Replacement Link Assembly Replacement
Link Assembly
Bushing Screw
Figure 5-91: Right Link Assembly Bushing Screws
d. Grasp the nut with a wrench and turn the screwdriver counterclockwise to
remove the nut securing the Link Assembly to the chassis. (Refer to
Figure 5-92.)
Nuts
Figure 5-92: Instrument Right Side
e. Remove the Link Assembly from the chassis.
5.32.2 Link Assembly Installation

1. To install the right side Link Assemblies:

452501-1EN1
Step-5 Drive Agitation Linkage Assembly Replacement Component Replacement
a. Position the Link Assembly on the chassis.

b. Insert a screwdriver into the head of the bushing screw. (Refer to
Figure 5-91.)
c. Grasp the nut with a wrench and turn the screwdriver clockwise to secure
the Link Assembly to the chassis. (Refer to Figure 5-92.)
d. Insert paper cardstock over the wide foam at the top of the door.
panel.
e. Install the right side panel.

f. Remove the paper cardstock.
2. To install the left side Link Assemblies:
a. Position the Link Assembly on the chassis.
b. Insert a screwdriver into the head of the interior bushing screw. (Refer to
Figure 5-89.)
c. Grasp the interior nut with a wrench and turn the screwdriver clockwise to
secure the Link Assembly and link cover to the chassis. (Refer to
Figure 5-90.)
d. Insert a screwdriver into the head of the exterior bushing screw. (Refer to
Figure 5-89.)
e. Grasp the exterior nut with a wrench and turn the screwdriver clockwise to
secure the Link Assembly to the chassis. (Refer to Figure 5-90.)
f. Insert paper cardstock over the wide foam at the top of the door.
panel.
g. Install the left side panel.

h. Remove the paper cardstock.
3. Install the rack assemblies. (Refer to Section 5.30.)
5.33 Step-5 Drive Agitation Linkage Assembly Replacement
5.33.1 Step-5 Drive Agitation Linkage Assembly Removal


452501-1EN1
Component Replacement Step-5 Drive Agitation Linkage Assembly Replacement
Figure 5-93.)
Top Panel
Screw Top Panel
Screw

4. Close the door.
6. Remove the bottom bushing nut. (Refer to Figure 5-94.)

452501-1EN1
Linkage Assembly
Connecting Link
Bottom
Bushing Nut
Figure 5-94: Instrument Rear View
7. From the reverse side of the connecting link, remove the bottom bushing screw
from the Drive Agitation Linkage Assembly.
8. Locate the setscrew points on the Motor Offset Round. (Refer to Figure 5-95.)
Motor Offset
Round
Bushing Screw
Drive Agitation
Linkage
Setscrew
Points
Figure 5-95: Motor Offset Round Setscrew Location

452501-1EN1
Component Replacement Step-5 Drive Agitation Linkage Assembly Replacement
9. Remove the first setscrew.
Note: Use a 3/32 in. Allen wrench to remove setscrews.
10. Rotate the Drive Agitation Linkage 90 degrees clockwise and remove the
second setscrew.
11. Slide the entire Drive Agitation Linkage Assembly, with the Motor Offset Round
attached, up and out of the instrument.
Note: The bottom part of the Linkage slides through a cutout hole in the support panel.
Note: When removing the entire Drive Agitation Linkage Assembly with the Motor Offset
Round attached, pull the Motor Offset Round slightly forward to slide the Motor Offset
Round off of the Step-5 Motor shaft.
12. Remove the Drive Agitation Linkage Assembly from the Motor Offset Round by
removing the bushing nut on the reverse side of the Motor Offset Round. (Refer
to Figure 5-96.)
Motor Offset
Round
Drive Agitation
Linkage
Bushing Nut
Figure 5-96: Drive Agitation Linkage Assembly with Motor Offset Round
13. Remove the bushing screw from the Drive Agitation Linkage Assembly. (Refer
to Figure 5-95.)
14. Set the Drive Agitation Linkage Assembly aside.
5.33.2 Step-5 Drive Agitation Linkage Assembly Installation

1. Position the Motor Offset Round on the Drive Agitation Linkage Assembly.
2. Install the bushing screw through the Drive Agitation Linkage Assembly and
Motor Offset Round. (Refer to Figure 5-95.)
3. Install the bushing nut on the reverse side of the Motor Offset Round. (Refer to
Figure 5-96.)
4. Slide the entire Drive Agitation Linkage Assembly, with the Motor Offset Round
attached, in place.

452501-1EN1
5. Position the motor offset round in place with proper orientation to the motor
shaft flats.
Note: Support the opposite end of the Step-5 Motor when pushing the motor offset round on
the Motor Shaft to prevent pushing the isolation grommets from their locations in the
chassis holes.
6. Insert the Offset Round Spacing tool between the system chassis and the Motor
Offset Round.
7. Install the first setscrew in the motor offset round. (Refer to Figure 5-95.)
8. Rotate the drive agitation linkage 90 degrees clockwise and install the second
setscrew.
9. Remove the Offset Round Spacing tool.
10. Ensure that the motor offset round and the drive agitation linkage are in the
correct position.
11. Align the Drive Agitation Linkage Assembly’s bottom bushing screw hole with
the hole in the connecting link. (Refer to Figure 5-94.)
12. From the reverse side of the connecting link, install the bottom bushing screw
into the Drive Agitation Linkage Assembly.
13. Install the bottom bushing nut. (Refer to Figure 5-94.)
panel.


(ESD).)

Figure 5-35.)
19. Close the door.

452501-1EN1
Component Replacement Gas Spring Assembly Replacement
5.34 Gas Spring Assembly Replacement
5.34.1 Gas Spring Assembly Removal

Figure 5-97.)
Top Panel
Screw Top Panel
Screw

(ESD).)
4. Close the door.

5. Remove the top protective cap with a small flat blade screwdriver. (Refer to
Figure 5-98.)
6. While holding the support bracket, pull and separate the spring assembly from
the top support bracket.
Note: The spring assembly (socket) and the support bracket (ball joint) serve as a ball joint
and socket assembly. It will require force to separate the two from each other.

452501-1EN1
Gas Spring Assembly Replacement Component Replacement
Protective Cap
Notch for
Screwdriver
Figure 5-98: Top Support Bracket
7. Remove the bottom protective cap with a small flat blade screwdriver. (Refer to
Figure 5-99.)
8. While holding the support bracket, pull and separate the spring assembly from
the bottom support bracket.
Protective Cap
Notch for
Screwdriver
Figure 5-99: Bottom Support Bracket
5.34.2 Gas Spring Assembly Installation

1. While holding the support bracket, push the spring assembly into the bottom
support bracket. (Refer to Figure 5-99.)
2. Install the bottom protective cap.

452501-1EN1
Component Replacement Magnetic Door Switches Replacement
3. While holding the support bracket, push the spring assembly into the top
support bracket. (Refer to Figure 5-98.)
4. Install the bottom protective cap.

(ESD).)

Figure 5-35.)
7. Close the door.
5.35 Magnetic Door Switches Replacement
5.35.1 Magnetic Door Switches Removal

Figure 5-100.)
Top Panel
Screw Top Panel
Screw

452501-1EN1
Magnetic Door Switches Replacement Component Replacement

(ESD).)
4. Keep the door open slightly to view the door magnets.

5. Determine which door switch is defective.
Note: The door switch LEDs are located on the ModSig PCBA at D55 and D66. (Refer to
Figure 5-102.)
6. Remove two nuts securing the Door Switch to the instrument chassis. (Refer to
Figure 5-101.)
Figure 5-101: Magnetic Door Switches
7. Disconnect the Door Switch connector at JP11 or JP12 on the ModSig PCBA,
depending on which Door Switch is defective. (Refer to Figure 5-102.)
Door
Switch
LEDs
JP11 JP12
Figure 5-102: Door Switch LEDs

452501-1EN1
Component Replacement Keyboard Replacement
8. Slide the JP11 or JP12 connector through the circular cut-out hole in the
chassis.
Note: The connector must go through vertically to fit through the hole.
Note: The front mounting screws of the ModSig PCBA may have to be loosened in order to
facilitate sliding the JP11 or JP12 connectors through the hole in the chassis.
9. Set the Door Switch aside.
5.35.2 Magnetic Door Switches Installation

(ESD).)
1. Position the door switch in place.

2. Install two nuts securing the Door Switch to the instrument chassis. (Refer to
Figure 5-101.)
3. Slide the JP11 or JP12 connector through the circular cut-out hole in the
chassis.
4. Connect the Door Switch connector at JP11 or JP12 on the ModSig PCBA,
depending on which Door Switch is being installed. (Refer to Figure 5-102.)
Figure 5-35.)
7. Close the door.
5.36 Keyboard Replacement
5.36.1 Keyboard Removal

2. Disconnect the keyboard cable connector from the Keyboard port on the rear
panel of the instrument. (Refer to Figure 5-103.)

452501-1EN1
Barcode Scanner Replacement Component Replacement
Keyboard Port
5.36.2 Keyboard Installation

1. Connect the keyboard cable connector to the Keyboard port on the rear panel
of the instrument. (Refer to Figure 5-103.)
3. If the keyboard is not working after installation, refer to Chapter 7, Diagnostics
and Troubleshooting Information.
5.37 Barcode Scanner Replacement
5.37.1 Barcode Scanner Removal

2. Disconnect the Barcode Scanner cable connector from the BARCODE port on
the rear panel of the instrument. (Refer to Figure 5-104.)
Barcode Port

452501-1EN1
Component Replacement Fax Modem Replacement
5.37.2 Barcode Scanner Installation

1. Connect the Barcoade Scanner cable connector to the BARCODE port on the
rear panel of the instrument. (Refer to Figure 5-104.)
3. If the Barcode Scanner is not working after installation, refer to Chapter 7,
Diagnostics and Troubleshooting Information.
5.38 Fax Modem Replacement
5.38.1 Fax Modem Removal

1. Disconnect the Fax Modem cable from the MODEM port on the rear panel of
the instrument. (Refer to Figure 5-105.)
Modem Port
2. Disconnect the Fax Modem cable from the fax modem. (Refer to Figure 5-106.)
Line In (TELCO) Cable

Phone Cable
Fax Modem Cable
Figure 5-106: Modem Cable Connections

452501-1EN1
UPS Replacement Component Replacement
3. Disconnect the AC adapter.

4. Disconnect the Phone cable from the fax modem.
5. Disconnect the telephone Line In (Telco) cable from the fax modem.
6. Set the fax modem aside.
5.38.2 Fax Modem Installation

1. Place the fax modem in position.
2. Connect the Fax Modem cable to the MODEM port on the rear panel of the
instrument. (Refer to Figure 5-105.)
3. Connect the Fax Modem cable to the fax modem. (Refer to Figure 5-106.)
4. Connect the Phone cable to the fax modem.
5. Connect the telephone Line In (Telco) cable to the fax modem.
6. Ensure the DIP switch settings are set correctly. (Refer to Figure 5-107.)
Note: The international modem has two additional DIP switch settings (9 and 10). Both
additional DIP switch settings should be set to ON.
Figure 5-107: Modem DIP Switch Settings
7. Connect the AC adapter.

5.39 UPS Replacement
5.39.1 UPS Removal

2. Unplug the UPS power cord from the AC outlet.

452501-1EN1
Component Replacement UPS Replacement
3. Disconnect the UPS cable connector from the UPS port on the rear panel of the
UPS Port
4. Disconnect the UPS cable connector from the Computer Interface port on the
rear of the UPS.
5. Set the UPS aside.
5.39.2 UPS Installation
Note: Step 1 through Step 9 should only be performed if installing a new UPS. Step 1
through Step 9 should not be performed if installing the UPS after removing the UPS
to facilitate higher maintenance.
1. Unpack the new UPS from the box.

2. Lay the UPS on its side.
3. Remove two screws securing the battery compartment cover to the UPS. (Refer
to Figure 5-109.)
Screws
Battery
Compartment
Cover
Figure 5-109: UPS Battery Compartment
4. Remove the battery compartment cover.

452501-1EN1
UPS Battery Replacement Component Replacement
5. Slide the battery out on its side.

6. Connect the black negative lead to the battery’s negative terminal. (Refer to
Figure 5-110.)
Note: The red positive lead should already be connected to the battery’s positive terminal.
Black Negative
Lead
Figure 5-110: UPS Battery Leads
7. Slide the battery back into the UPS.

8. Position the battery compartment cover on the UPS.
9. Install two screws to secure the battery compartment cover to the UPS.
10. Position the UPS in place.
11. Connect the UPS cable connector to the Computer Interface port on the rear
of the UPS.
12. Connect the UPS cable connector to the UPS port on the rear panel of the
13. Plug in the UPS power cord to the AC outlet.
5.40 UPS Battery Replacement
5.40.1 UPS Battery Removal

2. Unplug the UPS power cord from the AC outlet.
3. Disconnect the UPS cable connector from the UPS port on the rear panel of the

452501-1EN1
Component Replacement UPS Battery Replacement
UPS Port
4. Lay the UPS on its side.

5. Remove two screws securing the battery compartment cover to the UPS. (Refer
to Figure 5-112.)
Screws
Battery
Compartment
Cover
Figure 5-112: UPS Battery Compartment
6. Remove the battery compartment cover.

7. Slide the battery out on its side.
8. Disconnect the black negative lead from the battery’s negative terminal. (Refer
to Figure 5-113.)

452501-1EN1
Reflective Standard Discs Replacement Component Replacement
Red
Positive
Lead
Black
Negative
Lead
Figure 5-113: UPS Battery Leads
9. Disconnect the red positive lead from the battery’s positive terminal.
10. Remove the battery from the UPS and set it aside.
5.40.2 UPS Battery Installation

1. Slide the battery partially in the UPS.
2. Connect the red positive lead to the battery’s positive terminal.
3. Connect the black negative lead to the battery’s negative terminal.
4. Slide the battery completely into the UPS.
5. Position the battery compartment cover on the UPS.
6. Install two screws to secure the battery compartment cover to the UPS.
7. Position UPS in place.
8. Connect the UPS cable connector to the UPS port on the rear panel of the
9. Plug in the UPS power cord to the AC outlet.
5.41 Reflective Standard Discs Replacement
The customer may order new reflective standards that are verified as being within
calibration. Another option is for the Field Engineer to replace the Reflective Standard

452501-1EN1
Component Replacement Reflective Standard Discs Replacement
Discs. For replacement of the Reflective Standard Discs, use the part numbers listed
in Table 5-7.
Table 5-7: Reflectance Standard Part Numbers
Part Number Item Name
32449-4 DISC REFL N7.5 STD#1
5.41.1 Reflective Standard Discs Removal

1. Remove the Reflective Standard Discs from the Reflective Standard.
2. Remove all residue from the Reflective Standard.
3. Ensure that the slug ends are clean and smooth.
5.41.2 Reflective Standard Discs Installation

1. Install the Reflective Standard Discs on the Reflective Standard.
2. Ensure the Reflective Standard Discs are pressed flat and adhere well to the
Reflective Standard.
3. Ensure that the Reflective Standard Discs do not have scratches or smudges.
CAUTION: Reflective Standard Discs that are not pressed flat or adhere
well to the Reflective Standard may result in errors in calibration testing.
Reflective Standard Discs that are scratched or have smudges may also
result in errors in calibration testing.
4. Select the cell for verification:
Note: The cell must be empty and free of alarms.
Note: The status (empty, occupied, disabled, etc.) for any cell can be determined by viewing
the View Cell Status screen.
a. From the Main screen, click the Incubation Chamber on the Instrument
icon. (Refer to Figure 5-114.)

452501-1EN1
Incubation
Chamber
Instrument
Icon
b. Verify the View Cell Status screen appears.
Example
Previous Selected
Screen Cell
Button
Figure 5-115: View Cell Status Screen
c. Ensure that the desired cell is empty and free of alarms by viewing the
View Cell Status screen.
Note: The cell pictorial in the View Cell Status Screen must indicate it is empty and free of
alarms by not showing a bold cell outline or red icons.
d. Once the location and cell status are verified, record all of the cell location
information in the ID column of the Cell Information Table.

452501-1EN1
Note: Cell location information includes the module, drawer, rack, and cell number. (Refer to
Figure 5-116 for an example.)
Note: A blank table is provided at the end of this procedure. (Refer to Table 5-12.)
Cell ID S/N
Module 1 708BS1807
Drawer A N/A
Rack A3 02273324
Cell 49 N/A
Figure 5-116: Cell Information Table Example
e. Click the Previous Screen button to return to the Main screen.

5. Determine the S/N of the rack:
a. At the Main screen, click the Next Screen button. (Refer to Figure 5-117.)
Next Screen
Button
b. Verify the Setup screen appears. (Refer to Figure 5-118.)

452501-1EN1
Key Symbol
Button
Previous
Screen
Button View Incubation
Module Information
Button
c. Enter the Field Engineer password 43432121.
Note: The password is company confidential. Do not provide it to the customer.
d. Click the Key Symbol button.

e. Click the View Incubation Module Information button.
f. Verify that the Module and Rack Information screen appears. (Refer to
Figure 5-119.)
Incubation
Module
Indicator
Module Serial
Number
Rack Serial
Number
Previous
Screen
Button
Figure 5-119: Module and Rack Information Screen

452501-1EN1
g. Locate the Module Serial Number on the Module and Rack Information
screen and record the information in the Cell Information Table.
Note: Module and Rack serial numbers must be entered as eight characters, including
leading zeros. Nine character module serial numbers must be entered as eight
characters by omitting the “I” in the serial number.
h. Locate the Rack Serial Number on the Module and Rack Information
screen and record the information in the Cell Information Table.
6. Press Esc and type yes.
7. Insert the BTA3D Field Utilities Zip® disk into the D drive.
8. At the DOS prompt, type D: and press Enter.
9. Type SLGCHK3D and press Enter.
Note: When the program begins, screens will appear in succession to prompt the entry of
the QC Reflectance Standards, Test Reflectance Standards, Module, and Rack serial
numbers of the cell.
10. Enter the QC Reflectance Standard serial number and press Enter.
11. Enter the Test Reflectance Standard serial number and press Enter.
12. Enter the Module serial number and press Enter.
13. Enter the Rack serial number and press Enter.
14. If a mistake is made entering Module or Rack serial numbers, click the Change
Cell button on the Main menu and repeat Step 12 and Step 13.
15. Verify that the Main menu of the QC Reflectance Std Test appears.
16. Use the Up or Down Arrow key to select Run QC Verify and press Enter.
Note: The screen may go blank momentarily before the CAL1 Main menu appears.
17. Use the Up or Down Arrow key to select Current Selection and press Enter.
18. Use the Up or Down Arrow key to select the module containing the selected
test cell and press Enter.
19. Verify the QC Reflectance Standard:
a. Use the Up or Down Arrow key to select CALIBRATE/VERIFY and
press Enter.
b. Use the Up, Down, Left or Right Arrow key to select VER adjacent to
the range containing the verification cell selected in the table and press
Enter.
c. Verify that the Select Single Cell menu appears.
d. Use the Up, Down, Left or Right Arrow key to select the verification cell
selected in the table and press Enter.
Note: A series of on-screen prompts will appear.

452501-1EN1
e. At the prompt, open the door and insert the 50% value QC Reflectance
Standard.
Note: The cell LED will begin flashing when the screen prompts you to insert the reference
standards.
f. At the prompt, remove the 50% value QC Reflectance Standard and

insert the 35% value QC Reflectance Standard.
g. At the prompt, remove the 35% value QC Reflectance Standard and
h. At the prompt, remove the 20% value QC Reflectance Standard and
i. At the prompt, remove the 5% value QC Reflectance Standard and close
the door.
j. At the prompt, press any key to continue.
20. Verify the Test Reflectance Standard:
a. Use the Up or Down Arrow key to select CALIBRATE/VERIFY and
press Enter.
b. Use the Up, Down, Left or Right Arrow key to select VER adjacent to
the range containing the verification cell selected in the table and press
Enter.
c. Verify that the Select Single Cell menu appears.
d. Use the Up, Down, Left or Right Arrow key to select the verification cell
selected in the table and press Enter.
Note: A series of on-screen prompts will appear.
e. At the prompt, open the door and insert the 50% value Test Reflectance
Standard.
Note: The cell LED will begin flashing when the screen prompts you to insert the reference
standards.
f. At the prompt, remove the 50% value Test Reflectance Standard and
insert the 35% value Test Reflectance Standard.
g. At the prompt, remove the 35% value Test Reflectance Standard and
h. At the prompt, remove the 20% value Test Reflectance Standard and
i. At the prompt, remove the 5% value Test Reflectance Standard and close
the door.
j. At the prompt, press any key to continue.
21. When the menu appears, press Esc twice to return to the Main menu.

452501-1EN1
22. Use the Up, Down, Left or Right Arrow key to select Print Report from the
Main menu and press Enter.
23. Review the screen information.
Note: It is not necessary for the Field Service Engineer to print or retain this report. If,
however, the customer desires, the report may be printed and retained by the
customer.
24. Press Esc to exit the Print Report screen.

25. If the Test Result is Pass, proceed to Step 27.
26. If the Test Result is Failed and this is the first attempt, proceed to Chapter 7,
Diagnostics and Troubleshooting Information, and perform the troubleshooting
task QC Reflectance Standard fails verification (alone or in conjunction with
other failures) on the first attempt or Test Reflectance Standard fails verification
(alone or in conjunction with other failures) on the first attempt in Table 7-1.
Note: After the troubleshooting task is complete, return to this procedure and begin at
Step 25.
27. Use the Up, Down, Left or Right Arrow key to select Quit to DOS from the
Main menu and press Enter.
28. At the DOS prompt, type C: and press Enter.
29. Type XBTA3D and press Enter.
30. Verify that the BacT/ALERT® 3D 60 software reboots.
31. Remove the BTA3D Field Utilities Zip® disk from the D drive.
32. If you get a pass test result, the Test Reflectance Standard is verified to be
acceptable for continued use in the field.
33. Place the calibration label near the center of the calibration slug on the Test
Reflectance Standard that received pass test results.
Note: Do not label Reflectance Standards that are unacceptable for certifying.
Note: The calibration label will validate slug calibration for two years from the date it was
tested. Test verification will be performed at approximately 12 months (every annual
PM).
34. If you are unable to get a pass test results after two tries, the Test Reflectance
Standards are unacceptable for certifying and should be replaced with new
Reflectance Standards (P/N 32005-2, article code 06543) that are verified as
being within calibration.
Note: The slug set must be retested and pass test results before applying new calibration
labels.

452501-1EN1
Post Service Validation Component Replacement
5.42 Post Service Validation
This section provides the procedures for verifying the proper functioning of the
BacT/ALERT® 3D 60 after a service call (repairs, alignments). They are not used after
PMs or installations, as they are covered separately.
5.42.1 Required Materials

The following items are needed (as a minimum) to complete the validation:
• 3D 60 Module
• Field Utilities Zip® Disk
5.42.2 Procedures
1. In the incubation chamber, verify that the internal temperature has stabilized
and then verify that the displayed temperature on the 3D 60 display is within
± 0.5 °C of the calibrated reference thermometer. (Refer to Section 4.7.)
2. Verify that the Barcode Scanner will load a bottle by using the Load Bottles
function:
a. From the Main screen, click the Load Bottles button.
b. Verify the Load Mode screen appears.
c. Verify the Bottle ID field appears white.
d. Scan the bottle.
e. Verify the Bottle ID number from the bottle appears in the Bottle ID field.
f. Click the Check button to return to the Main menu.
Note: If no operator or bottle loading activity has been recorded in a period of 2 minutes, the
instrument will terminate the Load Bottle operation. Operator activity includes pressing
keys on the keyboard, scanning barcodes, clicking the mouse, and loading or
unloading bottles.
3. Disconnect the UPS from the AC wall outlet and verify the audible alarm,
emergence of the red triangle icon and the UPS alarm activate. Immediately
connect the UPS to the AC wall outlet.
Note: Try not to keep AC power off for too long. If the AC is allowed to remain off more than
1 minute, the 3D 60 instrument will begin an orderly shutdown. If this occurs, the
system will require rebooting.

452501-1EN1
Component Replacement Post Service Validation
Table 5-8: Bottle Counts and Software Version
Bottle Counts:
Software Version: _________
Table 5-9: Local and CMOS Date/Time
Description Time
Local Date/Time
CMOS Date/Time
Table 5-10: Calculations for Time Spent Replacing CPU PCBA
Description Time
Local Time at Start
Local Time at Finish
Time Spent Replacing

CPU PCBA
Table 5-11: Calculations for New CMOS Time
Description Time
CMOS Time at Start

CPU PCBA
New CMOS Date and

Time

452501-1EN1
Post Service Validation Component Replacement
Table 5-12: Cell Information
Cell ID S/N
Module
Drawer N/A
Rack
Cell N/A

452501-1EN1
Chapter 6: Alignment and Adjustment
Procedures
About this Chapter
This chapter contains alignment and adjustment procedures for the

BacT/ALERT® 3D 60. This chapter also contains conversion and correction
procedures.
Chapter Contents
6.1 System Power Supply • 6-2

6.2 Temperature Calibration • 6-2
6.3 MB Conversion • 6-4
6.4 Optics • 6-8
6.5 Operator: Single Slug Calibration • 6-8
6.6 Rack Calibration — Cal 10 Software • 6-8
6.7 Single Cell Calibration — 3D 60 Software • 6-15
6.8 Single Cell Calibration — Cal 10 A Software • 6-19
6.9 Adjust the Power Supply • 6-25
6.10 Drawer Micro Switch Check Procedure • 6-29

452501-1EN1
System Power Supply Alignment and Adjustment Procedures
6.1 System Power Supply
Refer to Section 6.9 and perform the Adjust the 3D 60 Power Supply procedure.
Adjust only if required. The measured voltage should be +5.2 ± 0.5 VDC.
6.2 Temperature Calibration
The Incubation Chamber temperature should be calibrated if the actual temperature

(measured with a calibrated thermometer) varies by ± 0.5 °C from the module's set
point temperature. (Refer to Section 4.7 to verify the instrument temperature.)
Next Screen
Button


452501-1EN1
Alignment and Adjustment Procedures Temperature Calibration
Key Symbol
Button
Calibrate Module
Temperature
Button
5. Click the Calibrate Module Temperature button. (Refer to Figure 6-2.)
Note: The Calibrate Module Temperature screen overlays and disables the Setup screen.
Internal Air Optimal Temp

Temp Indicator Scroll Buttons
Time Remaining
Until Stable Actual Temp
Indicator Scroll Buttons
Setup Screen
(Disabled)
Previous
Screen Button
Figure 6-3: Calibrate Module Temperature Screen
6. Enter the temperature from the thermometer in degrees Celsius (°C) on the
Actual Temp scroll buttons. (Refer to Figure 6-3.)
7. Click the Check button to initiate the calibration, or click the Cancel button to
retain the previous calibration.

452501-1EN1
MB Conversion Alignment and Adjustment Procedures
8. Observe the icon to the left of the Actual Temp scroll buttons.
Indicates the temperature is not stable. Do not

read the Reference Thermometer at this time.
Indicates the temperature is nearly stable. The

time underneath the hourglass is the number of
minutes: seconds remaining until stable
temperature is reached.
Indicates the temperature is stable. The

Reference Thermometer may be read.
9. When the icon to the left of the Actual Temp scroll buttons indicates that
temperature is stable, check the temperature to verify the calibration was
successful.
10. Click the Previous Screen button to return to the Setup screen.
6.3 MB Conversion
By removing power from the agitation (Step-5) motor and anchoring the linkage
assembly that rocks the racks, the incubation chamber can be converted to a
stationary (MB) configuration.

(ESD).)
Figure 6-4.)

452501-1EN1
Alignment and Adjustment Procedures MB Conversion
Top Panel
Screw Top Panel
Screw

4. Close the door.
5. Disconnect the connector from J4 on the Step-5 PCBA. (Refer to Figure 6-5.)
Note: This removes +12 VDC power to the Step-5 PCBA and Motor.
Step-5 PCBA
J1
J4
Figure 6-5: Step-5 PCBA

452501-1EN1
MB Conversion Alignment and Adjustment Procedures
6. Disconnect the connector from J1 on the Step-5 PCBA.
Note: This removes communication between the ModSig PCBA and Step-5 PCBA and
+5 VDC Power. This will also remove false (agitation) Stepper Motor errors in the
software.
7. Clip J1 and J4 connectors to one wire of the five Step-5 Motor wires connected
to J3. (Refer to Figure 6-6.)
J1 Connector
J4 Connector
Figure 6-6: Step-5 Motor Wires
9. Remove the MB conversion lock screw from Hole #1. (Refer to Figure 6-7.)

452501-1EN1
Alignment and Adjustment Procedures MB Conversion
Agitation Arm in
the Lowest Position
Hole #2
Hole #1
Figure 6-7: MB Conversion Lock Screw
10. Ensure the agitation arm is at its lowest position. (Refer to Figure 6-7.)
11. Install the MB conversion lock screw into Hole #2. (Refer to Figure 6-7.)
Note: It may be necessary to shift the racks slightly forward or backward to align the screw
with the screw hole in the linkage.
panel.

Figure 6-4.)
17. Close the door.
18. Refer to Section 4.1.2 and perform the Incubation Module Power Up procedure.
19. Perform the steps to configure the software for the MB (Mycobacteria)
conversion. (Refer to Section 2.7.3.)
20. Perform Post Service Validation.

452501-1EN1
Optics Alignment and Adjustment Procedures
6.4 Optics
Bottle Racks are pre-calibrated at the factory, and while they are designed not to
require any re-calibration in the field, an initial calibration is required for validation
purposes.
6.5 Operator: Single Slug Calibration
Cells can be individually calibrated (Single-Slug), or all cells in a rack can be

calibrated simultaneously (Ten-Cell). For information on single cell calibration, refer to
the current version of the BacT/ALERT® 3D 60 User Manual for specific details.
6.6 Rack Calibration — Cal 10 Software
This procedure is for calibration of the BacT/ALERT® 3D 60 while utilizing the Cal 10
software and calibration rods. This will allow the FSE to calibrate complete racks
instead of calibrating single cells. This procedure will only work on BacT/ALERT® 3D
systems.
IMPORTANT: Before performing this procedure, it should be completely read and fully
understood. Call bioMérieux immediately if you have any questions.
IMPORTANT: Cal 10 software or 10 rod calibration rods are not for customer use.
WARNING
WARNING
Use of the Cal 10 program stops the bottle reading function. If blood
culture bottle readings have been interrupted for 1 hour or longer, the
bottles must be subcultured. If MP/MB bottle readings have been
interrupted for 4 hours or longer, the bottles must be subcultured. The
B.25 software monitors for a gap in the readings. If an hour gap is
detected, the software will flag all bottles affected with a Fault Code
#80 Reading Gap Detected. Failure to attend to fault conditions
reported by the instrument within 1 hour may lead to invalid test
results and the need to subculture bottles.

452501-1EN1
Alignment and Adjustment Procedures Rack Calibration — Cal 10 Software
WARNING
Bottles loaded into the system during the calibration procedure (or
any procedure requiring the drawer to be open too long) may be
falsely detected as positives due to temperature fluctuations during
and after calibrating the racks. Do not leave drawers open too long.
WARNING
If a Temperature Unstable message is displayed during calibration,
promptly halt the procedure. Start the 3D 60 software and allow
bottles to be monitored. If calibrating multiple incubators, shut the
drawers for the incubator with the temperature error and start the
calibration in a different incubator. Failure to comply may result in a
subculture event.
Perform the following steps to calibrate a complete rack:
IMPORTANT: The customer should move any bottles occupying cells targeted for calibration
prior to the FSE performing this procedure. MP/MB bottles should never be
moved.
1. If bottles were not removed from the target cells, press Ctrl + F10 and unload
the bottles from the drawer.
2. Reload the bottles one at a time into a new drawer.
Note: The bottles do not have to be scanned when loaded using the special unload function
(Ctrl + F10).
IMPORTANT: If bottles were moved in the incubator, allow the temperature to stabilize for a
minimum of 1 hour before proceeding with this procedure.
3. Press Esc and type yes to exit the 3D 60 software.

4. At the C:\> prompt, make a note of the time. You will have 1 hour from this point
to complete the procedure.
5. Insert the BTA 3D Utilities Zip® Disk (P/N 22155-5) in the Zip® Drive.
6. At the C:\> prompt, type d:cal10 A and press Enter.
7. The Calibration menu will appear. (Refer to Figure 6-8.) Incubation Module 1
will be chosen by default.

452501-1EN1
Rack Calibration — Cal 10 Software Alignment and Adjustment Procedures
Figure 6-8: Calibration Menu
8. Press Enter to display the Incubator Module submenu.

9. Using the Up or Down Arrow key, select the desired Incubation Module and
press Enter.
10. Using the Up or Down Arrow key, highlight FLAG CHECK/CALIBRATE and
press Enter.
11. Verify the Retrieving Calibration Data window appears. (Refer to Figure 6-9.)
The display will continue to report the row in which data is being retrieved until
all data is collected.
Figure 6-9: Retrieving Calibration Data Window
12. Verify the Retrieving Flag Readings window appears. (Refer to Figure 6-10.)
Figure 6-10: Retrieving Flag Readings Window
13. The Cell Status Report screen will appear when the Retrieving Flag Readings
window disappears. (Refer to Figure 6-11.)

452501-1EN1
Figure 6-11: Cell Status Report Screen
Note: The cells highlighted with red indicate cells that are out of range and should be
calibrated. The cells that contain **** indicate a cell where a bottle is loaded.
14. Press Esc to save the values to the Zip® disk.

15. The Calibration menu will appear. (Refer to Figure 6-8.)
16. Using the Up or Down Arrow key, highlight CALIBRATE/VERIFY and press
Enter.
17. The Reflectance Calibration screen will appear. (Refer to Figure 6-12.) By
default, the highlighted section starts on Drawer A rack 1-10 [CAL].
Figure 6-12: Reflectance Calibration Screen
18. Using the Up or Down Arrow key, select the drawer and rack to be calibrated
and press Enter.

452501-1EN1
19. The Calibrating Cells window will appear. (Refer to Figure 6-13.) The bottles
should already be removed from the rack to be calibrated.
WARNING
Any bottles removed at this point will need to be subcultured. Failure
to comply could result in false readings.
Figure 6-13: Calibrating Cells Window
20. Press the Space Bar to continue.

21. When the 50 Percent window appears, open the applicable drawer and insert
the 50 percent calibration rod into the appropriate rack. (Refer to Figure 6-14.)
Figure 6-14: 50 Percent Window

23. When the Remove Standard window appears, remove the 50 percent
calibration rod. (Refer to Figure 6-15.)
Figure 6-15: Remove Standard Window
24. Press any key to continue.

25. When the 35 Percent window appears, insert the 35 percent calibration rod into
the appropriate rack. (Refer to Figure 6-16.)

452501-1EN1



35. When the Remove Standard window appears, remove the 5 percent calibration
rod. (Refer to Figure 6-15.)
36. Close the drawer.
38. The message Saving Calibration to Cells will appear, followed by the Reading
Complete screen. (Refer to Figure 6-19.)

452501-1EN1
Figure 6-19: Readings Complete Window
39. Verify the Results screen appears. (Refer to Figure 6-20.)
Figure 6-20: Results Screen
40. Examine the Results screen and note if all cells in the status row indicate pass
and not FAIL.
Note: Cells that fail calibration should be calibrated in the 3D 60 software calibration screen.

42. The Reflectance Calibration screen will appear again. (Refer to Figure 6-12.)
The row just calibrated will illuminate green if all cells passed calibration and will
illuminate red if any cells within the row failed calibration. By default, the next
row in sequence will be highlighted.

452501-1EN1
Alignment and Adjustment Procedures Single Cell Calibration — 3D 60 Software
43. Repeat Step 18 through Step 42 until all desired racks have been calibrated.
44. Press Esc to exit the Reflectance Calibration screen.
45. Using the Up or Down Arrow key, highlight EXIT and press Enter to exit the
Calibration menu.
46. At the C:/> prompt, press Ctrl + Alt + Delete to restart the 3D 60 software.
47. After the system has restarted, verify the instrument is running properly by
observing that the time display is updating approximately every second.
48. Make a note of the time and ensure less than 1 hour has passed since
beginning this procedure.
Note: Proceed to Step 49 only if any cells failed calibration. If all cells passed calibration,
you have completed the procedure.
49. Refer to Section 6.7 and perform the 3D 60 Software Single Cell Calibration
procedure for each cell that failed calibration.
6.7 Single Cell Calibration — 3D 60 Software
Rack Cells can be individually calibrated using the B.25 software feature found under
the Incubation Module Flag Check diagnostic. (Refer to Section 7.5.8.) This method
of calibration will enable cells that are currently testing to remain operational, while
concurrently calibrating rack cells that are out of calibration.
Perform the following steps to calibrate single cells:
1. From the Main screen, click the Next Screen button to access the Setup
screen.

452501-1EN1
Single Cell Calibration — 3D 60 Software Alignment and Adjustment Procedures
Key Symbol
Button
4. Click the Key Symbol button to access the Diagnostic Test Selection screen.
Main Selection
List
Sub-selection
Key Symbol
List
Button
Next
Screen
Button
1.7 Flag Check
Figure 6-23: Diagnostic Test Selection Screen — Flag Check
5. Select 1.0 Inc Module from the Main Selection List.

6. Select 1.7 Flag Check from the Sub-Selection List.

452501-1EN1
Alignment and Adjustment Procedures Single Cell Calibration — 3D 60 Software
7. Click the Next Screen button to start the Flag Check diagnostic. Allow enough
time for the diagnostic to gather flag readings. When the diagnostic completes,
the screen in Figure 6-24 appears.
Scroll Up/Down
Button
Print Current
Page Button
Figure 6-24: Incubator Flag Check — Cell Differences Screen
8. Observe the cells displayed in the Differences % > 1.5 section on the screen
(use the Scroll Up/Down buttons to find this section, if necessary).
9. Write down the cell numbers or (if printer is available) click the Print Current
Page button to print out the list of cell numbers.
10. Press C to access the Cell Calibration screen. (Refer to Figure 6-25.)
Cell
Selection
Buttons
Calibration
Staircase
Icon
Check Button
Previous
Screen
Button
Figure 6-25: Flag Check — Cell Calibration Screen
11. Click the Cell Selection buttons to choose the appropriate cell (1–60).

452501-1EN1
Single Cell Calibration — 3D 60 Software Alignment and Adjustment Procedures
The first screen displays an X at the base of the Calibration Staircase icon.
This prompts the user to verify the cell is empty and the door is closed. If
instrument Fault Code #20 Drawer Open For Too Long appears on the top of
the Calibration Staircase icon, the door is not closed. Close the door before
going to Step 12 below.
Note: The Cell Selection scroll buttons will be grayed out and inactive until calibration of the
cell is complete.
12. Click the Check button.
Note: The cell light of the cell selected for calibration is now illuminated and #1 appears
above the first step of the Calibration Staircase icon.
13. Insert Standard Number One into the selected cell. (A single ring around the
end of the reflectance standard identifies Standard #1.)
14. Click the Check button. #2 will appear above the second step of the
Calibration Staircase icon.
15. Insert Standard Number Two into the selected cell. (Two rings around the end
of the reflectance standard identifies Standard #2.)
16. Click the Check button. #3 will appear above the third step of the Calibration
Staircase icon.
17. Insert Standard Number Three into the selected cell. (Three rings around the
end of the reflectance standard identifies Standard #3.)
18. Click the Check button. #4 will appear above the fourth step of the Calibration
Staircase icon.
19. Insert Standard Number Four into the selected cell. (Four rings around the end
of the reflectance standard identifies Standard #4.)
21. If a check mark appears at the top of the Calibration Staircase icon, then the
calibration of the cell was successful.
22. Remove Standard Number Four and click the Check button to save the new
calibration values.
23. If Fault Code #60 Cell Failed QC appears at the top of the Calibration
Staircase icon, then the calibration of the cell was unsuccessful. Click the
Cancel button and perform Step 11 through Step 22 to recalibrate the cell.
Note: The calibration process can be canceled, and any new calibration values discarded,
by clicking the Cancel button at any time during the calibration process.
24. Click the Previous Screen button to return to the Flag Check Test screen.

452501-1EN1
Alignment and Adjustment Procedures Single Cell Calibration — Cal 10 A Software
6.8 Single Cell Calibration — Cal 10 A Software
This procedure is for calibration of the BacT/ALERT® 3D 60 while utilizing the

Cal 10 A software and calibration rods. This will allow the FSE to calibrate single cells.
This procedure will only work on BacT/ALERT® 3D systems.
IMPORTANT: Before performing this procedure, it should be completely read and fully
understood. Call bioMérieux immediately if you have any questions.
IMPORTANT: Cal 10 A software and/or calibration rods are not for customer use.
WARNING
WARNING
Use of the Cal 10 A program stops the bottle reading function. If blood
culture bottle readings have been interrupted for 1 hour or longer, the
bottles must be subcultured. If MP/MB bottle readings have been
interrupted for 4 hours or longer, the bottles must be subcultured. The
B.25 software monitors for a gap in the readings. If an hour gap is
detected, the software will flag all bottles affected with a Fault Code
#80 Reading Gap Detected. Failure to attend to fault conditions
reported by the instrument within 1 hour may lead to invalid test
results and the need to subculture bottles.
WARNING
Bottles loaded into the system during the calibration procedure (or
any procedure requiring the drawer to be open too long) may be
falsely detected as positives due to temperature fluctuations during
and after calibrating the racks. Do not leave drawers open too long.

452501-1EN1
Single Cell Calibration — Cal 10 A Software Alignment and Adjustment Procedures
WARNING
If a Temperature Unstable message is displayed during calibration,
promptly halt the procedure. Start the 3D 60 software and allow
bottles to be monitored. If calibrating multiple incubators, shut the
drawers for the incubator with the temperature error and start the
calibration in a different incubator. Failure to comply may result in a
subculture event.
Perform the following steps to calibrate a single cell:
IMPORTANT: The customer should move any bottles occupying cells targeted for calibration
prior to the FSE performing this procedure. MP/MB bottles should never be
moved.
1. If bottles were not removed from the target cells, press Ctrl + F10 and unload
the bottles from the drawer.
2. Reload the bottles one at a time into a new drawer.
Note: The bottles do not have to be scanned when loaded using the special unload function
(Ctrl + F10).
IMPORTANT: If bottles were moved in the incubator, allow the temperature to stabilize for a
minimum of 1 hour before proceeding with this procedure.

4. At the C:\> prompt, make a note of the time. You will have 1 hour from this point
to complete the procedure.
5. Insert the BTA 3D Utilities Zip® Disk (P/N 22155-5) in the Zip® Drive.
6. At the C:\> prompt, type d:cal10 A and press Enter.
7. The Single Cell Mode Calibration menu will appear. (Refer to Figure 6-26.)
Incubation Module 1 will be chosen by default.
Figure 6-26: Single Cell Mode Calibration Menu

452501-1EN1
8. Press Enter to display the Incubator Module submenu.

9. Using the Up or Down Arrow key, select the desired Incubation Module and
press Enter.
10. Using the Up or Down Arrow key, highlight FLAG CHECK/CALIBRATE and
press Enter.
11. Verify the Retrieving Calibration Data window appears. (Refer to Figure 6-27.)
Figure 6-27: Retrieving Calibration Data Window
12. Verify the Retrieving Flag Readings window appears. (Refer to Figure 6-28.)
Figure 6-28: Retrieving Flag Readings Window
13. The Cell Status Report screen will appear when the Retrieving Flag Readings
window disappears. (Refer to Figure 6-29.)

452501-1EN1
Figure 6-29: Cell Status Report Screen
Note: The cells highlighted with red indicate cells that are out of range and should be
calibrated. The cells that contain **** indicate a cell where a bottle is loaded.
14. Press Esc to save the values to the Zip® disk.

15. The Single Cell Mode Calibration menu will appear. (Refer to Figure 6-26.)
16. Using the Up or Down Arrow key, highlight CALIBRATE/VERIFY and press
Enter.
17. The Reflectance Calibration screen will appear. (Refer to Figure 6-30.) By
default, the highlighted section starts on Drawer A rack 1-10 [CAL].
18. Using the Up or Down Arrow key, highlight [CAL] and press Enter.

452501-1EN1
19. Verify the Single Cell Calibration Selection screen appears. (Refer to
Figure 6-31.)
20. Using the Up or Down Arrow key, select the cell that requires calibration and
press Enter.
21. When the 50 Percent window appears, open the applicable drawer and insert
the 50 percent calibration rod into the appropriate rack. (Refer to Figure 6-32.)

Figure 6-33: Remove Standard Window


452501-1EN1



35. When the Remove Standard window appears, remove the 5 percent calibration
rod. (Refer to Figure 6-33.)
36. Verify the Reading Complete window appears. (Refer to Figure 6-37.)

452501-1EN1
Alignment and Adjustment Procedures Adjust the Power Supply
Figure 6-37: Readings Complete Window
37. Close the drawer.

38. Verify the Pass or Fail screen appears. (Refer to Figure 6-38.)
Figure 6-38: Pass or Fail Screen
39. Press the Space Bar to return to the Reflectance Calibration screen. (Refer to
Figure 6-30.)
40. Repeat Step 18 through Step 39 to calibrate other cells.
Reflectance Calibration screen.
Single Cell Mode Calibration menu.
43. At the C:/> prompt, press Ctrl + Alt + Delete to restart the 3D 60 software.
44. After the system has restarted, verify the instrument is running properly by
observing that the time display is updating approximately every second.
45. Make a note of the time and ensure less than 1 hour has passed since
beginning this procedure.
6.9 Adjust the Power Supply
The DC Power Supply is mounted on the System Power Panel (located on the right-
hand side of the 3D 60's chassis). A metal housing encloses the DC Power Supply.
Since the adjustment POT is only accessible through a hole in the metal housing, the
instrument's top and right side panels must be removed to facilitate maintenance.

452501-1EN1
Adjust the Power Supply Alignment and Adjustment Procedures
IMPORTANT: It is recommended that you perform a backup of the records stored on the
BacT/ALERT® 3D 60 before continuing this procedure. (Refer to Section 4.4.)
1. Press Ctrl + Alt + Delete to exit the software, but do not turn the instrument off.
Figure 6-39.)
Top Panel
Screw Top Panel
Screw

DC Power
Supply
Figure 6-40: System Power Panel and DC Supply

452501-1EN1
Alignment and Adjustment Procedures Adjust the Power Supply
5. On the ModSig PCBA, connect both of the DC voltmeter's POS (RED) lead and
the NEG (BLACK) lead to respective VCC (Orange Wire) and Ground (White
Wire) on JP31. (Refer to Figure 6-41.)
Ground Wire
at JP31
+5 VDC Test
Point at JP31
Figure 6-41: ModSig PCBA with +5 VDC Test Points
6. The measured voltage should be +5.2 ± 0.5 VDC.

7. If the voltage reading is out of tolerance, insert a plastic tuning wand into the
POT access hole. While observing the reading, adjust voltage until it meets
specifications in Step 6. (Refer to Figure 6-42.)
POT Access
Figure 6-42: Power Supply
Note: Do not make any adjustments if the voltage meets specifications.
8. On the ModSig PCBA, disconnect both of the DC voltmeter's POS (RED) lead
and the NEG (BLACK) lead from the respective VCC (Orange Wire) and
Ground (White Wire) on JP31. (Refer to Figure 6-41.)
9. Although adjustments are not required, there should be +12 V at J4 on the
Step 5 PCBA. The measured voltage tolerance should be within ±1 VDC. (Refer
to Figure 6-43.)

452501-1EN1
Adjust the Power Supply Alignment and Adjustment Procedures
Ground Wire
at J4
+12 VDC Test

Point at J4
Figure 6-43: Step 5 PCBA with +12 VDC Test Points
10. At the C:\ > prompt, type XBTA3D and press Enter to restart the software.
panel.

15. Install two screws to secure the top panel. (Refer to Figure 6-44.)

452501-1EN1
Alignment and Adjustment Procedures Drawer Micro Switch Check Procedure
Top Panel
Screw Top Panel
Screw
16. Close the door.

6.10 Drawer Micro Switch Check Procedure
1. Press Ctrl + Alt + Delete to exit the software, but do not turn the instrument off.
Figure 6-45.)

452501-1EN1
Drawer Micro Switch Check Procedure Alignment and Adjustment Procedures
Top Panel
Screw Top Panel
Screw

4. With the door open, check LEDs D55 and D56 on the ModSig PCBA to ensure
they are not lit.
5. Close the door and check LEDs D55 and D56 to ensure both are illuminated.
6. If either LED is not illuminated, refer to Section 5.35 to replace the defective
switch.
7. At the C:\ > prompt, type XBTA3D and press Enter to restart the software.
Figure 6-45.)
10. Close the door.

452501-1EN1
Chapter 7: Diagnostics and Troubleshooting
Information
About this Chapter
This chapter contains the most common malfunctions of the BacT/ALERT® 3D 60,
and their corresponding resolutions.
Chapter Contents
7.1 Diagnostics and Troubleshooting Introduction • 7-3

7.2 Symptomatic Troubleshooting • 7-4
7.3 Fault/Status Code Troubleshooting • 7-16
7.4 Special Equipment • 7-51
7.5 Incubator Diagnostic Procedures • 7-52
7.5.1 Access the Diagnostic Test Selection Screen • 7-52
7.5.2 Loopback Method • 7-53
7.5.2.1 Test Procedure • 7-54
7.5.3 Port Stats • 7-54
7.5.4 Message Stats • 7-55
7.5.5 Message Log • 7-56
7.5.6 Temperature Log • 7-57
7.5.7 Reading Log • 7-58
7.5.8 Flag Check • 7-59
7.5.9 Drawer/Heater • 7-61
7.5.10 LED Check • 7-62
7.6 Controller Module Diagnostic Tests • 7-64
7.6.1 Zip® Drive Test • 7-64
7.6.2 Barcode Loopback • 7-66
7.6.3 Modem Loopback • 7-67
7.6.4 Power Event Log • 7-68
7.6.5 View Files • 7-69
7.6.5.1 .BID Files • 7-70
7.6.5.2 .BTF Files • 7-71

452501-1EN1
Diagnostics and Troubleshooting Information
7.6.5.3 .APF Files • 7-71

7.6.5.4 .LOG Files • 7-71
7.6.5.5 PLDSTORE.DAT Files • 7-72
7.6.6 Software • 7-72
7.6.6.1 Debug • 7-72
7.6.6.2 Software Exception Log • 7-73
7.6.6.3 Operating System Exception Log • 7-73
7.6.6.4 Modem Activity Log • 7-74
7.6.6.5 Association Tables • 7-74
7.6.6.6 Bottle Processing Tables • 7-74
7.6.6.7 Audit Trail • 7-75
7.6.7 Scandisk Output • 7-75
7.7 LIS Diagnostic Tests • 7-77
7.7.1 Loopback • 7-77
7.7.2 Port Stats • 7-78
7.7.3 Message Stats • 7-79
7.7.4 Message Log • 7-80

452501-1EN1
Diagnostics and Troubleshooting Information Diagnostics and Troubleshooting Introduction
7.1 Diagnostics and Troubleshooting Introduction
Diagnostics and troubleshooting are currently limited to Error Codes and the Cause/
Solution associated with the error. Of course, troubleshooting also depends on the
technician's system knowledge and understanding of the equipment.
Section 7.2 pertains to the symptomatic problems that may appear during normal
operations of the BacT/ALERT® 3D 60. These errors may or may not cause an error
code to appear. Error Code listings and associated troubleshooting procedures can
be found in Section 7.3.
WARNING
WARNING
The customer could have a subculture event present if the instrument
is shut down for more than an hour. The B.25 software monitors for a
gap in the readings. If an hour gap is detected, the software will flag
all bottles affected with a Fault Code #80 Reading Gap Detected.

(ESD).)
IMPORTANT: Before you perform maintenance or troubleshooting procedures, perform the

Decontamination procedure. (See Appendix B, Decontamination Procedures.)

452501-1EN1
Symptomatic Troubleshooting Diagnostics and Troubleshooting Information
7.2 Symptomatic Troubleshooting
Table 7-1: Symptomatic Troubleshooting
Symptom Malfunction Corrective Action
Anonymous Bottle The cell is calibrated incorrectly. 1. Calibrate the cell. (Refer to
indicated in an empty Section 6.7 or Section 6.8.)
cell
2. If an anonymous bottle is still
indicated in an empty cell,
proceed to the next malfunction.
The cell contains dirt or debris. 1. Inspect the cell for dirt or
debris.
2. Clean the cell.
3. Calibrate the cell. (Refer to

Section 6.7 or Section 6.8.)

indicated in an empty cell,
The Rack Assembly is defective. 1. Replace the Rack Assembly.

(Refer to Section 5.30.)

indicated in an empty cell, contact
bioMérieux.
System locks up after System error. 1. Press Esc, then type yes or
modem connection is press Ctrl + Shift + Alt + 2.
established with
Customer Service 2. At the C:\ > prompt, press Ctrl
+ Alt + Delete to reboot the
system.
3. If the system is still locked up

after reboot, contact bioMérieux.
Cell Indicator(s) The rack cable connections are 1. Remove the rack cables.
never illuminate loose or not routed correctly. (Refer to Section 5.30.1 and
perform Step 1 through Step 10.)
Note: Investigate all
fault codes reported 2. Install the rack cables. (Refer
for this module before to Section 5.30.2 and perform
making these checks. Step 6 through Step 13.)
3. If the cell indicator(s) still do

not illuminate, proceed to the next
malfunction.
The Rack Assembly is defective. 1. Replace the Rack Assembly.


452501-1EN1
Diagnostics and Troubleshooting Information Symptomatic Troubleshooting
Table 7-1: Symptomatic Troubleshooting (Continued)
2. If the cell indicator(s) still do

not illuminate, contact
bioMérieux.
The alarm does not The operator has disabled all 1. Navigate to the Set Audible
sound audible alarms. Alarms screen and adjust the
See Note 1 below. alarm options as required.
2. If the alarm still does not

sound, proceed to the next
malfunction.
The cable from the ModSig PCBA 1. Tighten the cable connections
(JP15) to CPU PCBA (J3) is from the ModSig PCBA to the
loose. CPU PCBA.

malfunction.
The cable from the ModSig PCBA 1. Remove and replace the cable.
(JP15) to CPU PCBA (J3) is
defective. 2. If the alarm still does not
malfunction.
The ModSig PCBA is defective. 1. Replace the ModSig PCBA.


malfunction.
The CPU PCBA is defective. 1. Replace the CPU PCBA.

(Refer to Section 5.3 or
Section 5.4.)

sound, contact bioMérieux.
Barcode Scanner The Barcode Scanner needs to 1. Scan the barcode label in
does not beep be reprogrammed to the default Figure 7-1 or Figure 7-2. (The
settings. label scanned will depend on the
model of barcode scanner in use.)
2. If the Barcode Scanner still

does not beep, proceed to the
next malfunction.
The Barcode Scanner connector 1. Remove the Barcode Scanner.

cable is loose. (Refer to Section 5.37.1.)
2. Install the Barcode Scanner.

(Refer to Section 5.37.2.)

452501-1EN1

next malfunction.
The fuse F2 on the ModSig PCBA 1. Replace fuse F2 on the

is blown. ModSig PCBA. (Refer to
Section 5.10.)

next malfunction.
The Barcode Scanner or Barcode 1. Replace the Barcode Scanner.

Scanner connector cable is (Refer to Section 5.37.)
defective.
does not beep, contact
bioMérieux.
Barcode Scanner The Barcode Scanner trigger is 1. Verify that scanner is pressed
does not auto scan not depressed. down in its cradle so the trigger
switch on the handle is
depressed.

does not auto scan, proceed to
the next malfunction.
The fuse is blown. 1. Replace fuse F2 on the

ModSig PCBA. (Refer to
Section 5.10.)

The Barcode Scanner needs to 1. Scan the barcode label in

be reprogrammed to the default Figure 7-1 or Figure 7-2. (The
settings. label scanned will depend on the

The Barcode Scanner is 1. Replace the Barcode Scanner.

defective. (Refer to Section 5.37.)

does not auto scan, contact
bioMérieux.

452501-1EN1
Barcode Scanner The Barcode Scanner needs to 1. Scan the barcode label in
scans, but nothing is be reprogrammed to the default Figure 7-1 or Figure 7-2. (The
read settings. label scanned will depend on the
fault codes reported 2. If the Barcode Scanner scans,
for this module before but still nothing is read, proceed
making these checks. to the next malfunction.
The Barcode Scanner connector 1. Remove the Barcode Scanner

cable is loose. connector cable. (Refer to
Section 5.37.1.)
2. Install the Barcode Scanner

connector cable. (Refer to
Section 5.37.2 and perform
Step 1 and Step 2.)
3. If the Barcode Scanner scans,

but still nothing is read, proceed
to the next malfunction.
The connector cable between the 1. Check the connector cable

ModSig PCBA and the CPU running between JP13 on the
PCBA is loose. ModSig PCBA and J2 or J19
(depending on the model of the
CPU) on the CPU board.
2. Secure the connector cable.

The Barcode Scanner is 1. Replace the Barcode Scanner.



Section 5.4.)

but still nothing is read, contact
bioMérieux.

452501-1EN1
The Keyboard is not The fuse is blown. 1. Replace fuse F3 on the

responding ModSig PCBA. (Refer to
Section 5.10.)
fault codes reported 2. If the Keyboard still will not
for this module before respond, proceed to the next
making these checks. malfunction.
The Keyboard connector cable is 1. Remove the Keyboard

loose. connector cable. (Refer to
Section 5.36.1.)
2. Remove the Keyboard

connector cable. (Refer to
Step 1 and Step 2.)
3. If the Keyboard still will not

respond, proceed to the next
malfunction.
The connections on the cable 1. Check cable running from

running from JP 15 on the ModSig JP15 on the ModSig PCBA to J3
PCBA to J3 or J26 (depending on or J26 (depending on the model
the model of CPU) on the CPU of CPU) on the CPU PCBA.
PCBA are loose.
2. Secure the cable connections.

malfunction.
The Keyboard is defective. 1. Replace the Keyboard. (Refer

to Section 5.36.)

malfunction.

Section 5.4.)

respond, contact bioMérieux.

452501-1EN1
On the UPS, the The power cables are not 1. Refer to Section 5.39.1 and
Power On LED will connected properly. perform Step 1 through Step 4.
not illuminate and/or
the UPS does not 2. Refer to Section 5.39.2 and
start perform Step 11 through Step 14.
3. If the Power On LED still will

not illuminate and/or the UPS
does not start, proceed to the
next malfunction.
The UPS is in Standby mode. 1. Press and hold the On/Off

button until the UPS emits an
audible beep.

next malfunction.
The UPS breaker needs to be 1. Reduce the electrical load on

reset. the UPS and press the Overload
Reset switch on the rear of the
UPS to reset the breaker.

next malfunction.
The UPS battery is defective. 1. Replace the UPS battery.


next malfunction.
The ModSig PCBA is defective. 1. Replace the ModSig PCBA.


next malfunction.
The UPS is defective. 1. Replace the UPS. (Refer to

Section 5.39.)

does not start, contact
bioMérieux.

452501-1EN1
The UPS does not The UPS battery is defective. 1. Replace the UPS battery.
provide expected (Refer to Section 5.40.)
backup time
2. If the UPS still does not provide
expected backup time, proceed to

Section 5.39.)
2. If the UPS still does not provide

expected backup time, contact
bioMérieux.
On the UPS, the On The UPS internal temperature is 1. Refer to Section 4.1.1 and
Battery LED is too high. perform the Power Down
illuminated and a procedure.
loud tone is heard
continuously 2. Remove any blockage from the
vents of the UPS.
3. Ensure that the UPS is not

around any heat source.
4. Ensure the airflow around the

UPS is not restricted.
5. Wait 5 minutes.
6. Refer to Section 4.1.2 and

perform the Power Up procedure.
7. If the On Battery LED is still

illuminated and a loud tone is still
heard continuously, proceed to
the next malfuntion.
The UPS battery is defective. 1. Replace the UPS battery.


heard continuously, proceed to
the next malfuntion.

Section 5.39.)

heard continuously, contact
bioMérieux.

452501-1EN1
Printer will not Printer is configured incorrectly. 1. Turn the printer power off.
function after (Lexmark E352dn only)
following the setup 2. Press and hold both the Back
procedure button and the Check button on
the printer while powering on the
printer.
3. Release the Back button and

the Check button when
Performing Self Test appears on
the LCD of the printer.
4. Press the left or right arrow

key until Factory Defaults is
displayed on the LCD of the
printer.
5. Press the Check button on the

printer.
6. Repeat the setup steps

provided with the printer.
7. If the printer will not function

after following the setup
procedure, contact bioMérieux.
Printer will not Incompatible printer is installed. 1. Ensure that the printer
function installed is an HP® 1320,
Lexmark E352dn, or Lexmark
E360dn printer.
2. If the printer installed is not an

HP® 1320, Lexmark E352dn, or
Lexmark E360dn printer, refer to
Section 2.10.6 and install a printer
that is approved for use with the
BacT/ALERT® 3D 60.
3. If the printer still will not

function, proceed to the next
malfunction.
Printer settings are incorrect. 1. Return the printer to its default

settings.

malfunction.

452501-1EN1
Parallel Port is configured 1. Press Esc and type yes to exit

incorrectly in BIOS. the program.
(Configurations with LBC-GX500
CPU PCBA installed only) 2. Press Ctrl + Alt + Delete to
restart the 3D 60 software.
3. Press F1 at the bioMérieux

splash screen to enter the Main
Menu of the BIOS screen.
4. Press C on the keyboard or

highlight C. Motherboard Device
Configuration and press Enter.
5. Press C or highlight C. Super

I / O Configuration and press
Enter.
6. Verify the Parallel Port setting

is set to 0x278.
7. If the Parallel Port setting is

not set to 0x278, press the Up or
Down Arrow key on the
keyboard to highlight Parallel
Port and press Enter.
8. Enter 0x278 and press the

Enter key.
9. Highlight Z. Save values to

EEPROM and Exit and press
Enter to reboot the system.

malfunction.
Parallel cable is disconnected, 1. Ensure the Parallel cable is

loose or defective. securely connected to the
PRINTER port on the rear panel
of the 3D 60.
2. If the Parallel cable is

defective, disconnect the Parallel
cable from the PRINTER port,
replace it with a new cable, and
connect the new Parallel cable to
the PRINTER port on the rear of
the 3D 60.

malfunction.

452501-1EN1
ModSig PCBA is defective. 1. Replace the ModSig PCBA.


function, contact bioMérieux.
QC Reflectance Cell used for verification is out of 1. Calibrate the cell used for
Standard fails calibration. verification. (Refer to Section 6.7
verification (alone or or Section 6.8.)
in conjunction with
other failures) on the 2. Refer to Section 5.41 and
first attempt perform Step 4 through Step 24.
3. If the QC Reflectance Standard

still fails verification (alone or in
conjunction with other failures),
Cell used for verification is 1. Refer to Section 5.41 and

malfunctioning. perform Step 4 through Step 24
using an alternate cell.

Cell used for verification was 1. Refer to Section 5.41 and

calibrated between the QC perform Step 4 through Step 24.
Reflectance Standard verification
pass and the Test Reflectance 2. If the QC Reflectance Standard
Standard verification pass. still fails verification (alone or in
QC Reflectance Standard is 1. Replace the QC Reflectance

faulty. Standard or replace the QC
Reflectance Standard disks.
2. Refer to Section 5.41 and

perform Step 4 through Step 24.

contact bioMérieux.

452501-1EN1
Test Reflectance Cell used for verification is out of 1. Calibrate the cell used for
Standard fails calibration. verification. (Refer to Section 6.7
verification (alone or or Section 6.8.)
in conjunction with
other failures) on the 2. Refer to Section 5.41 and
first attempt perform Step 4 through Step 24.
3. If the Test Reflectance

Standard still fails verification
(alone or in conjunction with other
failures), proceed to the next
malfunction.
Cell used for verification is 1. Refer to Section 5.41 and

malfunctioning. perform Step 4 through Step 24
using an alternate cell.

malfunction.

pass and the Test Reflectance 2. If the Test Reflectance
Standard verification pass. Standard still fails verification
malfunction.
Test Reflectance Standard is 1. Replace the Test Reflectance

faulty. Standard or replace the Test
Reflectance Disks.


failures), contact bioMérieux.

452501-1EN1
Reflectance Standard Reflectance Standard verification 1. Refer to Section 5.41 and

verification Test procedure is missing one of two perform Step 4 through Step 24,
Results indicate verification tests (QC Reflectance ensuring that all steps are
Failed with an invalid Standard verification or Test completed.
data error on the first Reflectance Standard verification)
attempt required. 2. If the Reflectance Standard
verification Test Results still
indicate Failed with an invalid
data error, proceed to next
malfunction.

pass and the Test Reflectance 2. If the Reflectance Standard
Standard verification pass. verification Test Results still
indicate Failed with an invalid
data error, contact bioMérieux.
Reflectance Standard CAL1 did not complete a 1. Refer to Section 5.41 and
verification Test verification pass. perform Step 4 through Step 24
Results indicate using an alternate cell.
Failed with a file not
found error on the 2. If the Reflectance Standard
first attempt verification Test Results still
indicate Failed with a file not
found error, proceed to the next
malfunction.
Module or Rack serial numbers 1. If a mistake is made entering

were entered incorrectly. Module or Rack serial numbers,
click the Change Cell button on
the Main menu.
2. Enter the module serial

number and press Enter.
3. Enter the rack serial number

and press Enter.

5. If the Reflectance Standard

verification Test Results still
found error, proceed to the next
malfunction.

452501-1EN1
Fault/Status Code Troubleshooting Diagnostics and Troubleshooting Information

pass and the Test Reflectance 2. If the Reflectance Standard
Standard verification pass. verification Test Results still
found error, contact bioMérieux.
*NOTE1: Investigate any fault codes reported before making any checks. To test the speaker click the Load
Bottles button on the Main screen. The speaker should beep once.
Figure 7-1: Scanner Default Settings Barcode Label for Older Barcode Scanner
Figure 7-2: Scanner Default Settings Barcode Label for Newer Barcode Scanner
7.3 Fault/Status Code Troubleshooting
WARNING
Instrument Fault Codes appear in the Instrument icon. A description of each

Instrument Fault Code is provided. The following is an example of an Instrument icon
with Instrument Fault Codes 4, 10, and 47. Fault codes are displayed on the particular
components where the errors are located on the Instrument icon.

452501-1EN1
Diagnostics and Troubleshooting Information Fault/Status Code Troubleshooting
Fault Codes
Figure 7-3: Instrument Icon with Fault Codes
Note: Locate specific bottles with fault by clicking the Incubator on the Instrument icon on
the Main screen to display the View Cell Status screen.
CAUTION: Fault codes referring to loss of incubator temperature may

adversely affect bottle testing and should be addressed immediately.
Instrument Status Codes appear in a separate window on the Main screen and are
identified by a 98 in the top left corner. A description of each Instrument Status Code
is provided. The following is an example of an Instrument Status Code #710
Incubation Module Initialization.
Status
Code
Figure 7-4: Instrument Status Code #710
Table 7-2: Fault/Status Code Troubleshooting
Fault/Status Number
Malfunction Corrective Action
Displayed
#1 Power Fault In Fuse is blown in Power Entry 1. Replace the PEM fuse. (Refer
Incubation Chamber Module. to Section 5.22.)

452501-1EN1
Table 7-2: Fault/Status Code Troubleshooting (Continued)
Fault/Status Number
Displayed
2. If the Instrument icon still

displays the fault code, proceed
Power Supply cable is loose or 1. Verify the power cable from the
disconnected. Incubator Power Supply is
connected and secured to
ModSig PCBA.

Power Supply output voltage is 1. Adjust the Power Supply.

out of range. (Refer to Section 6.9.)

Fuse F6 is blown on ModSig 1. Replace the ModSig PCBA

PCBA. fuse F6. (Refer to Section 5.10.)



Power Supply is defective. 1. Replace the DC Power Supply.


Power Supply Transformer is 1. Replace the Power Supply

defective. Transformer. (Refer to
Section 5.17.)

displays the fault code, contact
bioMérieux.

452501-1EN1
Fault/Status Number
Displayed
#2 Communication Lost Communication cable between 1. Verify both ends of the

with Incubation the Controller Module and the communication cable are secure
Chamber Incubator is missing or loose. and connected.

Cable from the Step-5 Motor to 1. Refer to Section 5.12.1 and

the Step-5 PCBA is disconnected, perform Step 1 through Step 4.
loose, or defective.
2. Verify cable is securely
connected to the Step-5 PCBA.
3. If cable is defective, refer to

Step 5 to remove defective cable.
Refer to Section 5.12.2 and
perform Step 12 to install a new
cable.


Internal cable from the bulkhead 1. Refer to Section 5.9.1 and

to the ModSig PCBA is perform Step 1 through Step 4.
disconnected, loose, or defective.
connected to the ModSig PCBA.

Section 5.9.1 and perform Step 5
to remove defective cable. Refer
to Section 5.12.2 and perform
Step 12 to install a new cable.


Step-5 Motor is faulty. 1. Replace the Step-5 Motor.


bioMérieux.

452501-1EN1
Fault/Status Number
Displayed


The Quad Serial PCBA is 1. Replace the Quad Serial

defective. PCBA. (Refer to Section 5.6.)

CPU PCBA is defective. 1. Replace the CPU PCBA.

Section 5.4.)

Occurs in conjunction with Fault 1. Refer to Section E.1.3 and

Code #47 No Bottle Rack in perform the CPU BIOS Settings
Drawer is Responding, Verification procedure.
indicating that the BIOS settings
are set incorrectly. 2. If the Instrument icon still
Note: This only applies to the to the next malfunction.
CPU PCBA (P/N 750-0070-902).
Occurs in conjunction with Fault 1. Replace the appropriate Rack

Code #41–46 Bottle Rack(s) Not Assembly. (Refer to
Responding and #47 No Bottle Section 5.30.)
Rack in Drawer is Responding, • #41 Top Bottle Rack
indicating that the Rack PCBA is
• #42 Middle Bottle Rack
defective.
• #43 Top and Middle Bottle
Racks
• #44 Bottom Bottle Rack
• #45 Top and Bottom Bottle
Racks
• #46 Middle and Bottom Bottle
Racks
• #47 All Bottle Racks


452501-1EN1
Fault/Status Number
Displayed
Occurs in conjunction with Fault 1. Refer to Section 5.9.1 and

Code #41–46 Bottle Rack(s) Not perform Step 1 through Step 4.
Responding and #47 No Bottle
Rack in Drawer is Responding, 2. Verify cable is securely
indicating that the cable connected to the ModSig PCBA
connecting the ModSig PCBA to and Rack PCBA.
the Rack PCBA is loose or 3. If the cable is defective, refer to
defective for: Section 5.9.1 and perform Step 7
• #41 Top Bottle Rack to remove defective cable. Refer
• #42 Middle Bottle Rack to Section 5.9.2 and perform
• #43 Top and Middle Bottle Step 25 to install a new cable.
Racks
• #44 Bottom Bottle Rack perform Step 28 through Step 31.
Racks 5. If the Instrument icon still
• #46 Middle and Bottom Bottle to the next malfunction.
Racks
Occurs in conjunction with Fault 1. Refer to Section 5.9.1 and

Code #41–46 Bottle Rack(s) Not perform Step 1 through Step 4.
Responding and #47 No Bottle
Rack in Drawer is Responding, 2. Verify cable is securely
indicating that the cable connected to the ModSig PCBA
connecting the ModSig PCBA to and Step-5 PCBA.
the Step-5 PCBA is loose or 3. If the cable is defective, refer to
defective for: Section 5.9.1 and perform Step 5
• #41 Top Bottle Rack to remove defective cable. Refer
• #42 Middle Bottle Rack to Section 5.9.2 and perform
• #43 Top and Middle Bottle Step 27 to install a new cable.
Racks
• #44 Bottom Bottle Rack perform Step 28 through Step 31.
Racks 5. If the Instrument icon still
bioMérieux.
Racks
#3 Incubation Chamber Set-point temperature has been 1. No action required. Wait

Temperature is too changed and not enough time has 1 hour.
High lapsed to reach the new
Bottle Readings are not temperature. 2. If more than 1 hour passes and
taken while this error the Instrument icon still displays
condition exists the fault code, proceed to the next
malfunction.

452501-1EN1
Fault/Status Number
Displayed
Ambient room temperature is too 1. Verify ambient room

high. temperature is at least 8° lower
than the set-point.
2. If not, advise the customer to

lower room temperature or use a
different set-point.
3. If ambient room temperature is

at least 8° lower than the set-
point, proceed to the next
malfunction.
Temperature Calibration was not 1. Refer to Section 6.2 and

performed correctly. perform Step 1 through Step 5.
2. Press Ctrl + R to reset the

temperature calibration.
3. Repeat Temperature
Calibration at desired set-point.
(Refer to the Section 6.2.)



Solid State Relay is defective. 1. Replace the K3 relay (heater

control). (Refer to Section 5.19.)

Faulty temperature sensors. 1. Replace the appropriate Rack

Assembly. (Refer to
Section 5.30.)

bioMérieux.

452501-1EN1
Fault/Status Number
Displayed
#4 Incubation Module One or more drawers have been 1. Ensure all drawers are tightly
Temperature is too Low left open or ajar for an extended closed.
period of time.
Note: Bottle Readings 2. If more than ½ hour passes
are not taken while this and the Instrument icon still
error condition exists. displays the fault code, proceed
Set-point temperature has been 1. No action required. Wait

changed and not enough time has 1 hour.
lapsed to reach the new
temperature. 2. If more than 1 hour passes and
the Instrument icon still displays
the fault code, proceed to the next
malfunction.
The drawer micro switch is 1. Check drawer micro switch.

2. Replace drawer micro switch.


Temperature Calibration was not 1. Refer to Section 6.2 and

performed correctly. perform Step 1 through Step 5.
2. Press Ctrl + R to reset the

temperature calibration.
3. Repeat Temperature
Calibration at desired set-point.
(Refer to the Section 6.2.)

Thermal switch has been tripped. 1. Refer to Section 5.25.1 and

2. Press the Reset button on the

Thermal switch.



452501-1EN1
Fault/Status Number
Displayed
Thermal switch is defective. 1. Test the Thermal switch with

an ohmmeter.
2. If the ohmmeter determines

that the Thermal switch is
defective, replace the Thermal
switch. (Refer to Section 5.25.)

Heater is defective. 1. Test the heater with an

ohmmeter.
2. If the heater element does not

register between 22–30 ohms,
replace the heater. (Refer to
Section 5.24.



Solid State Relay is defective. 1. Replace the K3 relay (heater

control). (Refer to Section 5.19.)

Faulty temperature sensors. 1. Replace the appropriate Rack

Assembly. (Refer to
Section 5.30.)

bioMérieux.

452501-1EN1
Fault/Status Number
Displayed
#6 Agitation Stepper Cable from the Step-5 Motor to 1. Refer to Section 5.12.1 and
Motor Fault the Step-5 PCBA is disconnected, perform Step 1 through Step 4.
loose or defective.
connected to the Step-5 PCBA.

cable.


Step-5 Motor is faulty. 1. Replace the Step-5 Motor.


bioMérieux.
#10 Controller Module A/C power cable is missing or 1. Secure both ends of power
Power Fault loose. cable.

UPS cable is loose or 1. Verify the UPS cable is

disconnected from the UPS port connected and secured to the
on the rear panel. UPS port on the rear panel.

Fuse is blown in Power Entry 1. Replace the PEM fuse. (Refer

Module. to Section 5.22.)

Power Supply cable (MS-JP31) is 1. Verify the power cable from the
loose or disconnected between Power Supply is connected and
ModSig PCBA (JP31). secured to the ModSig PCBA.

452501-1EN1
Fault/Status Number
Displayed

Power Supply output voltage is 1. Adjust the Power Supply.

out of range. (Refer to Section 6.9.)

UPS battery is defective. 1. Replace the UPS battery.


UPS is defective. 1. Replace the UPS. (Refer to

Section 5.39.)

Power Supply is defective. 1. Replace the Power Supply.


Power Supply Transformer is 1. Replace Power Supply

defective. Transformer. (Refer to
Section 5.17.)

bioMérieux.
#11 Insufficient Charge UPS cable is loose or 1. Verify the cable from the UPS
in UPS disconnected from the UPS port is connected and secured to the
on the rear panel. UPS port on the rear panel.

UPS battery has low voltage. 1. Replace the UPS battery.


452501-1EN1
Fault/Status Number
Displayed

UPS is defective. 1. Replace the UPS. (Refer to

Section 5.39.)

bioMérieux.
#14 System Unresponsive state detected in Contact bioMérieux immediately.

Automatically the software.
Rebooted
System performance may
be compromised while
this error condition exists.
#19 Software Exception Automatic or manual backup 1. Press Esc, then type yes.
System performance may attempted with a defective Zip®
be compromised while disk. 2. At the C:\ > prompt, press Ctrl
this error condition exists. + Alt + Delete to reboot the
system.
3. Verify that the automatic

backup function is disabled.
(Refer to Section 2.7.4.)

perform the 3D 60 Backup
procedure with a new Zip® disk.
5. Verify that the backup is

successful.

Problem in the 3D 60 software. 1. Verify the system clock is

running.
2. Refer to Section 7.6.6.2 and

perform the Software Exception
Log procedure.
3. Correct the cause of the

software exception.
4. If you are unable to determine

or correct the cause of the
software exception, contact
bioMérieux.

452501-1EN1
Fault/Status Number
Displayed
#20 Drawer Open For Door has been open too long or 1. Close the door.
Too Long ajar for an extended period.
2. If the Instrument icon does not
clear itself in 30 minutes or the
door was not ajar or open too
long, proceed to the next
malfunction.
Drawer Closed switch is 1. Check the drawer micro switch.

2. Replace drawer micro switch.




Internal cable from the ModSig 1. Refer to Section 5.9.1 and

PCBA to the Rack Controller perform Step 1 through Step 4.
PCBA is disconnected, loose or
defective. 2. Verify cable is securely
connected to the ModSig PCBA
and Rack PCBA.
3. If the cable is defective, refer to



bioMérieux.
#21 Drawer Agitation Mechanical failure in the agitation 1. Replace faulty agitation linkage
Failure linkage. components.


452501-1EN1
Fault/Status Number
Displayed
Mechanical configuration of 1. Verify the agitation link pin is

drawer is incorrect. mounted in the engaged position.

Step-5 Motor MCJ3 cable 1. Refer to Section 5.12.1 and

connector is loose or perform Step 1 through Step 4.
disconnected.
2. Verify the MCJ3 cable
connector is securely connected
to the Step-5 Motor and Step-5
PCBA.

cable.


Step-5 PCBA is defective. 1. Replace the Step-5 PCBA.


Step-5 Motor is faulty. 1. Replace Step-5 Motor. (Refer

to Section 5.12.)

Agitation sensor on bottle rack is 1. Replace the bottom Rack

defective. Assembly. (Refer to
Section 5.30.)

bioMérieux.

452501-1EN1
Fault/Status Number
Displayed
#22 Unexpected Mechanical configuration of 1. Verify the instrument is

Agitation drawer is incorrect. mechanically configured as an
MB instrument. (Refer to
Section 6.3.)

System software is configured 1. Check the Configuration

incorrectly. screen and verify that the drawer
type is MB.

Agitation detection logic on the 1. Replace the bottom Rack

Rack Controller PCBA is Assembly. (Refer to
defective. Section 5.30.)

bioMérieux.
#39 Rack Temperature Door has been open too long or 1. Close the door.
Fault ajar for an extended period.
2. If the fault code does not clear
itself in 30 minutes or the door
was not ajar or open too long,
Temperature sensor has failed. 1. Remove all positive bottles

(anonymous and identified) via
the Unload Bottles function on
the Main screen from the affected
Rack Assembly.
2. From the Main screen, press

Ctrl + F10. Cells with bottles
loaded are lit continuously.
Note: Anonymous bottles cannot

be relocated to another cell until a
bottle ID has been entered for the
bottle.
3. Pull bottles out one at a time

and immediately reload one at a
time in to a Rack Assembly that
does not have the Fault Code
#39.

452501-1EN1
Fault/Status Number
Displayed
4. If the bottle is anonymous

(Bottle ID field is blank), then
enter the bottle ID.
5. When all bottles have been

relocated, click the Check button
on the Main screen.

perform the Incubator
Temperature Verification
procedure.
7. If the temperature is high,

replace the appropriate Rack
Assembly. (Refer to
Section 5.30.)

bioMérieux.
#41–46 Bottle Rack(s) Cable connecting the Rack 1. Refer to Section 5.9.1 and
Not Responding Controller PCBA to ModSig PCBA perform Step 1 through Step 4.
is loose or defective.
and Rack PCBA.




452501-1EN1
Fault/Status Number
Displayed
Rack Assembly PCBA is 1. Replace the appropriate Rack

Section 5.30.)
• #41 Top Bottle Rack
• #42 Middle Bottle Rack
• #43 Top and Middle Bottle
Racks
• #44 Bottom Bottle Rack
Racks
Racks

bioMérieux.
#47 No Bottle Rack in Fault Code #2 Communication 1. Address Fault Code #2

Drawer is Responding Lost with Incubation Chamber Communication Lost with
is also being displayed. (Problem Incubation Chamber first.
causing this fault may also be
causing Fault Code #47). 2. If the problem was not
corrected by performing the
troubleshooting procedures for
Fault Code #2 Communication
Lost with Incubation Chamber,
Blown fuse on the ModSig PCBA. 1. Replace Fuse F1. (Refer to

Section 5.10.)

Internal cable from the ModSig 1. Refer to Section 5.9.1 and

PCBA to the Rack Controller perform Step 1 through Step 4.
PCBA is disconnected, loose or
defective. 2. Verify cable is securely
and Rack PCBA.



452501-1EN1
Fault/Status Number
Displayed

bioMérieux.
#51–57 Bottle Rack One or more cells on bottle rack 1. Perform cell calibration on the
Hardware Failure are out of calibration. entire bottle rack. (Refer to
Section 6.6.)

Rack Controller PCBA is 1. Replace the appropriate Rack

Section 5.30.)
• # 51 Top Bottle Rack
• # 52 Middle Bottle Rack
• # 53 Top and Middle Bottle
Racks
• # 54 Bottom Bottle Rack
• # 55 Top and Bottom Bottle
Racks
• # 56 Middle and Bottom Bottle
Racks
• # 57 Top, Middle, and Bottom
Bottle Racks

bioMérieux.
#60 Cell Failed QC A cell failed the automatic internal 1. Calibrate the cell indicated.
diagnostic check and needs to be (Refer to Section 6.7 or
calibrated. Section 6.8.)

Bottle Rack retaining screws are 1. Remove the bottle rack. (Refer
not tightened completely. to Section 5.30.1.)
2. Inspect the screws on the back

securing the stiffening bar and
Rack PCBA to the Rack
assembly. If the screws are loose,
tighten them.
3. Install the bottle rack. (Refer to

Section 5.30.2.)

452501-1EN1
Fault/Status Number
Displayed

Rack Controller PCBA is 1. Replace the Rack Assembly.


bioMérieux.
#62 Erroneous Cell Cell is out of calibration. Empty 1. Disable the affected cell for a
Load Status cells that are in the process of minimum of 10 minutes. Refer to
falling out of calibration can the BacT/ALERT® 3D 60 User
sometimes falsely report that they Manual.
are loaded before the auto QC
logic detects that the cell is out of 2. Enable the affected cell. Refer
calibration. In some cases the cell to the BacT/ALERT® 3D 60 User
transitions from the loaded state Manual.
back to the unloaded state when 3. Calibrate the affected cell.
in fact no bottle has been loaded (Refer to Section 6.7 or
or unloaded from that cell. Section 6.8.)

bioMérieux.
#71 Invalid Time Stamp BIOS (CMOS) clock and real time 1. Refer to Section 7.6.7.1 and
Bottle Readings are not clock are out of sync with each perform the Scandisk Output Test
taken while this error other, improper time change or Procedure.
condition exists. If not CPU hardware fault involving the
cleared within 1 hour, real time clock. 2. Determine how many bottle
then the affected bottles readings have been missed. If the
must be subcultured. time passed is greater than
1 hour, bottles must be
subcultured.

bioMérieux.
#72 Invalid Calculation Hardware failure involving the 1. Determine how long bottle
Data non-volatile random access readings have not been taken. If
Bottle Readings are not memory. the time passed is greater than
taken while this error 1 hour, bottles must be
condition exists. Bottles subcultured.
with fault are flagged
positive. 2. Unload affected bottles via the
Unload Positive button on the
Main screen.

452501-1EN1
Fault/Status Number
Displayed
3. Subculture bottles if
necessary.
4. Reload bottles via the Load

Bottles function on the Main
screen.

bioMérieux.
#73 Invalid Method Data Information needed for the Each bottle type uses the same
Bottle Readings are not analysis of bottle readings is method data. Eventually all
taken while this error corrupt. bottles of the same type will show
condition exists. the fault.
Bottles with fault are
flagged positive 1 hour 1. Refer to Section 4.3 and
after the fault first perform the Compact Flash
appears. Adapter Data Backup Restore
procedure.

bioMérieux.
#74 Algorithm Change Incorrect media type has been 1. Unload affected bottles via the
previously assigned to a bottle or Unload Positive button on the
an anonymous bottle has been Main screen.
placed in an inappropriate drawer.
2. Subculture the bottle.
3. Reload bottles via the Load

screen.

bioMérieux.

452501-1EN1
Fault/Status Number
Displayed
#75 Bottle Data Data integrity check has found 1. Unload affected bottles via the
Corrupted corrupt bottle data. Unload Positive button on the
Bottle Readings are not Main screen.
taken while this error
condition exists. Bottles 2. Subculture the bottles.
with fault are flagged 3. Reload bottles via the Load
positive. Bottles function on the Main
screen.
• Original load date and time will
be replaced with reloaded date
and time.
• Maximum test time is set to the
default associated with the
bottle type.
4. If desired, the maximum test

time may be shortened so the
bottle completes testing when
expected.

bioMérieux.
#77 Reading An incorrect bottle type has been 1. Unload affected bottles via the
Polynomial Change previously assigned to a bottle. Unload Positive button on the
Bottle Readings are not Main screen.
taken while this error
condition exists. Bottles 2. Subculture the bottles.
with fault are flagged 3. Reload bottles via the Load
positive. Bottles function on the Main
screen.
be maintained.

bioMérieux.

452501-1EN1
Fault/Status Number
Displayed
#78 Incomplete Test This fault occurs when an 1. Unload affected bottles via the
Data identified bottle is reloaded Unload Positive button on the
Bottle Readings are not anonymously and later is Main screen.
taken while this error identified and reloaded in the
condition exists. Bottles instrument. The original bottle 2. Subculture the bottle.
with fault are flagged data cannot be merged with the 3. Reload bottles via the Load
positive. data collected when the bottle Bottles function on the Main
was anonymous and therefore the screen.
data is incomplete.
be maintained.

bioMérieux.
#80 Reading Gap A gap in bottle readings greater There are two procedures that
Detected than 1 hour has occurred due to can be followed when this fault
power loss to instrument or occurs.
incubator or a negative-to-date
Solution 1: This procedure
bottle was unloaded, then
instructs you to unload and
reloaded more than 1 hour later.
subculture each bottle to clear the
80 fault.
Note: On the Load, Status and
Unload reports, bottles with Fault 1. Print an Unload report before
Code #80 will be marked on the clearing this fault to ensure that
report with a Gap Detection you have a record of all bottles
indicator (!) next to the result. If a with an 80 fault.
negative bottle has a Fault Code
#80 while it is unloaded, the Gap 2. From the Main screen, press
Detection indicator will remain on Ctrl + F3 to enter a special unload
the report. mode.
3. Subculture the bottle.
4. Reload the bottle via the Load

screen to restart testing.

bioMérieux.

452501-1EN1
Fault/Status Number
Displayed
Solution 2: This procedure

allows you to clear 80 faults for
each affected bottle without
unloading.
WARNING
These bottles must have a terminal subculture performed if their final status is
negative.
1. Print an Unload report before

clearing this fault to ensure that
you have a record of all bottles
with an 80 fault.
2. From the Setup screen, enter

the system password.
3. Press Alt + F5 to clear all faults

at the same time.

bioMérieux.
#81 Bottle Loaded in A bottle was loaded in a cell that 1. From the Main screen, press
Cell During QC has not completed the QC cycle. Ctrl + F10 on the keyboard and
verify that the Unload Screen
appears.
Note: Anonymous bottles cannot

be relocated to another cell until a
bottle ID has been entered for the
bottle.
2. Unload the bottle from the cell

that was just loaded and check
the screen to ensure that bottle ID
appears. If it is blank, scan the
bottle ID.
3. Reload the bottle into an

available cell. (One that has its
cell indicator light lit.)

bioMérieux.

452501-1EN1
Fault/Status Number
Displayed
#99 Bottle Loaded in a Bottle currently loaded in either a 1. Determine how long bottle
Non-Operational Cell disabled cell or a cell that is not readings have not been taken.
Bottle Readings are not taking readings.
taken in cells with this 2. If time is less than 1 hour, it is
error condition. only necessary to relocate the
bottle.
3. If the time passed is greater

than 1 hour, bottles must be
subcultured and reloaded.

bioMérieux.
#710 Incubation Module Turning on the power to an No operator action required.

Initialization Incubator or clicking the Restart Instrument Status Code #710
Incubation Module button will clear when initialization is
invokes the start up sequence. It complete.
is not possible to perform any
action when the Instrument
Status Code #710 is displayed.
#800 Printer Fault Printer is not connected to the 1. Connect the printer to the
3D 60 is unable to print to 3D 60. 3D 60.
the printer.
2. If the Instrument Status Code
window still displays the status
code, proceed to the next
malfunction.
Paper is jammed in the printer. 1. Remove paper jam from the

printer.

malfunction.
Incompatible printer is installed. 1. Ensure that the printer installed

is an HP® 1320, Lexmark
E352dn, or Lexmark E360dn
printer.
2. If the printer installed is not an

HP® 1320, Lexmark E352dn, or
Lexmark E360dn printer, refer to
Section 2.10.6 and install a printer
that is approved for use with the
BacT/ALERT® 3D 60.

452501-1EN1
Fault/Status Number
Displayed

malfunction.
Printer is defective. 1. Replace the printer.

code, contact bioMérieux.
#810 Backup Failed Zip® disk is missing from Zip® 1. Insert a Zip® disk in the drive.
3D 60 was unable to write drive.
backup data to the Zip® 2. Refer to Section 4.4 and
disk. perform the 3D 60 Module Data
Backup procedure.

malfunction.
Zip® disk is corrupted. 1. Remove Zip® disk and replace

with a different Zip® disk.

perform the 3D 60 Module Data
Backup procedure with a new
Zip® disk.

malfunction.
Zip® drive failure. 1. Replace the Zip® drive. (Refer

to Section 5.15.)

perform the 3D 60 Module Data
Backup with a new Zip® drive.

#820 Zip® Disk Missing Zip® disk is not fully inserted into 1. Remove the Zip® disk and re-
or Zip® Drive Fault the drive. insert into the drive.

malfunction.

452501-1EN1
Fault/Status Number
Displayed
Zip® disk is corrupted. 1. Remove Zip® disk and replace

with a different Zip® disk.

malfunction.
Zip® drive failure. 1. Replace the Zip® drive. (Refer

to Section 5.15.)

#901 Corrupted Bottle Corrupted bottle record has been 1. This error will automatically
Record Has Been selected for the Edit Bottle Detail disappear.
Selected screen.
2. Verify there is not a Fault
Code #75 Bottle Data
Corrupted. If there is, follow the
troubleshooting steps for Fault
Code #75 Bottle Data
Corrupted.
#902 Required Data Required data not entered while 1. Remove the bottle from the cell
Missing loading bottles. that was just loaded.
2. Complete required data fields

and reload the bottle.

#909 Invalid Cell Load – A bottle was loaded in a cell that 1. Remove the bottle from the cell
Cell QC in Process had not completed the QC cycle. that was just loaded.
Note: The error message will

disappear.
2. Scan the bottle ID and enter

the accession number, if needed.
3. Reload the bottle into an

available cell (one with a green
cell indicator light lit).


452501-1EN1
Fault/Status Number
Displayed
#910 Invalid Cell Load Indicates a bottle was loaded in a 1. Remove the bottle from the cell
cell belonging to the wrong that was just loaded. The cell ID
drawer type or in a cell that is will be displayed in the error
disabled or non-functional. This window on the 3D 60. The cell will
status code occurs if a bottle is also have a rapidly flashing cell
loaded while an Unload function indicator light. If in the Load
is active. function, load the bottle in an
indicated cell. Removing the
indicated bottle also causes the
Operation error screen to vanish.
2. DO NOT click the Check

button on the Operation error
screen except to intentionally
ignore the error and leave the
bottle loaded.
3. Loading another bottle will

clear the error and leave the
original bottle loaded in the non-
functional cell.

#911 Invalid Cell Unload Indicates a bottle was unloaded 1. Replace the bottle from the cell
from a non-indicated cell or that a that was just unloaded. The cell
bottle was unloaded while not in ID will be displayed in the error
an Unload function. window on the 3D 60. The cell will
also have a rapidly flashing cell
indicator light. If in the Load
function, load the bottle in an
indicated cell.
2. Reloading the indicated bottle

also causes the Operation error
screen to vanish.
3. Click the Check button ONLY

if the unload was intentional.


452501-1EN1
Fault/Status Number
Displayed
#912 Invalid Cell Reload When reloading a bottle, the 1. Remove the bottle from the
bottle was placed in a disabled or non-functional cell whose
non-functional cell. indicator light will be flashing
rapidly. The cell ID will be
displayed in the error window on
the 3D 60. Reload the bottle into
a different cell. Moving the
indicated bottle also causes the
Operation error screen to vanish.
2. Do Not click the Check button

on the Operation error screen
except to intentionally ignore the
error and leave the bottle loaded
in the non-functional cell.
3. Ignoring the error leaves the

original bottle in a non-functional
cell.

#913 Bottle ID Just Bottle ID is incorrect for the bottle 1. Rescan the bottle and click the
Entered Matches That being loaded or unloaded. Check button after it turns red.
of a Currently Loaded
Bottle 2. If the Instrument Status Code
Bottle ID just entered is window still displays the status
displayed at the top of the code, proceed to the next
Operator Error screen. malfunction.
The cell location of a If the bottle ID is correct for the 1. Record the cell location
bottle loaded with the bottle being loaded or unloaded, displayed in the Error box.
same ID is displayed the bottle ID for the bottle in the
below the bottle ID. cell location indicated was 2. If the error occurred while
incorrect. loading, then do not load the
bottle at this time. Set the bottle
aside and go to Step 4.
3. If the error occurred while

unloading an anonymous bottle,
attach a generic barcode, enter
the generic bottle ID, select the
correct bottle type, and set the
bottle aside.

452501-1EN1
Fault/Status Number
Displayed
4. Pull the bottle from the cell

recorded in Step 1 and record its
bottle ID. (Ignore the Instrument
Status Code #911 Invalid Cell
Unload that appears. DO NOT
click the Check button).
5. Return the above bottle to the

cell from which it came. (LED will
be flashing.)
6. Go to the Edit Cell Contents

screen and select the cell record
for the bottle in Step 2. Edit
Bottle Detail will be displayed.
7. Enter the correct bottle ID in

the Bottle ID field.
9. Reload the bottle that triggered

the error. Be sure to scan the
generic bottle ID barcode label if
one was applied.
10.If the Instrument Status

Code window still displays the
status code, contact bioMérieux.
#921 Barcode Scan Not Barcode was scanned but current No action required to correct this
Allowed in this Mode screen does not accept barcodes. error. It automatically resolves
Frequently occurs if appropriate after 2 seconds.
function is not initiated, such as
load or unload bottles.
#923 Invalid Barcode Scanned barcode cannot be 1. Acknowledge error and rescan
Entry accepted because it is the wrong the bottle.
length, has the wrong starting
character, or has an invalid 2. If the error persists after
character. rescanning the barcode, attempt
1) Unacceptable bottle ID to enter the accession number or
characters are ',",\,*. bottle ID via the keyboard.
2) Unacceptable Accession 3. Ensure barcode is entered into
Number characters are the correct field
',",\,*,@.
4. If error persists, use a generic
bottle ID barcode label.

452501-1EN1
Fault/Status Number
Displayed

malfunction.
BPA/BPN barcodes are not 1. Activate BPA/BPN barcodes.

activated. (Only valid when
scanning BPA or BPN barcodes.) 2. If the Instrument Status Code
#930 Incorrect or A previously identified bottle is 1. If an error was made during the
Unexpected Barcode unloaded, but the wrong label scanning of the bottle, rescan the
Label Scanned While was scanned while unloading the bottle and click the Check button.
Unloading a Bottle bottle. The instrument determines
that it is not the same barcode
currently associated with the 2. If the Instrument Status Code
bottle and reports this error. window still displays the status
Note: Two bottle ID's are malfunction.
displayed in a box on the
Operation Error screen. At the top
is the bottle ID of the bottle just
unloaded and scanned. The
second bottle ID displayed was
assigned to the bottle when it was
originally loaded or identified.
The correct barcode label was 1. If the unloaded bottle was

scanned after unloading the scanned correctly, DO NOT select
bottle, but the incorrect label was anything on the screen.
scanned when the bottle was
originally loaded. 2. Record the bottle ID and the
cell ID, and return the bottle to the
cell from which it was removed.
3. Go to the Select Bottle to Edit

screen and use the scroll buttons
to enter the cell ID recorded.
4. Click the Check button to

display this bottle's information on
the Edit Bottle Detail screen.
5. Edit the bottle ID to match the

bottle ID recorded and click the
Check button.
6. Return to the Unload function

to unload the original bottle.

452501-1EN1
Fault/Status Number
Displayed

#931 Detection An anonymous or identified bottle 1. If the bottle has multiple labels,
Algorithm Has Been is unloaded and its barcode is it may be that the wrong label was
Changed scanned. The instrument scanned. Try re-scanning the
All affected bottles must determines that the media type bottle ID and if correctly entered,
be subcultured. associated with the barcode does click the Check button.
not match the algorithm used in
analyzing the initial data. 2. If no changes are made and
the Check button is clicked, the
bottle will be flagged positive and
Fault Code #74 Algorithm
Change or #77 Reading
Polynomial Change will appear
in the cell where the bottle was
loaded.
3. Unload the bottle with the fault

via the Positive Button Unload
function.
4. Subculture the bottle and

reload the bottle to restart testing.
5. Troubleshoot for Fault Code

#74 Algorithm Change or #77
Reading Polynomial Change.

malfunction.
An anonymous bottle is unloaded 1. Note that the Operator Error

with a generic barcode label. The screen also has a Bottle Type
operator uses Bottle Type scroll scroll button.
button to specify the media type.
The error is reported while 2. If an incorrect media type was
selecting the bottle type. entered, correct it now and click
the Check button.
3. If no changes are made and

the Check button is clicked, the
bottle will be flagged positive and
Instrument Fault Code #74
Algorithm Change or #77
Reading Polynomial Change
will appear in the cell where the
bottle was loaded.

452501-1EN1
Fault/Status Number
Displayed
4. Unload the bottle with the fault

via the Positive Button Unload
function.
5. Subculture the bottle and

reload the bottle to restart testing.
6. Troubleshoot for Fault Code

#74 Algorithm Change or #77
Reading Polynomial Change.

#932 Bottle ID Scanned An anonymous bottle is identified 1. If the bottle ID was entered
Matches that of a with a previously unloaded incorrectly, perform the following
Previously Unloaded bottle's ID. procedure:
Bottle
a. Enter the correct bottle ID.
b. Click the Check button.
2. If the bottle ID was entered

correctly, perform the following
procedure:
a. Re-enter the bottle ID and

click the Check button.
Note: The bottle readings for the

previously unloaded bottle will be
lost and the Bottle ID, Accession
Number, First Loaded Time,
Maximum Test Time, and Bottle
Type will be assigned to the newly
identified bottle.
b. Reload the bottle, if desired.

Fault Code #78 Incomplete
Test Data appears and the
bottle is flagged positive (see
Test Data).
c. If the bottle is not reloaded

(and another bottle is unloaded
or the Cancel button is
clicked), the bottle record will
be lost.

452501-1EN1
Fault/Status Number
Displayed
d. If the bottle is returned to its

cell without identifying the
bottle, the bottle will remain
anonymous and the
Instrument Status Code #932
will disappear.

#940 Bottle Detail Not Occurs only in the Select Bottle to 1. This Instrument Status Code
Found Edit/Graph screen when: will terminate spontaneously after
1. An empty cell is selected. being briefly displayed. When the
2. The bottle ID entered is not Select bottle to Edit / Graph
recognized as belonging to a screen is displayed again, correct
currently loaded or recently the previous entry or click the
unloaded bottle. Cancel button.

malfunction.
This error may occur while in the Contact bioMérieux.

Edit Cell Contents screen when a
loaded cell is selected, but no
bottle record is found.
#941 Bottle ID Entered The bottle ID entered on the Edit If the bottle ID is correctly
Matches that of a Bottle Bottle Detail screen is the same entered, perform the following
that is Currently as the bottle ID of a bottle loaded procedure:
Loaded in a Different in a different cell. 1. Click the Cancel button on the
Cell Edit Bottle Detail screen.
2. Enter the same bottle ID (the

one used on the previous screen)
and click the Check button to
view information on this bottle.
3. Note the cell location on the

Edit Bottle Detail screen and
remove the bottle currently in that
cell to record the actual bottle ID.
4. Ignore the Instrument Status

Code #911 Invalid Cell Unload
that appears on the screen when
the bottle is unloaded.

452501-1EN1
Fault/Status Number
Displayed
5. DO NOT click the Check

button.
6. Return the bottle to the same

cell from which it was removed.
7. Correct the bottle ID and click

the Check button. It is now
possible to edit or identify the
original bottle ID.

#942 Bottle Type In the Edit Bottle Detail screen, a 1. If an error was made entering
Changed Requires bottle's media type has been the new media, perform the
Different Algorithm changed to a media type that following procedure:
requires a different data analysis.
a. Click the Cancel button and
return to the Edit Bottle Detail
screen to correct the entry.
b. Click the Check button on

the Edit Bottle Detail screen to
save the changes.
2. If an error was not made,

perform the following procedure:
a. Click the Check button to

override the error. Note the cell
ID of the bottle.
b. Click the Check button on

the Edit Bottle Detail screen to
save the changes.
c. Go to the View Cell Status

screen and check the cell for
Fault Code #74 Algorithm
Change.
d. If the Instrument Status

Code window still displays the
status code, follow the
procedure provided to correct
the problem (see Fault Code
#74 Algorithm Change).

452501-1EN1
Fault/Status Number
Displayed

#943 Identified Bottle The Bottle ID field has been 1. Click the Cancel button to
Changed to cleared for an identified bottle in return to the Edit Bottle Detail
Anonymous the Edit Bottle Detail screen. screen.
2. Enter a bottle ID and click the

Check button.

#944 Manual Unload of An attempt was made to manually 1. Click the Cancel button to
Anonymous Bottle unload an anonymous bottle from return to the Edit Bottle Detail
the Edit Bottle Detail screen. screen.
2. Enter a bottle ID or change the

Load Status slide bar switch
back to the load position (1).

#945 Bottle ID Entered In the Edit Bottle Detail screen, a 1. If the bottle ID was entered
Matches That of a bottle has been given the bottle incorrectly, perform the following
Previously Unloaded ID of a previously unloaded bottle. procedure.
Bottle
a. Click the Cancel button on
the error screen.
b. Enter the correct bottle ID

on the Edit Bottle Detail screen
and click the Check button.
2. If the bottle ID was entered

correctly, perform the following
procedure.
a. Re-enter the bottle ID and

click the Check button.
Note: The bottle readings for the

previously unloaded bottle will be
lost and the Bottle ID, Accession
Number, First Loaded Time,
Maximum Test Time, and Bottle
Type will be assigned to the
newly identified bottle.

452501-1EN1
Diagnostics and Troubleshooting Information Special Equipment
Fault/Status Number
Displayed
b. Reload the bottle, if desired.

Test Data appears and the
bottle is flagged positive (see
Test Data).
c. If the bottle is not reloaded

(and another bottle is unloaded
or the Cancel button is
clicked), the bottle record will
be lost.

#960 Duplicate Entries Two or more label entry fields on 1. Change one of the duplicate
the Label Entry screen contain labels to a unique entry and click
the same entry when the Check the Check button.
button was clicked.
#961 Invalid Blank Field One of the label fields on the 1. Enter a label in the blank field
Label Entry screen was blank and click the Check button.
when the Check button was
clicked. 2. If the Instrument Status Code
7.4 Special Equipment
Several diagnostics are provided to test the various communications ports on the
3D 60. The tests require special cables/connectors, as described below.
Table 7-3: Special Equipment List
Part Number Description Usage
43013-1 TOOL RS485 This cable is included in the diagnostic kit, but is not
LOOPBACK 3D used on the 3D 60.
43014-1 TOOL CA ASSY RS485 This cable is included in the diagnostic kit, but is not
LOOPBACK 3D used on the 3D 60.
43205-7 CA ASSY BLKHD/MDL This cable is included in the diagnostic kit, but is not
CONT used on the 3D 60.

452501-1EN1
Incubator Diagnostic Procedures Diagnostics and Troubleshooting Information
Table 7-3: Special Equipment List (Continued)
Part Number Description Usage
43012-1 TOOL RS232 Loopback diagnostics for LIS, BARCODE, and

LOOPBACK 3D MODEM ports.
43005-19 KIT, CALIBRATION/ This kit includes the parts above (P/N 43013-1,
TOOL 3D and COMBO 43014-1, 43205-7 and 43012-1) along with parts
used for calibrating cells.
7.5 Incubator Diagnostic Procedures
This section will detail the procedures to troubleshoot problems with various
components of the Incubator.
7.5.1 Access the Diagnostic Test Selection Screen
Note: This procedure will be used to access the Diagnostic Test Selection screen for the
Incubator, Controller Module, and LIS diagnostic procedures.
Next Screen
Button


452501-1EN1
Diagnostics and Troubleshooting Information Incubator Diagnostic Procedures
Key Symbol
Button
5. Verify the Diagnostic Test Selection screen appears. (Refer to Figure 7-7.)
Key
Symbol
Main Selection
Button
List
Sub-Selection
List
Next
Previous Screen
Screen Button
Button
Figure 7-7: Diagnostic Test Selection (Setup) Screen
7.5.2 Loopback Method

Bottle testing is affected while the instrument is performing this diagnostic test.
There are also keyboard functions used in the procedure. Pressing the R — Resets
counts on lines 1.1–1.5, 2.1–2.4, 3.2, 4.1, 4.2, 4.2.1, 4.2.2 to 0 and pressing Run
status once started, the diagnostic runs continuously and updates the display data
continuously. (Refer to Section 3.7.3.1 for an example of the Loopback Method
screen content.)

452501-1EN1
7.5.2.1 Test Procedure
1. Access the Diagnostic Test Selection screen. (Refer to Section 7.5.1.)

3. Select Loopback from the Sub-Selection List.
5. Press R to reset fault counts.
6. Let the diagnostic run for 2 minutes and verify that line 4.2 shows a value of 0.
7. Click the Previous Screen button to exit the Loopback screen.
Note: The Instrument Status Code #710 Incubation Module Initialization screen will
appear momentarily. This is normal.
Figure 7-8: Inc Module/Loopback Screen
7.5.3 Port Stats

This diagnostic displays statistics for the serial hardware that is used to communicate
with a given incubator. Bottle testing is not affected by this diagnostic test.
counts on lines 1.1–1.5, 2.1–2.4, and 3.2 to 0 and the Run Status runs continuously
and updates the display data continuously. (Refer to Section 3.7.3.2 for an example of
the Port Stats screen content.)

452501-1EN1

3. Select Port Stats from the Sub-Selection List.
6. Let the diagnostic run for 2 minutes and verify that the values on the Port Stats
screen are all within the proper range. (Refer to Section 3.7.3.2.)
7. Click the Previous Screen button to exit the Port Stats screen.
Figure 7-9: Inc Module/Port Stats Screen
7.5.4 Message Stats

This screen displays statistics related to messages exchanged between the
instrument controller and incubator. It also displays statistics related to incubator
power faults and event requests. Bottle testing is not affected by this diagnostic.
counts on all lines to 0 and the Run Status runs continuously and updates the display
data continuously. (Refer to Section 3.7.3.3 for an example of the Message Stats
screen content.)


452501-1EN1
3. Select Message Stats from the Sub-Selection List.

6. Let the diagnostic run for 2 minutes and verify that the values on the Message
Stats screen are all within the proper range. (Refer to Section 3.7.3.3.)
7. Click the Previous Screen button to exit the Message Stats screen.
Figure 7-10: Inc Module/Message Stats Screen
7.5.5 Message Log

The Message Log displays the recent history of commands and responses
exchanged between the instrument controller and incubator. Bottle testing is not
affected by this diagnostic.
The Run Status runs continually and adds new messages to the end of the display as
they occur. (Refer to Section 3.7.3.4 for an example of the Message Log screen
content.)

3. Select Message Log from the Sub-Selection List.

452501-1EN1
6. Let the diagnostic run for 2 minutes and verify that the values on the Message
Log screen are all within the proper range. (Refer to Section 3.7.3.4.)
7. Click the Previous Screen button to exit the Message Log screen.
T: Timestamp (shown for

reference, not actually
part of the message data)
Out: Data sent to the

incubator
In: Data received from the

incubator
Figure 7-11: Inc Module/Message Log Screen
7.5.6 Temperature Log

The Temperature Log displays the history or heater temperature data from the still
displays, the fault code, and sensor on the racks. Bottle testing is not affected by this
diagnostic.
The Run Status runs continually and adds new temperature readings to the end of the
display as they occur.
The Drawer open (DRW OPEN) and Close (DRW CLOS) events are also displayed,
but are not shown in Figure 7-12 and events are logged when they occur.
MOD TEMP events are logged every 5 minutes. RCK TEMP events are logged
approximately once per hour per rack. TEMP SET events are logged when they
occur. (Refer to Section 3.7.3.5 for an example of the Temperature Log screen
content.)

3. Select Temperature Log from the Sub-Selection List.

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6. Let the diagnostic run for 2 minutes and verify that the values on the
Temperature Log screen are all within the proper range. (Refer to
Section 3.7.3.5.)
7. Click the Previous Screen button to exit the Temperature Log screen.
Time of Event in
dd/mm/yy hh:mm:ss format
Event Location
ModSig entry shows heater

inlet and outlet sensor
readings along with
average of the readings.
Rack Temperature entry
shows readings of two
still displays, the fault code
on rack, latest
module temperature
setpoint, and average of
rack sensor readings.
This entry indicates that a
temperature calibration or
temperature setpoint
change occurred.
Figure 7-12: Inc Module/Temperature Log Screen
7.5.7 Reading Log

The Reading Log screen displays the most recent readings taken on incubator cells.
Each line of the display identifies each cell the reading was taken from, followed by:
• the status of the cell: LOAD, UNLOAD, OUT OF CAL

• the reading
• the number of the polynomial used to normalize the reading
The Run Status runs continually and adds new readings to the end of the display as
they occur. Bottle testing is not affected by this diagnostic. (Refer to Section 3.7.3.6
for an example of the Reading Log screen content.)

3. Select 1.6 Reading Log from the Sub-Selection List.

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6. Let the diagnostic run for 2 minutes and verify that the values on the Reading
Log screen are all within the proper range. (Refer to Section 3.7.3.6.)
7. Click the Previous Screen button to exit the Reading Log screen.
Figure 7-13: Inc Module/Reading Log Screen
7.5.8 Flag Check

This diagnostic gathers calibration information for all the cells in an incubator.
Specifically, the current flag reading and the flag reading at calibration time are
obtained. The percentage difference (Delta) between the current and calibrated
readings is calculated and displayed. Bottle testing is not affected by this diagnostic.
(Refer to Section 3.7.3.7 for an example of the Flag Check screen content.)
Keyboard functions include:
• 1 — Display the Percentage Difference screen.

• 2 — Display the Details screen.
• C — Enter the Cell Calibration screen.

3. Select Flag Check from the Sub-Selection List.

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5. When the diff % (Delta) data appears, scroll up to find the cells in the
Difference > 1.5% group. (Refer to Figure 7-14.)
Cells whose
difference is greater
than or equal to
1.0%
Cell location
(% diff.)
Figure 7-14: Inc Module/Flag Check Screen
6. Note the cells listed in this group.

7. Press C to access the Cell Calibration screen. (Refer to Figure 7-15.)

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Figure 7-15: Cell Calibration Screen
8. Perform a single cell calibration for each of the cells noted in Step 6. (Refer to
Section 6.7 and perform Step 11 through Step 24 for each cell.)
9. Click the Run Continuously button to restart the diagnostic and gather new
readings. (Refer to Figure 7-16.)
Figure 7-16: Run Continuously Button
10. Click the Previous Screen button to exit the Flag Check screen.
7.5.9 Drawer/Heater
This diagnostic displays the state of the drawer switch and heater function in an
Incubator. Bottle testing is not affected by this diagnostic and the Run Status runs
continuously and updates the display continuously. (Refer to Section 3.7.3.8 for an
example of the Drawer/Heater screen content.)

3. Select Drawer/Heater from the Sub-Selection List.

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6. Let the diagnostic run for 2 minutes and verify that the values on the Drawer/
Heater screen are all within the proper range. (Refer to Section 3.7.3.8.)
7. Click the Previous Screen button to exit the Drawer/Heater screen.
Average of heater inlet

and outlet sensor plus
calibration offset.
Offset determined when

temperature was last
calibrated.
Amount of heater power

currently applied to
maintain temperature.
(Note: goes to 0% if the
drawer is opened.)
Value is updated every
30 seconds
Switch position (Switch
function) current state.
Figure 7-17: Inc Module/Drawer/Heater Screen
7.5.10 LED Check

This diagnostic provides a way to turn all the LEDs ON and also to blink them in a
pattern to verify that they all work and that no LEDs are shorted together. Bottle
testing is not affected by this diagnostic. (Refer to Section 3.7.3.9 for an example of
the LED Check screen content.)
The keyboard functions are:
• 1 — Turns on all LEDs.

• 2 — Initiates the Walking LED pattern.
The Run Status runs continuously and updates the display continuously.

3. Select LED Check from the Sub-Selection List.

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5. Open the door and verify that all the LEDS on the cells are ON. (Refer to
Figure 7-18.)
Note: Upon initial entry to diagnostic, all LEDs are turned on and the display appears as
shown in Figure 7-18.
Figure 7-18: Inc Module/LED Check
6. Press the 2 key.

7. Open the door and verify from the Walking pattern that only one cell LED turns
on at a time for the top rack.
8. Verify from the Walking pattern that only one cell LED turns on at a time for the
middle rack.
9. Verify from the Walking pattern that only one cell LED turns on at a time for the
lower rack.
10. Click the Previous Screen button to exit the LED Check screen.

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Controller Module Diagnostic Tests Diagnostics and Troubleshooting Information
Figure 7-19: Inc Module/LED Check (Walking)
7.6 Controller Module Diagnostic Tests
This section will focus on the diagnostic testing procedures that relate to the Controller
Module (Instrument Controller).
7.6.1 Zip® Drive Test

This verifies that data can be written to (and read from) the Zip® drive. Bottle testing is
not affected by this diagnostic. (Refer to Section 3.7.4.1 for an example of the Zip
Drive Test screen content.)
Keyboard functions include: Press R to reset counts.
1. Remove the Zip® disk from the Zip® drive and replace it with a known good Zip®
disk.
3. Select 2.0 Instrument Cntrl from the Main Selection List.
4. Select Zip Drive Test from the Sub-Selection List.
6. Let run for at least 2 minutes.

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Diagnostics and Troubleshooting Information Controller Module Diagnostic Tests
7. Verify that no FAIL counts are displayed.

8. Click the Previous Screen button to exit the Zip Drive Test screen.
9. Put the original Zip® disk back into Zip® drive.
11. Select Zip Drive Test from the Sub-Selection List.
12. Clear the PASS and FAIL counters.
13. Open a file on the Zip® disk. If the file cannot be opened, increment the Open
Error Counter (line 2.1).
14. Write garbage to the file.
15. Go back to the start of the file and write the current date and time. If an error is
generated while writing, increment the Write Error Counter (line 2.3).
16. Go back to the start of the file and read the data. If an error is generated while
reading the data or the data does not match what was written, increment the
Read Error Counter (line 2.2).
Figure 7-20: Instrument Cntrl/Zip Drive Test Screen
17. Close the file.

18. Repeat Step 13 through Step 17 until the diagnostic is terminated.
19. Click the Previous Screen button to exit the Zip Drive Test screen.

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7.6.2 Barcode Loopback

Special equipment required: P/N 43012-1
This diagnostic verifies the operation of the serial hardware that makes up the
interface to the barcode scanner. It isolates problems to either the barcode scanner or
3D 60. Bottle testing is not affected by this diagnostic. (Refer to Section 3.7.4.2 for an
example of the Barcode Loopback screen content.)
The only keyboard function is: R — Resets values on lines 1.1–1.5, 2.1–2.4, 3.2, 4.1,
4.2, and 4.2.1–4.2.4 to 0.
the 3D 60 rear panel. (Refer to Figure 7-21.)
Barcode
Port
Figure 7-21: Barcode Scanner Connection
2. Remove the Barcode Scanner.

3. Connect the loopback connector P/N 43012-1 to the BARCODE port on the
3D 60 rear panel.
6. Select Barcode Loopback from the Sub-Selection List.
8. Let the diagnostic run for a period of 2 minutes.
9. Verify that FAIL count on line 4.2 is 0. (Refer to Figure 7-22.)

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Figure 7-22: Instrument Cntrl/Barcode Loopback Screen
10. Click the Previous Screen button to exit the Barcode Loopback screen.
11. Disconnect the loopback connector P/N 43012-1 from the BARCODE port on
the 3D 60 rear panel.
12. Position the Barcode Scanner in place.
13. Connect the Barcode Scanner cable connector to the BARCODE port on the
3D 60 rear panel. (Refer to Figure 7-21.)
7.6.3 Modem Loopback

Special equipment required: P/N 43012-1
This diagnostic verifies the operation of the serial hardware that makes up the
interface to the external modem. It isolates problems to either the external modem or
3D 60. Bottle testing is not affected by this diagnostic.
The Run Status runs continuously and updates the display continuously. (Refer to
Section 3.7.4.3 for an example of the Modem Loopback screen content.)
1. Disconnect the modem cable connector from the rear panel of the 3D 60.
2. Connect the loopback connector P/N 43012-1 to the MODEM port on the rear
panel of the 3D 60.

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5. Select Modem Loopback from the Sub-Selection List.

7. Let the diagnostic run for a period of 2 minutes.
8. Verify that FAIL count on line 4.2 is 0.
9. Click the Previous Screen button to exit the Modem Loopback screen.
10. Disconnect the loopback connector P/N 43012-1 from the MODEM port on the
rear panel of the 3D 60.
11. Connect the modem cable connector to the MODEM port at the 3D 60 end.
7.6.4 Power Event Log

Shows recent history of power faults in the instrument controller and incubation
chamber. Bottle testing is not affected by this diagnostic.
The Run Status runs continuously and updates the display continuously. (Refer to
Section 3.7.4.4 for an example of the Power Event Log screen content.)
Time of event in
dd/mm/yy hh:mm:ss
format.
Figure 7-23: Instrument Cntrl/Power Event Log Screen

3. Select Power Event Log from the Sub-Selection List.

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5. Let the diagnostic run for 2 minutes and verify that the values on the Power
Event Log screen are all within the proper range. (Refer to Section 3.7.4.4.)
6. Click the Previous Screen button to exit the Power Event Log screen.
7.6.5 View Files

This function allows contents of selected files to be viewed. Bottle testing is not
affected by this diagnostic. The Keyboard functions select the file that is to be viewed.
File types that may be selected are all .BID, .BTF, .APR, all event log files
(LOG\*.EVT), and the preload data file (PLDSTORE.DAT).
The Run Status only runs once and stops.
Each line in the event logs for .BID, .BTF, and .APR have the same format. The only
difference between them is that the file name extension will differ depending on the
type of event log accessed.
LOG files are similar to the event logs for .BID, .BTF, and .APR except that log files in
the \LOG directory, specifically EVENT14.LOG, EVENT13.LOG and so on to
EVENT0.LOG are displayed. EVENT0.LOG contains the most recent data and
appears at the bottom of the display. EVENT14.LOG contains the oldest data and
appears at the top of the display. If there is more log data than can be displayed, the
oldest log data is omitted from the display. An example is shown in Figure 7-24. Refer
to Section 3.7.4.9 for details on what the contents of .LOG file mean.

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FILE : EVENT1.LOG
------------------------------------------------------------
!! 139719250(06/06/01 08:04:34) 0x38(DTChg) 4294948672
!! 139719253(06/06/01 08:04:37) 0x4(ICFlt) 0
!! 139719253(06/06/01 08:04:37) 0x3(IMFlt) 1 0 0 0 0 0
!! 139719253(06/06/01 08:04:37) 0x3(IMFlt) 2 0 0 0 0 0
!! 139719253(06/06/01 08:04:37) 0x3(IMFlt) 3 0 0 0 0 0
!! 139719253(06/06/01 08:04:37) 0x3(IMFlt) 4 0 0 0 0 0
!! 139719253(06/06/01 08:04:37) 0x3(IMFlt) 5 0 0 0 0 0
!! 139719253(06/06/01 08:04:37) 0x3(IMFlt) 6 0 0 0 0 0
!! 139719258(06/06/01 08:04:42) 0x30(IMPwr) 1
!! 139719258(06/06/01 08:04:42) 0x30(IMPwr) 2
!! 139719535(06/06/01 08:09:19) 0x4(ICFlt) 12
!! 139721277(06/06/01 08:38:21) 0x38(DTChg) 4294948672
!! 139721279(06/06/01 08:38:23) 0x4(ICFlt) 0
!! 139721280(06/06/01 08:38:24) 0x3(IMFlt) 1 0 0 0 0 0
FILE : EVENT0.LOG
------------------------------------------------------------
!! 139809948(07/06/01 09:16:12) 0x38(DTChg) 4294948672
!! 139809951(07/06/01 09:16:15) 0x4(ICFlt) 0
!! 139809951(07/06/01 09:16:15) 0x3(IMFlt) 1 0 0 0 0 0
!! 139809951(07/06/01 09:16:15) 0x3(IMFlt) 2 0 0 0 0 0
!! 139809951(07/06/01 09:16:15) 0x3(IMFlt) 3 0 0 0 0 0
!! 139809951(07/06/01 09:16:15) 0x3(IMFlt) 4 0 0 0 0 0
!! 139809951(07/06/01 09:16:15) 0x3(IMFlt) 5 0 0 0 0 0
!! 139809951(07/06/01 09:16:15) 0x3(IMFlt) 6 0 0 0 0 0
!! 139809956(07/06/01 09:16:20) 0x30(IMPwr) 1
!! 139809956(07/06/01 09:16:20) 0x30(IMPwr) 2
!! 139810161(07/06/01 09:19:45) 0x4(ICFlt) 12
!! 139810363(07/06/01 09:23:07) 0x3(IMFlt) 2 0 0 74 0 0
!! 139811149(07/06/01 09:36:13) 0x4(ICFlt) 0
!! 139812682(07/06/01 10:01:46) 0x38(DTChg) 4294948672
!! 139812694(07/06/01 10:01:58) 0x4(ICFlt) 0
!! 139812695(07/06/01 10:01:59) 0x3(IMFlt) 1 0 0 0 0 0
!! 139812695(07/06/01 10:01:59) 0x3(IMFlt) 2 0 0 0 0 0
!! 139812695(07/06/01 10:01:59) 0x3(IMFlt) 3 0 0 0 0 0
!! 139812695(07/06/01 10:01:59) 0x3(IMFlt) 4 0 0 0 0 0
!! 139812695(07/06/01 10:01:59) 0x3(IMFlt) 5 0 0 0 0 0
!! 139812695(07/06/01 10:01:59) 0x3(IMFlt) 6 0 0 0 0 0
!! 139812700(07/06/01 10:02:04) 0x30(IMPwr) 2
!! 139812700(07/06/01 10:02:04) 0x30(IMPwr) 1
!! 139813009(07/06/01 10:07:13) 0x3(IMFlt) 1 0 20 0 0 0
!! 139813053(07/06/01 10:07:57) 0x3(IMFlt) 1 0 0 0 0 0
!! 139813314(07/06/01 10:12:18) 0x3(IMFlt) 1 0 99 0 0 0
!! 139813764(07/06/01 10:19:48) 0x3(IMFlt) 1 0 51 0 0 0
Figure 7-24: FILE : EVENT1.LOG and EVENT0.LOG
7.6.5.1 .BID Files
For each file in the c:\btlprocs directory of the flash drive with a .BID extension, the file
(Refer to Section 3.7.4.6 for an example of the .BID Files screen content.)
Procedure:

3. Select View Files from the Sub-Selection List.
5. Press 2 to generate the .BID Event Log.
6. Click the Previous Screen button to exit the .BID Event Log screen.
7. Click the Previous Screen button to exit the View Files screen.

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7.6.5.2 .BTF Files
For each file in the c:\btlprocs directory of the flash drive with a .BTF extension, the file
(Refer to Section 3.7.4.7 for an example of the .BTF Files screen content.)
Procedure:

5. Press 3 to generate the .BTF Event Log.
6. Click the Previous Screen button to exit the .BTF Event Log screen.
7.6.5.3 .APF Files
For each file in the c:\btlprocs directory of the flash drive with an .APF extension, the
file. (Refer to Section 3.7.4.8 for an example of the .APF Files screen content.)
Procedure:

5. Press 4 to generate the .APF Event Log.
6. Click the Previous Screen button to exit the .APF Event Log screen.
7.6.5.4 .LOG Files
For each file in the c:\btlprocs directory of the flash drive with an .LOG extension, the
file. (Refer to Section 3.7.4.9 for an example of the .LOG Files screen content.)
Procedure:


452501-1EN1
5. Press 5 to generate the .LOG Event Log.

6. Click the Previous Screen button to exit the .LOG Event Log screen.
7.6.5.5 PLDSTORE.DAT Files
For each file in the c:\btlprocs directory of the flash drive with an PLDSTORE.DAT
extension, the file name is displayed, followed by a row of dashes, followed by the
contents of the file.
Procedure:

5. Press 6 to generate the PLDSTORE.DAT Event Log.
6. Click the Previous Screen button to exit the PLDSTORE.DAT Event Log
screen.
7.6.6 Software
The software function displays data used to debug, verify and validate the instrument
software. It also displays logs of exception conditions detected by the software. The
Run Status runs continually and updates display when new information needs to be
displayed. Bottle testing is not affected by this diagnostic. (Refer to Section 3.7.4.10
for an example of the Software screen content.)
7.6.6.1 Debug
The Debug screen displays software debug messages intended for development
activity and is intended for the 3D 60 software development team. The format and
content messages put in this log are determined by the software implementor and no
design specifications are imposed. (Refer to Section 3.7.4.11 for information on the
Debug screen content.)
Procedure:

3. Select Software from the Sub-Selection List.
5. Press 1 to access the Debug screen.

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6. Click the Previous Screen button to exit the Debug screen.

7. Click the Previous Screen button to exit the Software screen.
7.6.6.2 Software Exception Log
The Software Exception Log screen displays software exceptions messages intended
for the 3D 60 software development team. Access this screen if a Fault Code #19
Software Exception is being displayed on the Main screen. The format and content
messages put in this log are determined by the software implementor and no design
specifications are imposed. (Refer to Section 3.7.4.12 for information on the Software
Exception Log screen content.)
Procedure:

5. Press 2 to access the Software Exception Log screen.
6. Press Ctrl + R to clear the fault 19.
7. Verify that a short beep sounds from the speaker.
8. Refer to Table 3-10 to determine the cause of the software exception.
9. Click the Previous Screen button to exit the Software Exception Log screen.
7.6.6.3 Operating System Exception Log
The Operating System Exception Log screen displays exceptions reported by the 3D
60 operating system (SMX). The format and content messages put in this log are
determined by the operating system vendor (Micro Digital) and no design
specifications are imposed. (Refer to Section 3.7.4.13 for information on the
Operating System Exception Log screen content.)
Procedure:

5. Press 3 to access the Operating System Exception Log screen.
6. Click the Previous Screen button to exit the Operating System Exception Log
screen.

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7.6.6.4 Modem Activity Log
The Modem Activity Log screen displays software debug messages intended for
development activity and is intended for the 3D 60 software development team. The
format and content messages put in this log are determined by the software
implementor and no design specifications are imposed. (Refer to Section 3.7.4.14 for
information on the Modem Acitivy Log screen content.)
Procedure:

5. Press 4 to access the Modem Activity Log screen.
6. Click the Previous Screen button to exit the Modem Activity Log screen.
7.6.6.5 Association Tables
The Association Tables screen displays current content of various dictionaries and
association tables used to keep track of bottle and pre-load data. (Refer to
Section 3.7.4.15 for an example of the Association Tables screen content.)
Procedure:

5. Press 5 to access the Association Tables screen.
6. Click the Previous Screen button to exit the Association Tables screen.
7.6.6.6 Bottle Processing Tables
The Bottle Processing Tables screen displays the current content of the tables that
drive the way the 3D processes bottles. (Refer to Section 3.7.4.16 for an example of
the Bottle Processing Tables screen content.)
Procedure:


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5. Press 6 to access the Bottle Processing Tables screen.
6. Click the Previous Screen button to exit the Bottle Processing Tables screen.
7.6.6.7 Audit Trail
The Audit Trail screen displays the audit trail settings that are used to determine the
BacT/ALERT® 3D 60's operation. (Refer to Section 3.7.4.17 for information on the
Audit Trail screen content.)
Procedure:

5. Press 7 to access the Audit Trail screen.
6. Click the Previous Screen button to exit the Configuration Tables screen.
7.6.7 Scandisk Output

Scandisk, as its name implies, is a function that runs periodically to check the integrity
of the C and D drives. For the C drive, an additional set of checks is made to verify the
size of the fixed size files associated with the 3D application. This is not done for the
D drive.

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The output of this operation is displayed on the Misc. screen.
When replacing a CPU board, it is crucial to transfer the CMOS date/time from the old
board to the new board. This is not possible if the old board is not functioning.
Consequently, when the instrument is powered up, it is possible that Fault Code #71
Invalid Time Stamp is reported. This diagnostic screen provides the best chance of
fixing the CMOS time.
1. If Fault Code #71 Invalid Time Stamp appears, turn off the incubators.
6. Note the date and time on line 3.1.
7. Determine the amount of time that the instrument was down and add that to
date/time from Step 6.
8. Simultaneously, press Ctrl + Alt + Delete.
Note: The screen will go blank and then text will appear.
9. Immediately begin pressing and releasing the Delete key. Keep doing this until
the CMOS Setup screen appears.

452501-1EN1
Diagnostics and Troubleshooting Information LIS Diagnostic Tests
10. Once the CMOS Setup screen appears, use the Arrow keys to select
STANDARD CMOS SETUP (will be highlighted red) and press Enter.
11. Enter the time from Step 7 into the CMOS clock.
12. Press Esc and then F10.
Note: The message Save CMOS and EXIT (Y/N)? will appear.
13. Press Y followed by Enter to save the change(s).

14. Restart the 3D 60 software.
7.7 LIS Diagnostic Tests
7.7.1 Loopback
Special equipment needed: P/N 43012-1
This diagnostic verifies that interrupts, transmit data, receive data, clear to send and
data set ready are working on the incubator's communication port. Bottle testing is not
affected by this diagnostic. (Refer to Section 3.7.5.1 for an example of the Loopback
screen content.)
Keyboard functions:
R — Resets counts on lines 1.1–1.5, 2.1–2.4, 3.0, 4.1, 4.2, 4.2.1, 4.2.2, 4.2.3, and
4.2.4 to 0.
Run status: Once started, the diagnostic runs continuously and updates the display
data continuously.
1. Disconnect the LIS cable from the 3D 60 end and replace with the loopback
connector P/N 43012-1.
3. Select 3.0 LIS from the Main Selection List.
4. Select Loopback from the Sub-Selection List.
6. Run the diagnostic for at least 2 minutes and verify that the values on the
Loopback screen are all within the proper range. (Refer to Section 3.7.5.1.)
7. Verify that FAIL count on line 4.2 is 0.
8. Click the Previous Screen button to exit the Loopback screen.
9. Disconnect the loopback connector P/N 43012-1 and connect the LIS cable to
the 3D 60.

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LIS Diagnostic Tests Diagnostics and Troubleshooting Information
Figure 7-26: LIS/Loopback Screen
7.7.2 Port Stats

This diagnostic displays statistics for the serial hardware used to communicate with
the LIS. Bottle testing is not affected by this diagnostic. (Refer to Section 3.7.5.2 for an
example of the Port stats screen content.)
Keyboard functions:
R — resets counts on lines 1.1–1.5, 2.1–2.4, and 3.0 to 0.
Run Status: Runs continuously and updates the display data continuously.

3. Select Port Stats from the Sub-Selection List.
5. Run the diagnostic for at least 2 minutes and verify that the values on the Ports
Stats screen are all within the proper range. (Refer to Section 3.7.5.2.)
6. Click the Previous Screen button to exit the Port Stats screen.

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Figure 7-27: LIS/Port Stats Screen
7.7.3 Message Stats

This screen displays statistics related to messages exchanged between the 3D 60
and LIS. Bottle testing is not affected by this diagnostic. (Refer to Section 3.7.5.3 for
an example of the Message Stats screen content.)
Run Status: Runs and updates display values continuously.

3. Select Message Stats from the Sub-Selection List.
Message Stats screen are all within the proper range. (Refer to Section 3.7.5.3.)
6. Click the Previous Screen button to exit the Message Stats screen.

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Figure 7-28: LIS/Message Stats Screen
7.7.4 Message Log

This screen displays recent history of message data exchanged between the 3D 60
and LIS. Bottle testing is not affected by this diagnostic. (Refer to Section 3.7.5.4 for
an example of the Message Log screen content.)
Run Status: Runs and updates display values continuously.

3. Select Message Log from the Sub-Selection List.
Message Log screen are all within the proper range. (Refer to Section 3.7.5.4.)
6. Click the Previous Screen button to exit the Message Log screen.

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Figure 7-29: LIS/Message Log Screen

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Appendix A: Specifications
About this Appendix
This appendix outlines the physical and electronic characteristics of the

BacT/ALERT® 3D 60, and the environment in which the instrument is designed to
operate.
Appendix Contents
A.1 Physical Characteristics • A-2

A.2 Environmental Characteristics • A-2
A.3 Electrical Characteristics • A-2
BacT/ALERT® 3D 60 Service Manual A-1

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Physical Characteristics Specifications
A.1 Physical Characteristics
Dimensions Height: 61 cm (24 in.)

Width: 57.8 cm (22.75 in.)
Depth: 49.5 cm (19.5 in.)
Mass Unloaded: 41 kg (90 lb)
Loaded: 45 kg (98 lb)
A.2 Environmental Characteristics
Operating 10 °C to 30 °C (50 °F to 86 °F), measured 2.54 cm (1 in.) from

Temperature Range the unit cover.
Storage Temperature -17 °C to 57 °C (0 °F to 135 °F), measured 2.54 cm (1 in.) from

Range the unit cover.
Operating/Storage 10% to 90% Relative Humidity, Non-condensing

Humidity Range
Operating/Storage 2000 meters (6562 ft)

Altitude
Pollution Degree Degree 2 in accordance with IEC 664
Overvoltage Category II per IEC 664
Sound Emission 50.8 dB
A.3 Electrical Characteristics
Service Required 100/120 or 220/240 VAC 50/60 Hz

Power Consumed In Watts @ 120 VAC 480 W Max
@ 240 VAC 480 W Max
Heat Dissipated In BTU/hr 1639 Maximum
A-2 BacT/ALERT® 3D 60 Service Manual

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Appendix B: Decontamination Procedures
About this Appendix
This appendix contains detailed instructions on how to decontaminate a unit prior to

shipment. It also instructs on decontamination procedures of assemblies that may be
replaced.
WARNING
Handle specimens and inoculated culture bottles as though capable
of transmitting infectious agents.
Appendix Contents
B.1 Spills • B-2

B.2 Shipment of Instrument • B-2
B.3 Assemblies • B-3
BacT/ALERT® 3D 60 Service Manual B-1

452501-1EN1
Spills Decontamination Procedures
B.1 Spills
Any blood or test specimen spills within the unit need to be removed immediately.
Procedures outlining disinfection for spills are in the BacT/ALERT® 3D 60 User
Manual Safety Precautions and Procedures section.
B.2 Shipment of Instrument
Required Equipment:
• Gloves
• Cleaner
• Brush
• Paper Towels
• 5.25% bleach
• Mask
• Decontamination Certificate
• 700 PPM free chlorine solution (13 mL of 5.25% bleach to 1 liter of tap water)
Should the instrument require shipment to another location, perform the following
procedure:
1. Remove all tubing and trays and discard into an approved biohazard receptacle.
Remove crusted materials, blood, reagents, etc. using a 700 PPM free chlorine
solution (13 mL of 5.25% bleach to 1 liter of ph 8.0 tap water) and brush.
2. Dried and caked blood should be removed with a mild detergent and/or diluted
bleach solution before disinfection.
3. Using a 10% bleach disinfectant of 700 PPM free chlorine solution (13 mL of
5.25% bleach added to 1 liter of ph 8.0 tap water), wipe down the exterior of the
instrument. Pay particular attention to areas that are frequently touched.
4. Apply the 10% bleach solution or other EPA registered tuberculocidal
disinfectant. Gently cover the spill area with a PAPER TOWEL.
5. Wet down all surfaces with which the spill may have come in contact.
6. Allow all surfaces adequate contact time with the bleach solution (15–30
minutes) before cleanup.
7. After decontamination, wipe with damp (water only) paper towel and thoroughly
dry.
8. All materials used in the clean up should be treated as biohazardous waste.
9. Place instrument in sealed plastic bag before packaging.
Note: Solutions of sodium hypochlorite (household bleach) >5% are the recommended
concentrations and have demonstrated to have broad-spectrum germicidal properties.
Fresh dilutions should be used to prevent the loss of germicidal actions that occur
during storage.
B-2 BacT/ALERT® 3D 60 Service Manual

452501-1EN1
Decontamination Procedures Assemblies
B.3 Assemblies
Using the same equipment as mentioned in Section B.2, perform the following
procedures on assemblies before shipping:
Note: The assembly decontamination procedure is inclusive of all assemblies returned to

the factory repair center with the exception of printed circuit boards (PCBAs). Printed
circuit boards (PCBAs) are not required to be decontaminated; however, the
decontamination certificate MUST be completed noting that decontamination was not
performed.
1. Using a 10% bleach disinfectant of 700 PPM free chlorine solution (13 mL of
5.25% bleach to 1 liter of ph 8.0 tap water), wipe down all external surfaces of
the assembly.
2. After the decontamination procedure has been performed on the assembly,
complete the decontamination certificate, noting any areas that were unable to
be decontaminated. Attach the certificate to the assembly.
3. Place the assembly in a sealed plastic bag before packaging.
BacT/ALERT® 3D 60 Service Manual B-3

452501-1EN1
Assemblies Decontamination Procedures
B-4 BacT/ALERT® 3D 60 Service Manual

452501-1EN1
Appendix C: Installation Checklist
C.1 BacT/ALERT® 3D 60 Part Checklist
SITE NAME ________________________________ SERIAL # _____________________

CITY, STATE _______________________________ SERVICE CALL #_______________
Use the following checklist to verify and inspect kit contents (see Verifying Contents on page 2-2).
Contents
o BacT/ALERT® 3D 60 Instrument
o BacT/ALERT® 3D 60 Version B.25 User Manual
o 2 ea. 5 amp fuse
o 1 ea. 6.3 amp fuse
o 2 ea. Zip® Disk
o Decontamination Procedure
o Decontamination Certificate
o Anonymous BTL Labeling Set – WARNING –
o Rack — Bottle Carrier BTA
o Mouse and Mouse Pad
o Barcode Reader and Manual
o Barcode Reader Stand
o Keyboard
o Power Cord
o Printer
o Parallel Printer cable
o 1/4" X 20 X 5" bolt
o 1/4" flat washer
o UPS
o UPS Serial Cable
o CRT Monitor
o Calibration Standards Kit
o Certificate of Accuracy
o Digital Thermometer
o International Install Checklist
o MS-DOS 6.22 Software License
o Quick Reference Card
o Disk, BTA3D Installation and Utilities, Version B.25
o Super Cable Clamp
o Installation Instructions, UPS
o Cell Plug/Bottle Brush Kit
Optional Equipment
o Speaker Set — For 110 V BacT 3D 60
or
o Speaker Set — For 220 V BacT 3D 60
o Fax Modem — Domestic (Optional) — 120 V
or
o Fax Modem — International (Optional)
o Serial Modem Cable (Optional)
o UPS to Printer Power AC Adaptor
o UPS to Printer AC Power Cable
o Flat Panel Monitor
Note: This page may be copied for field use.
BacT/ALERT® 3D 60 Service Manual C-1

452501-1EN1
BacT/ALERT® 3D 60 Installation Checklist Installation Checklist
C.2 BacT/ALERT® 3D 60 Installation Checklist
SITE NAME ________________________________ SERIAL # _____________________

CITY, STATE _______________________________ SERVICE CALL #_______________
Preparation Pass Value Initials
Verify Site Requirements are met (see page 2-2) ____ _____
Unpack Contents (see page 2-3) ____ _____
Verify Contents (see page 2-2) ____ _____
Installation
Set AC Power (see page 2-6) ____ _____
Instrument Placement (see page 2-10) ____ _____
Restraint Installation, if required (see page 2-4) ____ _____
Instrument connections made (see page 2-10) ____ _____
Instrument powered up (see page 2-12) ____ _____
Verify BIOS Time and Date (see page 2-13) ____ _____
Set/Verify Optimal Temperature (see page 2-16) ____ ____ _____
Instrument Cell Calibration (see page 2-26) ____ _____
Configure Software (see page 2-14) ____ _____
Set Bottle Test Time (see page 2-14) ____ ____ _____
Enable Audio Alarms (see page 2-14) ____ _____
Select Instrument Installation Options (see page 2-16) ____ ____ ____ _____
Signature Select SelectLink
Configure the Screen (see page 2-17) ____ _____
Configure the Instrument (see page 2-19) ____ _____
Set User Preferences (see page 2-20) ____ _____
Configure the LIS — SelectLink Only (see page 2-23) ____ _____
Check for Disabled Components (see page 2-26) ____ _____
Check for Errors (see page 2-26) ____ _____
Log In — 21 CFR Part 11 (see page 2-28) ____ _____
Functional Testing
Modem Functional Test (see page 2-33) ____ _____
Barcode Reader Functional Test (see page 2-33) ____ _____
Verify Plastic Bottle Algorithms (see page 2-34) ____ _____
UPS Functional Test (see page 2-38) ____ _____
Install Printer (see page 2-39) ____ _____
Record Software Revision and Annotate Logbooks ____ _____
Sheet 1 of 2
C-2 BacT/ALERT® 3D 60 Service Manual

452501-1EN1
Installation Checklist BacT/ALERT® 3D 60 Installation Checklist
The following table shows items that may be connected to the instrument as “shipped”
or “optionally installed” parts:
_____ UPS _____ External Speaker Set (Domestic or

(Domestic or International) International)
_____ Monitor (Flat Panel or CRT) _____ Keyboard

(Must be installed with the instrument)
_____ Printer _____ Barcode Reader
_____ Modem AC Adapter (Must be installed _____ Mouse

with modem) (Must be installed with the instrument)
_____ Modem (Domestic or International)
Comments:
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
Sheet 2 of 2
BacT/ALERT® 3D 60 Service Manual C-3

452501-1EN1
C-4
bioMérieux, Inc.
BacT/ALERT® 3D 60
Standard Laboratory Operating Environment Requirements
Customer Information Ship to address (if different)
Facility Name: ___________________________________ Facility Name: _____________________________________
Address:________________________________________ Address: __________________________________________
City, State, Zip: __________________________________ City, State, Zip: _____________________________________
Contact: ________________________________________ Contact:___________________________________________
Telephone: ______________________________________ Telephone: ________________________________________
1. Physical Specifications:
Ɣ Receiving dock and the internal delivery route must be able to accommodate the size and weight of instruments being delivered.
BacT/ALERT® 3D 60 Installation Checklist
Requirements (SLOER) Form
3D-60 3D-60
(in) (cm) (lb) (kg)
Height: 24 60.9 Weight
Width: 23.1 59 With Bottles: 98 45
Depth: 19.5 50 Empty: 90 41
2. Electrical Requirements:
Ɣ Properly grounded dedicated A/C power branch circuit capable of providing typical:
20 Amps @ 120 Volts / 60 Hz North American
16 Amps @ 220 Volts / 50 Hz Europe
15 Amps @ 100 Volts / 50 - 60 Hz Japan
13 Amps @ 240 Volts / 50 Hz United Kingdom
Ɣ One branch circuit will provide power to the 3D 60, UPS, Printer, Speakers, Modem, (Total of 2 receptacles for the system are required).
Ɣ NO power strips or extension cords are to be used for power distribution to the BacT/ALERT® 3D 60 System.
Ɣ AC power outlets must be within 8 ft or 244 cm of the 3D 60 installed.
Ɣ Nonconformance to the above Electrical Requirements may result in voiding the equipment warranty or service contract resulting in a charge for service.
Ɣ To ensure proper operation, the supporting electrical circuit must be maintained as a dedicated power source (i.e. not serving large power consuming
devices including but not limited to, centrifuges, air conditioners, water baths, refrigerators, freezers, or any devices that radiate electrical noises)
Ɣ Note: It is recommended that each 3D-60 be connected to Emergency power branch circuits.
The BacT/ALERT® 3D 60 System cannot agitate, heat, or perform bottle readings during a power outage
BacT/ALERT® 3D 60 Standard Laboratory Operating Environment
December, 21, 2009 1 of 2

Installation Checklist
452501-1EN1
3. Seismic Restraint:
Ɣ Requirements for earthquake protection must be determined and provided by the customer.
4. Environmental Requirements:
452501-1EN1
Ɣ Temperature Range: 50º to 86ºF or 10º to 30ºC, with no wide temperature fluctuations
Ɣ Room Relative Humidity: 10% to 90%
5. Location of the BacT/ALERT® 3D System:
Installation Checklist
Ɣ A single Analog telephone line must be within 25 ft of the 3D 60 instrument for remote access modem capability to be utilized.
Ɣ Nonconformance to the above Modem Requirements may result in voiding the equipment warranty or service contract resulting in a charge for service.
Ɣ The BacT/ALERT® 3D 60 System should not be installed under or near a HVAC register or in direct sunlight or bright overhead lights.
Ɣ The Customer must certify that both the bench and the supporting floor structure are capable of supporting the sum weight of each 3D 60 installed.
Ɣ At least 4 inches or 10 cm of unobstructed clearance must be provided behind the rear of each CM and IM for proper airflow and cooling.
Ɣ To provide adequate service accessibility, a minimum unobstructed clearance of 12 inches or 30.5 cm must be provided above and on both sides of the
System.

6. Specific Customer Contact must be designated to coordinate the delivery and installation of the System.
Name: ________________________________________________________ Phone: ___________________________________
Ɣ Special days/hours of operation for the facility’s receiving dock ______________________________________________________________
Ɣ Customer established or local code restrictions of the size or type of transport vehicle that can deliver to receiving dock.
________________________________________________________________________________________________________________
7. Site Inspection
Ɣ A bioMérieux, Inc. Field Engineer may perform a site inspection to confirm the status of the above requirements prior to scheduling system installation.
Ɣ Routine site inspections by Field Engineers are not performed unless specifically requested or deemed necessary after consultation between Instrument
Service and Sales Management.
Customer Acknowledgement
To the best of my knowledge, I certify that all requirements above have been met or will be implemented prior to system installation.
Facility Signature: ___________________________________________________ Date: ____________________________________

Customer Signature: ________________________________________________ Date: _____________________________________
bioMérieux, Inc. Signature: ___________________________________________ Date: _____________________________________
bioMérieux, Inc., 100 Rodolphe St, Durham, NC 27712, 800-662-2666, Fax: 919-620-2291
December, 21, 2009 2 of 2
C-5
BacT/ALERT® 3D 60 Installation Checklist
BacT/ALERT® 3D 60 Installation Checklist Installation Checklist
C-6 BacT/ALERT® 3D 60 Service Manual

452501-1EN1
Appendix D: Schematics and Diagrams
About this Appendix
This appendix contains schematics and diagrams for the BacT/ALERT® 3D 60

Instrument.
Appendix Contents
D.1 CPU PCBA (P/N 750-0070-01 / -902) • D-2

D.1.1 CPU PCBA (P/N 750-0070-01) • D-2
D.1.2 CPU PCBA (P/N 750-0070-902) • D-3
D.2 UPS • D-5
D.3 ModSig PCBA • D-6
D.4 ModSig PCBA Fuses • D-8
D.5 Quad Serial PCBA • D-9
D.6 Step-5 PCBA • D-9
D.7 Outlet Thermistor PCBA • D-10
D.8 Inlet Thermistor PCBA • D-10
D.9 Power Supply Terminal Strip TB1 • D-11
D.10 Power Supply Solid State Relays • D-12
D.11 Power Entry Module • D-13
BacT/ALERT® 3D 60 Service Manual D-1

452501-1EN1
CPU PCBA (P/N 750-0070-01 / -902) Schematics and Diagrams
D.1 CPU PCBA (P/N 750-0070-01 / -902)
This section is for the connections for the Controller Module CPU PCBA (P/N 750-
0070-01 / -902). There are two models of CPU PCBA currently in use. Ensure that you
are using the correct subsection to reference connector locations.
D.1.1 CPU PCBA (P/N 750-0070-01)
J2 J3
D1
J3
J1
D2
C2
J2
C3 C4
J4
C1
+
J6
C6
R2
R3
R1
R4
C5
R5
J4 J7
C7
U6
U4
U7
J9
J8
C8
J11
J10
U10
J18
J5
Y2
U9
R16
U8
J18
J17
U15
U3
U5
U1
U2
Y1
J12
U14
U11
LITHIUM
KEEPER
II
LTC-3PN
J14
J15
J16
J5
J13
J13
U16 J20
T1
J19
J21
J19
U18
J27
U17
J23
J24
J25
J22
J26
J22
J27
J41
J28
J31
J23
J21
J30
U19
U20
LS1
U22
J33
T2
C9
D6 D5 D4 D3
U21
+ +
C11
C10
+
J37
J35
J34 Y3
U25 U26
U24
J38
U23
U28
U29
U27
J39
SIM1
J40
Figure D-1: CPU PCBA
Table D-1: CPU PCBA Connector Locations
Location
J2 COM 3/COM 4 Cable
J3 Multi I/O Cable
D-2 BacT/ALERT® 3D 60 Service Manual

452501-1EN1
Schematics and Diagrams CPU PCBA (P/N 750-0070-01 / -902)
Table D-1: CPU PCBA Connector Locations (Continued)
Location
J7 DC Power Supply Cable
J18 IDE (Signal) Cable
J22 COMM Cable (Ethernet)
J27 CRT (P27) Cable
J13, J19, 9-Pin Connector from CPU BIOS Clock Battery (if
J23 installed)
D.1.2 CPU PCBA (P/N 750-0070-902)
J14 J7
J2
J12
J19
J26
J46 J47 J43
Figure D-2: CPU PCBA (Front View)

452501-1EN1
CPU PCBA (P/N 750-0070-01 / -902) Schematics and Diagrams
J105
J103
Figure D-3: CPU PCBA (Back View)
Note: The old connector locations are also given in Table D-2 to aid in reconnection of the
cables to the new CPU PCBA, as some of the cables may still have the older
connections listed on them.
Table D-2: CPU PCBA Connector Locations
New Old Description

Connector Connector
Location Location
J14 N/A CPU BIOS Clock Battery (if installed)

452501-1EN1
Schematics and Diagrams UPS
Table D-2: CPU PCBA Connector Locations (Continued)
New Old Description

Connector Connector
Location Location
D.2 UPS
Table D-3: UPS Connector Locations
Location
UPS Power Cord UPS Extension Cord
Bottom 110V Outlet Power Supply Cord
COMM Port UPS Control Cord
Battery Red Lead Positive Terminal
Battery Black Lead Negative Terminal
Note: The DIP switches on the rear panel of the UPS are used to configure the UPS input
voltage/output voltage range. Output voltage default setting from the factory is 120V.
You should not need to change this setting.
Table D-4: UPS DIP Switch Settings
Input Voltage
Output Voltage DIP Switch 1 DIP Switch 2
Range
110V 99V–116V ON OFF/ON
120V 108V–127V OFF OFF/ON
220V 198V–233V ON OFF
230V 207V–243V OFF OFF/ON
240V 216V–254V ON ON

452501-1EN1
ModSig PCBA Schematics and Diagrams
D.3 ModSig PCBA
Step-5
PCBA
ModSig
PCBA
Figure D-4: ModSig PCBA Connector Locations
Table D-5: ModSig PCBA Connector Locations
Location
J1 Cable from J2 on Remote Speaker PCBA
JP1 Cable MS-JP1 from Inlet and Outlet Thermistor PCBA
J2 Cable MSJ1 on Step-5 PCBA
JP2 Heater, Blower, and Fan ON/OFF Time Control Signals
J3 Cable MSJ3 on Step-5 PCBA
JP10 Cable JP10/P1 from Rack Cable
JP11 Cable MS-JP11 from Front Door Interlock Switch
JP12 Cable MS-JP12 from Front Door Interlock Switch
JP13 Cable from J19 on CPU PCBA (P/N 750-0070-902)

or
Cable from J2 on CPU PCBA (P/N 750-0070-01)

or
JP16 Keyboard Connector Port

452501-1EN1
Schematics and Diagrams ModSig PCBA
Table D-5: ModSig PCBA Connector Locations (Continued)
Location

or

or

or
JP21 Cable JP21 from Zip® Drive
JP29 Quad Cable MS-JP29 from J6 on Quad Serial PCBA
JP30 Quad Cable MS-JP30 from J3 on Quad Serial PCBA
JP31 Cable MS-JP31 on DC Harness
P1 Barcode Scanner Port
P2 Mouse Port
P3 Debug Port
P4 Printer Port
P5 UPS Port
P6 Monitor Port
P7 Serial UPS Port
P8 LIS Port
P9 Modem Port
Table D-6: Audio Volume Selection at JP22
VOLUME JUMPER SETTINGS
Lowest 1&2, 5&6
Medium Low 2&3, 5&6
Medium High 1&2, 4&5
Highest 2&3, 4&5
Table D-7: Audio Frequency Selection at JP23 through JP26
600 Hz In In In In
800 Hz In In In Out

452501-1EN1
ModSig PCBA Fuses Schematics and Diagrams
Table D-7: Audio Frequency Selection at JP23 through JP26 (Continued)
1 KHz In In Out Out
1.5 KHz In Out Out Out
3 KHz Out Out Out Out
D.4 ModSig PCBA Fuses
F2
F7
F3
F5
F6
F4 F1
Figure D-5: ModSig PCBA Fuse Locations
Table D-8: ModSig PCBA Fuses
F1 250V 3.15 Amp Drawer Communications 870-0008-22
F2 250V 1 Amp Barcode Scanner 870-0008-17
F3 250V 1 Amp Keyboard 870-0008-17
F4 250V 1 Amp Remote Speaker 870-0008-17
F5 250V 0.5 Amp Audible Alarms 870-0008-14
F6 250V 3.15 Amp 5VDC 870-0008-22
F7 250V 1 Amp Step-5 PCBA 870-0008-17

452501-1EN1
Schematics and Diagrams Quad Serial PCBA
D.5 Quad Serial PCBA
Table D-9: Quad Serial PCBA Connector Locations
Location
J3 Quad Cable from JP30 on ModSig PCBA
J6 Quad Cable from JP29 on ModSig PCBA
D.6 Step-5 PCBA
Figure D-6: Step-5 PCBA Connector Locations
Table D-10: Step-5 PCBA Connector Locations
Location
J1 Cable MCJ1 on ModSig PCBA
J3 Cable MCJ3 on Step-5 Motor
J4 Cable MCJ4 on DC Harness

452501-1EN1
Outlet Thermistor PCBA Schematics and Diagrams
D.7 Outlet Thermistor PCBA
J3
Figure D-7: Outlet Thermistor PCBA Connector Location
Table D-11: Outlet Thermistor Connector Location
Location
J3 Cable OS-P2 to MS-JP1 harness to J6 on ModSig PCBA
D.8 Inlet Thermistor PCBA
J3
Figure D-8: Inlet Thermistor PCBA Connector Location
Table D-12: Inlet Thermistor Connector Location
Location
J3 Cable IS-P2 to MS-JP1 harness to J6 on ModSig PCBA

452501-1EN1
Schematics and Diagrams Power Supply Terminal Strip TB1
D.9 Power Supply Terminal Strip TB1
The Power Supply Terminal Strip TB1 is located near the Power Entry Module and
Isolation Transformer Assembly.
TB1-4A
TB1-4B
TB1-3A
TB1-3B
TB1-2A TB1-2B
TB1-1A
TB1-1B
Figure D-9: Terminal Board 1 Wiring
Table D-13: Power Supply TB1 Connector Locations
Location
1A K3-1
1B Isolation Transformer Secondary Red & Blue Wire
2A K4-1 & PSP1 Brn Wire
2B Metal Oxide Varistor Connector
3A HBP1-1 (Heater) & HBP1-4 (Blower)
3B Metal Oxide Varistor Connector
4A E-FAN & PSP1-3 BLU Wire
4B Isolation Transformer Secondary Green & Brown Wire

452501-1EN1
Power Supply Solid State Relays Schematics and Diagrams
D.10 Power Supply Solid State Relays
Blower Agitation Heater Power

Control Control Control Enable
Relay (K1) Relay (K2) Relay (K3) Relay (K4)
Figure D-10: Power Supply Relay Layout
Table D-14: Power Supply Solid State Relay Connector Locations
Location
K1-1 Connectors from K2-1 & K3-2 Solid State Relay
K1-2 HBP1-3
K1-3 BHP1-18 GRY Wire
K1-4 BHP1-17 BLK Wire
K2-2 HBP1-6
K2-3 BHP1-20 GRN Wire
K3-1 TB1-1A
K3-3 BHP1-16 YEL Wire
K4-1 Connector from TB1-2A
K4-2 E-FAN
K4-3 BHP1-14 BLU Wire

452501-1EN1
Schematics and Diagrams Power Entry Module
D.11 Power Entry Module
Figure D-11: Power Entry Module Simplified Schematic
Table D-15: Power Entry Module Connector Locations
Location
A Brown Isolation Transformer Connector
B Orange Isolation Transformer Connector
C Red Isolation Transformer Connector
D Yellow Isolation Transformer Connector

452501-1EN1
Power Entry Module Schematics and Diagrams

452501-1EN1
Appendix E: Instrument Improvements
About this Appendix
This appendix includes instrument improvements not previously discussed in this

manual.
Note: This appendix does not include all historical instrument improvements.
Appendix Contents
E.1 CPU PCBA (P/N 750-0070-902) Upgrade • E-2

E.1.1 CPU PCBA Upgrade Installation Procedures (P/N 750-0070-902) • E-2
E.1.2 CPU PCBA (P/N 750-0070-902) BIOS and Jumper Settings Reference •
E-13
E.1.3 CPU BIOS Settings Verification • E-14
E.2 CPU BIOS Version Update • E-19
E.2.1 BIOS Version Verification Procedure • E-19
E.2.2 Zip® Drive and UPS Functionality Verification Procedure • E-20
E.2.3 CPU BIOS Version Update Installation Procedure • E-23
E.3 CPU BIOS Clock Battery • E-24
E.3.1 CPU BIOS Clock Battery Installation Procedure for Older CPU PCBAs •
E-25
E.3.2 CPU BIOS Clock Battery Installation Procedure for Newer CPU PCBAs •
E-32
E.4 Barcode Scanner Kit (P/N 248013) • E-39
E.4.1 Barcode Scanner Kit (P/N 186208-910) Installation Procedures • E-39
BacT/ALERT® 3D 60 Service Manual E-1

452501-1EN1
CPU PCBA (P/N 750-0070-902) Upgrade Instrument Improvements
E.1 CPU PCBA (P/N 750-0070-902) Upgrade
A design improvement is available for the BacT/ALERT® Instrument. The CPU PCBA
(P/N 750-0070-01, Model LBC-586 PLUS) is no longer manufactured. If the CPU
PCBA requires replacement, it should be replaced with the CPU PCBA (P/N 750-
0070-902, Model LBC-GX500). This design improvement only applies to the B.25 (or
newer) firmware version. Firmware version B.12 (or prior) is not approved or validated
for use with the new CPU PCBA.
The new CPU PCBA has a compact flash socket on the board. The new CPU PCBA
also incorporates new RAM memory.
The current Zip® Drive will be upgraded to allow the new CPU PCBA to communicate
with the Zip® Drive. The CPU PCBA (P/N 750-0070-01) should be replaced utilizing
the CPU Replacement Kit for 3D 60 Instrument (P/N 450600-901). (Refer to
Table E-1.)
This design improvement was implemented into instrument production in November

2007 beginning with the serial number 711BS1876. For replacement of the CPU
PCBA for BacT/ALERT® 3D 60 Instruments after this serial number, or instruments
that have already been upgraded to the new CPU PCBA, refer to Section 5.3.
Table E-1: CPU Replacement Kit for 3D 60 Instrument
Quantity Part Number Description
1 ea 750-0070-902 Pkgd, PCBA, CPU GX500 w/Memory
1 rl 186179-1 Ribbon, Printer, 80x300, Wax
1 ea 950-2993-507 Tie, Cable
1 ea 514490-3 Disk, Ins & Util, 3D/3DC/3D60vB.25
1 ea 950-0105-02 Mount Cable
1 ea 3855-515 Bag, Ziplock 8 X 10
1 ea 395060-1 Box, 12 X 10 X 8
1 rl 395702-421 Bubble Pack, 24 in. wide
1 ea 390108-1 Label, Blank, 3” X 2”, 8” Dia
0.0001 rl 186171-1 Ribbon, Printer, 50 0.8mm X 340M, Blk
E.1.1 CPU PCBA Upgrade Installation Procedures (P/N 750-0070-902)
IMPORTANT: Read and understand this procedure before performing it. Contact Technical
Services if you do not understand this procedure.
IMPORTANT: The new style is validated for B.25 (or newer) firmware version only. Do not
install with B.12 firmware version (or older).
E-2 BacT/ALERT® 3D 60 Service Manual

452501-1EN1
Instrument Improvements CPU PCBA (P/N 750-0070-902) Upgrade
IMPORTANT: Installation can be accomplished in under 1 hour. If you are replacing the CPU
PCBA on a functioning system, be aware that a subculture event can occur if
replacement is not completed in 1 hour.
IMPORTANT: Record the BIOS time before replacing the CPU PCBA. If BIOS time is not set
correctly, Fault Code #71 Invalid Time Stamp may result. This could result in a
subculture event for all incubators installed on the system.
IMPORTANT: Current UTC may be obtained by telephone from the National Technical
Information Services WWV by calling 1-303-499-7111 (US) or may be obtained
from the web site http://tycho.usno.navy.mil/cgi-bin/timer.pl.
Note: To minimize the amount of time the system is down, Step 1 through Step 3 are
completed while the system is operational.
1. Print a copy of Table E-8 through Table E-10.
Note: Table E-9 and Table E-10 will be used later in this procedure.
2. Record the bottle counts and software version from the Main screen in
Table E-8.
3. Perform a system backup. (Refer to Section 4.4.)
Note: The 1 hour rule begins when the software shuts down.
5. Insert the B.25 Installation and Utilities disk (P/N 514490-3) into the Zip® Drive.
7. At the D:\ > prompt, type COPY IOMEGA\GUEST.INI C:\IOMEGA and press
Enter.
8. Select Y and press Enter to overwrite the existing files.
Note: One file is copied.
9. Press Ctrl + Alt + Delete to reboot the software.

menu. (Refer to Figure E-1.)

452501-1EN1
Figure E-1: CMOS Setup Screen
12. Verify the CMOS Setup Utility screen appears. (Refer to Figure E-2.)
Figure E-2: CMOS Setup Utility Screen
13. Record both the local date and time and CMOS date and time in Table E-9 that

452501-1EN1
17. Turn off the UPS and remove the power.

(ESD).)
Figure E-3.)
Top Panel
Screw Top Panel
Screw
Figure E-3: Top Panel Screws

20. Close the door.
21. Install a cable clamp and secure the IDE cable in the clamp. (Refer to
Figure E-4.)

452501-1EN1
Flash Adapter PCBA
Cable Clamp
IDE Cable
Figure E-4: Flash Adapter PCBA
to Figure E-5.)
Screws
Figure E-5: Quad Serial PCBA
disconnected.
23. Disconnect the cable assemblies from the CPU PCBA.

24. Remove six screws securing the CPU PCBA to the support standoffs.

452501-1EN1
26. Install the new RAM memory (P/N 186201-1) into the slot on the back of the
new CPU PCBA (P/N 750-0070-02).
Note: The new CPU PCBA may already have the memory installed.
27. Eject the Compact Flash Disk from the Flash Adapter PCBA.
28. Install the Compact Flash Disk into the slot on the back of the new CPU PCBA
(P/N 750-0070-02). (Refer to Figure E-6.)
RAM CPU PCBA

Compact Flash Disk
Figure E-6: CPU PCBA (Back View)
29. Disconnect the IDE and power cables from the Flash Adapter PCBA.
Note: The Flash Adapter PCBA will not be removed.
30. Position the new CPU PCBA on the top panel.

31. Install the screws and standoffs to secure the CPU PCBA to the top panel.
32. Connect the cable assemblies to the CPU PCBA. Refer to Figure E-7 and
Table E-2 for cable and component placement.
Note: Do not remove the existing jumpers from J31 on the CPU PCBA.

452501-1EN1
J2
J7 J12
J19
J26
J31
J46 J47 J43
Figure E-7: CPU PCBA Jumper Locations
Note: The old connection locations are also given in Table E-2 to aid in reconnection of the
cables to the new CPU PCBA.
Table E-2: CPU PCBA Connector Locations
New Old Description

Connector Connector
Location Location
Figure E-5.)

452501-1EN1
36. While the system is rebooting, press the F1 key to enter the BIOS screen.
(Refer to Figure E-8.)
Figure E-8: BIOS Screen
time:
a. Enter the Local Time from Table E-9 in the Time column next to the Local
Time at Start in Table E-10.
Finish in Table E-10.
in Table E-10.
d. Enter the CMOS Time from Table E-9 in the Time column next to the
CMOS Time at Start in Table E-11.
CPU PCBA in Table E-10 in the Time column next to Time Spent
Replacing CPU PCBA in Table E-11.
in Table E-11.
Note: If the CMOS date and time were not noted in Table E-9 due to a down system, set the

39. Enter the determined CMOS Date and Time from Table E-11 and press Enter.

452501-1EN1
system.
41. If the new Zip® drivers were successfully installed in Step 7, proceed to Step 43.
42. If the system stops with the error message Finding a drive letter for your
Iomega drive:
a. Press Ctrl + Alt + Delete to reboot the system.
Note: This should boot up the system to the Main screen. If the system stops again, repeat
Step 42a. If the system stops again, proceed to Step 42b to manually edit the existing
Zip® driver file. If the system does not stop, proceed to Step 43.
b. Press Ctrl + Alt + Delete to reboot the system.

c. Press and hold down the Left Shift key until the C:\ > prompt appears.
d. At the C:\ > prompt, type CD IOMEGA and press Enter.
e. At the C:\iomega prompt, type Edit Guest.ini and press Enter.
f. On line five, type rem before the statement ASPI=ASPIATAP.SYS/INFO/
SCAN.
g. Add line six and type ASPI=ASPIATAP.SYS.
Note: Refer to Figure E-9. The red text indicates information added to the file in Step 42f
and Step 42g.
[----scan for existing aspi managers---]

SCAN=ON
[----Load aspi managers----]
rem ASPI=ASPIIDE.SYS /SCAN /INFO
rem ASPI=ASPIATAP.SYS /INFO /SCAN
ASPI=ASPIATAP.SYS
rem ASPI=ASPI8DOS.SYS /D
rem ASPI=ADVASPI.SYS
rem ASPI=ASPIPC16.SYS /INFO
rem ASPI=ASPI1616.SYS /SCAN /INFO
rem ASPI=ASPIPPM1.SYS /INFO FILE=NIBBLE.ILM SPEED= 1
rem ASPI=ASPIPPM2.SYS /INFO FILE=NIBBLE2.ILM SPEED= 1
Figure E-9: Zip® Driver File
h. Press Alt + F and S to save the file.

i. Press Ctrl + Alt + Delete to reboot the system.
43. Verify the Main screen appears.

452501-1EN1

45. Insert the B.25 Installation and Utilities disk (P/N 514490-3) into the Zip® Drive.
47. At the D:\ > prompt, type COPY IOMEGA\GUEST.INI C:\IOMEGA and press
Enter.
48. Select Y and press Enter to overwrite the existing files.
50. After the instrument reboots, verify that the bottle count and software version
displayed on the Main screen matches the information recorded in Table E-8.
Note: This may not be applicable if the instrument was inoperable before beginning this
procedure.
51. At the Main screen, click the Next Screen button. (Refer to Figure E-10.)
Next Screen
Button
Figure E-10: Main Screen
52. Verify the Setup screen appears. (Refer to Figure E-11.)

452501-1EN1
Key Symbol
Button
Set Maximum
Test Time
Button
Figure E-11: Setup Screen

55. From the Setup screen, click the Set Date/Time button.
Figure E-12: Set Date/Time Button
The Set Date/Time screen (screen ID 2.1) overlays and disables the Setup
screen.
56. From the Set Date/Time screen, set the date/time to reflect the current date and
time at the site.
Note: Check with the customer to determine the desired format of the date and time.
Note: In some cases, Fault Code #71 Invalid Time Stamp may occur. Verify the CMOS
date and time were configured properly.

Figure E-13.)

452501-1EN1
Top Panel
Screw Top Panel
Screw
60. Close the door.

E.1.2 CPU PCBA (P/N 750-0070-902) BIOS and Jumper Settings

Reference
This section identifies the changes from the factory default BIOS settings that are
applied to the CPU PCBA. The BIOS/jumper settings are factory set and should only
be checked if there is a problem with the display or incubator communication.
BIOS Version Number: 33207207
Table E-3: Motherboard Device Configuration
Motherboard Device Configuration
Drive Configuration Boot Order Configuration 1) Hard Drive #1
2) None
3) None
I/O Configuration Serial Port 3: 0xe8 IRQ: 5
Serial Port 4: 0x2e8 IRQ:9
Super I/O Devices Parallell Port: 0x278

452501-1EN1
Table E-3: Motherboard Device Configuration (Continued)
Video and Flat Panel Flat Panel Mfr, Resolution: Sharp

Configuration 640x480
PCI Configuration PCI Interrupt Steering PCI INTA#: Disabled
PCI INTB#: Disabled
PCI INTC#: Disabled
PCI INTD#: Disabled
Table E-4: Jumper Settings
Function Description Jumper Number Setting
U4 Battery Power J1 2-3
D I/O Power J11 Open
Battery On J17 1-2
COM1 RS-232 J27 1-2
COM2 RS-232 J28 1-2
Multi I/O J29 1-2, 5-6, 7-8, 9-10, 17-18
On Board CF as Master J30 1-2
Video J31 3-4, 13-14, 17-18
AT Power J33 1-2, 3-4
E.1.3 CPU BIOS Settings Verification

This section identifies the functions available in BIOS, the correct BIOS settings for
BacT/ALERT® 3D 60 instruments with the WinSystems® LBC-GX500 CPU BIOS, and
the procedure describing how to verify and adjust the setttings.
Table E-5 lists the functions available from the Main screen of BIOS and lists the sub-
selections available. Functions that do not utilize sub-selection lists will be noted with
N/A in the BIOS Sub-Selection List field of the table to denote that the sub-selection
list is not applicable.

3. While the system is rebooting, press F1 to enter the BIOS screen. (Refer to
Figure E-14.)

452501-1EN1
4. Verify the BIOS Time (Coordinated Universal Time) and Date are set correctly.
CAUTION: Failure to correctly set the BIOS Coordinated Universal Time

and Date can cause Fault Code #71 Invalid Time Stamp and Fault Code
#80 Reading Gap Detected, resulting in a subculture situation for the
customer if not properly addressed.
5. Refer to Table E-5 to determine which item from the main selection list needs to
be selected to access the desired sub-selection settings screen.
Note: Functions that do not utilize sub-selection lists will be noted with N/A in the BIOS
Sub-Selection List field of the table to denote that the sub-selection list is not
applicable.
6. Highlight the desired selection from the main selection list and press Enter.
Note: The Motherboard Device Configuration screen is shown as an example of a sub-

selection list screen.
7. Highlight the desired sub-selection from the sub-selection list and press Enter.
8. Refer to Table E-5 and verify the settings are correct.

452501-1EN1
9. To change the settings:

a. Highlight the desired field and press Enter.
b. Enter the setting as shown in Table E-5.
10. Press Esc to return to the main selection screen, or press Esc twice to return
the system to the BIOS Main Menu.
11. Repeat Step 5 through Step 10, as applicable, for each additional setting that
needs to be verified.
12. Verify that the BIOS Time (Coordinated Universal Time) and Date on Main
Menu items A. Time and B. Date are correct.
13. Highlight Z. Save values to EEPROM and Exit and press Enter.
Table E-5: BIOS Settings
BIOS Main Selection List BIOS Sub-Selection List
A. Time N/A
B. Date N/A
C. Motherboard Device Configuration A. Drive Configuration
B. I/O Configuration

452501-1EN1
Table E-5: BIOS Settings (Continued)
C. Motherboard Device Configuration C. Super I/O Device Configuration

(Continued)
F. Video and Flat Panel Configuration
G. PCI Configuration
D. Memory and Cache Optimization Memory and Cache Setup

452501-1EN1
Table E-5: BIOS Settings (Continued)
F. Power Management Power Management
H. Miscellaneous Configuration Miscellaneous Configuration
J. Serial Console Configuration Serial Console Configuration
L. Load Defaults N/A

IMPORTANT: This function should
never be performed.
S. Save Values Without Exit N/A
Q. Exit Without Save N/A
X. Save values and Exit N/A
Z. Save values to EEPROM and Exit N/A

Note: This function is used when
saving changes to the BIOS.

452501-1EN1
Instrument Improvements CPU BIOS Version Update
E.2 CPU BIOS Version Update
A BacT\ALERT® 3D BIOS Version update (P/N 514589-901, Version: Release

070911-01 Built: 10/29/2007) for the WinSystems® LBC-GX500 CPU PCBA (P/N 750-
0070-902) is now available. The new BIOS version does not contain the operating
feature that can cause the BIOS settings to revert back to the default WinSystems®
settings.
The update is a program on Zip® disk that will automatically install the BIOS update
when the program is launched from the D drive. In addition to the new version of
BIOS, the update program will replace the WinSystems® factory settings in CPU
CMOS with the bioMérieux BIOS default settings.
This design improvement has been implemented into instrument production. 3D 60

Modules with the serial number range of 711BS1876 to 807BS2101 should apply this
update.
Modification of the BacT/ALERT® 3D 60 BIOS will not impact current bottles under
test. The BIOS update will not affect the BIOS date or time.
CAUTION: It is extremely important to perform the Zip® Drive and UPS

Functionality Verification Procedure in Section E.2.2 prior to beginning
the CPU BIOS Version Update Installation Procedure in Section E.2.3.
Failure to comply could result in damage to the Controller Module.
E.2.1 BIOS Version Verification Procedure

Figure E-16.)
BIOS Version
Number and
Build Date

452501-1EN1
CPU BIOS Version Update Instrument Improvements
4. If the Main Menu indicates Version Release 070911-01 Built: 10/29/2007, the
CPU PCBA has the latest version of BIOS loaded and no further action is
necessary.
5. If the Main Menu indicates Version: Release 070726-01 Built: 07/26/2007, the
new version of BIOS should be installed.
Note: If the Main Menu indicates Version Release 070911-01 Built: 10/29/2007, do not
continue with the procedure to update the BIOS version. If the Main Menu indicates
Version: Release 070726-01 Built: 07/26/2007, proceed to Step 6. If any version
other than 070911-01 or 070726-01 is shown, complete Step 6 through Step 8 and
contact Global System Support - BacT/ALERT® for assistance. Do not continue with
the procedure to update the BIOS version if any version other than 070911-01 or
070726-01 is installed on the system without guidance from Global System Support -
BacT/ALERT®.
6. Print a copy of Table E-9 and record the local date and time and the CMOS date
and time.
7. Highlight Q. Exit Without Save and press Enter.
8. Select Y when prompted to exit the BIOS screen.
E.2.2 Zip® Drive and UPS Functionality Verification Procedure
1. To verify Zip® drive functionality:

a. Insert a Zip® disk into the Zip® Drive.
Note: The BIOS Update Disk is acceptable for use in verifying the functionality of the Zip®
Drive.
b. From the Main screen, click the Next Screen button. (Refer to
Figure E-17.)

452501-1EN1
Next Screen
Button
c. Verify the Setup screen appears. (Refer to Figure E-18.)

d. From the Setup screen, enter the service password 12123434.
e. Click the Key Symbol button.
Key Symbol
Button
Figure E-18: Setup Screen with Field Engineer Password Activation
f. Verify the Diagnostic Test Selection screen appears.

g. Select 7.0 Instrument Cntrl from the Main Selection List.
h. Select Zip Drive Test from the Sub-Selection List.
i. Click the Next Screen button.

452501-1EN1
CPU BIOS Version Update Instrument Improvements
j. Allow 10 passes of the Zip® Drive Test to accumulate. The PASS count
on the Instrument Cntrl/Zip drive test screen will show PASS count: 10.
Figure E-19: Instrument Cntrl/Zip Drive Test Screen
k. Verify that no FAIL counts are displayed.

l. If instrument passes the Zip® Drive test, click the Previous Screen button
to return to the Main screen.
m. If instrument fails Zip® Drive test, refer to Chapter 7, Diagnostics and
Troubleshooting Information, to troubleshoot and correct the problem
before proceeding with the CPU BIOS Version Update Installation
procedure.
n. Remove the Zip® disk.
2. To verify UPS functionality:
a. Turn off the AC power at the rear of the 3D 60.
Note: After about 1 minute, the system should start an orderly shutdown.
b. If the system did not perform an orderly shutdown, refer to Chapter 7,

Diagnostics and Troubleshooting Information, to troubleshoot and correct
the problem before proceeding with the CPU BIOS Version Update
c. Turn on the AC power at the rear of the Controller Module and allow the
system to reboot.
IMPORTANT: Do not abort or interrupt the boot process.

452501-1EN1
E.2.3 CPU BIOS Version Update Installation Procedure
IMPORTANT: This update is for the new WinSystems® CPU PCBA (P/N 750-0070-902) only.
The WinSystems® CPU can quickly be identified by its on-board Flash Drive
mounted to the bottom side of the CPU board.
IMPORTANT: The BIOS version can be determined by the Version field on the BIOS Main
Menu. Version release 070726-01 is the original BIOS and should be updated.
CAUTION: If power is lost to the instrument while a BIOS update is in

progress, the CPU PCBA will no longer function correctly and will have
to be replaced.
1. Press Esc and type yes to exit the Controller Module software.
3. While the system is rebooting, press F1 to enter the BIOS screen.
IMPORTANT: Do not abort or interrupt the boot process.
6. Once the BacT\ALERT® 3D application has finished loading, press Esc and
type yes to exit the Controller Module software.
7. Insert the BacT\ALERT® 3D BIOS Version Update Zip® Disk into the Zip® Drive.
8. At the DOS prompt, type D: and press Enter.
9. At the D: prompt, type UPDATE and press Enter.
10. At the screen prompt, type Y to proceed with the BIOS update. (Refer to
Figure E-20.)
Figure E-20: BIOS Upgrade Screen Prompt

452501-1EN1
CPU BIOS Clock Battery Instrument Improvements
Note: The update is complete when the system returns the text shown in Figure E-21 and
returns to the D: prompt.
Note: The update should take well under 1 minute.
Figure E-21: BIOS Upgrade Complete Screen

12. While the system is rebooting, press F1 to enter the BIOS screen.
13. Using the information recorded earlier in Table E-9, subtract the current local
date and time from the recorded date and time to determine how long it took to
update the system.
14. Add the amount of time that it took to update the system to the CMOS time
recorded in Table E-9 earlier.
15. Ensure that the CMOS date and time are correct.
18. Print a copy of Table E-12 and use the checklist to verify that the
BacT/ALERT® 3D 60 operates correctly.
E.3 CPU BIOS Clock Battery
A new CPU BIOS Clock battery kit (P/N 193810-901) is available for the
BacT/ALERT® 3D 60. The kit can be installed on both the old CPU PCBAs (P/N 750-
0070-01) and the newer CPU PCBAs (P/N 750-0070-02 / -03). The kit provides a new
battery with extended life.

452501-1EN1
Instrument Improvements CPU BIOS Clock Battery
This design improvement was implemented into instrument production in March 2009
beginning with the serial number 711BS1876. For replacement of the CPU BIOS
Clock battery for BacT/ALERT® 3D 60 instruments after this serial number, or
instruments that have already been upgraded to the new CPU BIOS Clock battery,
refer to Section 5.5, CPU BIOS Battery Replacement.
Note: The CPU BIOS batteries should be replaced 10 years after their manufacture date.
The CPU BIOS battery has the part number and date code printed on it with the date
format of MMYYYY.
Table E-6: CPU BIOS Clock Battery Kit (P/N 193810-901)
1 ea 193810-1 Replacement Battery, BTA3D
1 ea 20600-1 Cable Tie, 0.625 Max Dia
E.3.1 CPU BIOS Clock Battery Installation Procedure for Older CPU
PCBAs
This procedure is only for systems that have the CPU PCBA with the part number
750-0070-01. Refer to Section E.3.2 to install the CPU BIOS Clock Battery if the CPU
PCBA in the system has the part number 750-0070-02 or higher.
IMPORTANT: Installation can be accomplished in under 1 hour. If you are installing the CPU
BIOS Clock Battery on a functioning system, be aware that a subculture event
can occur if installation is not completed in 1 hour.
IMPORTANT: Record the BIOS time before installing the CPU BIOS Clock Battery. If BIOS time
is not set correctly, Fault Code #71 Invalid Time Stamp may result. This could
result in a subculture event for all incubators installed on the system.
from the website http://tycho.usno.navy.mil/cgi-bin/timer.pl.
1. Verify the contents of the CPU BIOS Clock battery kit (P/N 193810-901) and
ensure all parts required are included. (Refer to Table E-6.)

(ESD).)

452501-1EN1
Figure E-22.)
Top Panel
Screw Top Panel
Screw

4. Close the door.
5. Print a copy of Table E-8 through Table E-10 on page E-43.
Table E-8.
Note: The 1 hour rule begins when the Controller Module software shuts down.

menu.
11. Ensure the CMOS SETUP menu appears. (Refer to Figure E-23.)

452501-1EN1

452501-1EN1

to Figure E-25.)
Screws
disconnected.

22. Remove the jumper at J13 and J19. (Refer to Figure E-26.)
23. Remove jumper pins 3-4 at J23.
IMPORTANT: Leave jumper pins 1-2 in place.
Jumper Pin J19 J13

3-4 at J23
Figure E-26: Jumper Pin Locations
24. Remove loop side of Velcro® dot from battery assembly.

452501-1EN1
25. Remove release liner and apply dot to top of U22 (just below beeper). (Refer to
Figure E-27.)
Velcro®
Dot
Figure E-27: Velcro® Dot Placement
26. Install 9-pin connector of battery assembly across all 3-jumper locations,
placing key between J23 and J19. (Refer to Figure E-28.)
9-Pin Connector
Figure E-28: 9-Pin Connector Placement
27. Affix battery assembly to Velcro® dot. (Refer to Figure E-29.)

452501-1EN1
CPU BIOS
Clock Battery
Figure E-29: 9-Pin Connector Placement

29. Install two screws and plug in the Quad Serial PCBA.
Figure E-22.)
32. Close the door.
menu.
35. Ensure the CMOS SETUP menu appears. (Refer to Figure E-30.)

452501-1EN1
38. Verify that the CMOS date and time updated correctly and did not reset. The
date should be the same and the time should update to include the amount of
time the system was down.
39. If the date and time did not update correctly, determine the time spent on the
CPU BIOS Clock Battery installation and new CMOS time:

452501-1EN1
in Table E-10.
in Table E-11.
40. To change the date or time settings, press Up or Down Arrow key on the
keyboard to highlight the value you want to change.
41. Enter the determined time and/or date from CMOS Date and Time in
Table E-11 and press Enter.
42. If no changes were made, press the Esc key, select Y, and press Enter to exit
the BIOS.
43. If changes were made, press F10, select Y, and press Enter to save to CMOS
and exit the BIOS.
present.
E.3.2 CPU BIOS Clock Battery Installation Procedure for Newer CPU
PCBAs
This procedure is only for systems that have the CPU PCBA with the part number
750-0070-02 or higher. Refer to Section E.3.1 to install the CPU BIOS Clock Battery if
the CPU PCBA in the system has the part number 750-0070-01.

452501-1EN1
IMPORTANT: Installation can be accomplished in under 1 hour. If you are installing the CPU
BIOS Clock Battery on a functioning system, be aware that a subculture event
can occur if installation is not completed in 1 hour.
IMPORTANT: Record the BIOS time before installing the CPU BIOS Clock Battery. If BIOS time
is not set correctly, Fault Code #71 Invalid Time Stamp may result. This could
result in a subculture event for all incubators installed on the system.
from the website http://tycho.usno.navy.mil/cgi-bin/timer.pl.
1. Verify the contents of the CPU BIOS Clock battery kit (P/N 193810-901) and
ensure all parts required are included. (Refer to Table E-6.)

(ESD).)
Figure E-32.)

452501-1EN1
Top Panel
Screw Top Panel
Screw

4. Close the door.
5. Print a copy of Table E-8 through Table E-10 on page E-43.
Table E-8.
Note: The 1 hour rule begins when the Controller Module software shuts down.

Figure E-33.)

452501-1EN1
12. Highlight Z. Save values to EEPROM and Exit and press Enter.
to Figure E-34.)
Screws
disconnected.

452501-1EN1
18. Remove the jumper at J17. (Refer to Figure E-35.)
CAUTION: Failure to remove the jumper at J17 will shorten the battery
life.
J14
J17
Figure E-35: Jumper and Connector Locations
19. Install the 3-pin connector of the battery assembly into J14.
20. Remove loop side of Velcro® dot from CPU BIOS Clock Battery.
21. Remove release liner and apply dot to unpopulated area below U4, to the left of
the CPU heat sink. (Refer to Figure E-36.)
Velcro® Dot
Figure E-36: Velcro® Dot Placement
22. Affix battery assembly to Velcro® dot.

452501-1EN1
23. Use the cable tie from the kit to secure the unused portion of the cable near the
battery. (Refer to Figure E-37.)
Cable
Tie
CPU BIOS
Clock Battery
Figure E-37: Battery Cable Tie

26. Install two screws to secure the Quad Serial PCBA to the CPU PCBA.
Figure E-32.)
29. Close the door.
31. While the system is rebooting, press the F1 key to enter the BIOS screen.

452501-1EN1
32. Verify that the CMOS date and time updated correctly and did not reset. The
date should be the same and the time should update to include the amount of
time the system was down.
33. If the date and time did not update correctly, determine the time spent on the
CPU BIOS Clock Battery installation and new CMOS time:
in Table E-10.
in Table E-11.

35. Enter the determined time from CMOS Date and Time in Table E-11 and press
Enter.
36. Highlight B. Date and press Enter.

37. Enter the determined date from CMOS Date and Time in Table E-11 and press
Enter.
38. If no changes were made, highlight Q. Exit Without Save and press Enter.
present.

452501-1EN1
Instrument Improvements Barcode Scanner Kit (P/N 248013)
E.4 Barcode Scanner Kit (P/N 248013)
A design improvement is available for the BacT/ALERT® 3D 60 instrument. The

Barcode Scanner (P/N 957-0004-291) is no longer manufactured. If the Barcode
Scanner requires replacement, it should be replaced with the Barcode Scanner (P/N
248013).
This design improvement was implemented into instrument production in May 2009
beginning with the serial number 905BS2376. For replacement of the Barcode
Scanner for BacT/ALERT® 3D Instruments after this serial number, or instruments
that have already been upgraded to the new Barcode Scanner, refer to Section 5.37.
Table E-7: Honeywell Barcode Scanner (P/N 248013)
1 ea 186208-10 Stand, Flex Neck, Scanner
1 ea 186208-1 (248013) Barcode Scanner, Honeywell
1 ea 812-0004-13 Suppr CA Clamp 4 to 7 mm
E.4.1 Barcode Scanner Kit (P/N 186208-910) Installation Procedures
IMPORTANT: Read and understand this procedure before performing it. Several equipment
upgrades may have been made to this instrument. It is very important that you
know which components are on this system prior to beginning this procedure
to avoid delays. Contact Technical Services if you do not understand this
procedure.
IMPORTANT: Installation can be accomplished in under 1 hour. If you are replacing the
Barcode Scanner on a functioning system, be aware that a subculture event can
occur if replacement is not completed in 1 hour.

the 3D 60 rear panel. (Refer to Figure E-39.)

452501-1EN1
Barcode Scanner Kit (P/N 248013) Instrument Improvements
Barcode Port
Figure E-39: Barcode Scanner Connection
3. Remove the Barcode Scanner and scanner stand.

4. Position the new Barcode Scanner and scanner stand in place.
5. Connect the Barcode Scanner cable connector to the BARCODE port on the
3D 60 rear panel. (Refer to Figure E-39.)
7. Verify the Main screen appears.
8. At the Main screen, click the Next Screen button. (Refer to Figure E-40).
Next Screen
Button
9. Verify the Setup screen appears. (Refer to Figure E-41.)

452501-1EN1
Select Bottle Key Symbol

to Edit/Graph Button
Button
Figure E-41: Setup Screen

12. From the Setup screen, click the Select Bottle to Edit/Graph button.
Figure E-42: Set Bottle to Edit/Graph Button
13. Print out a copy of Table E-13.
Note: Do not leave a copy of Table E-13 with the customer.
14. Using Table E-13, scan a barcode label in the Sample column and compare the
text displayed on the screen with the text in the Read Data column. (Refer to
Figure E-43.)

452501-1EN1
Displayed
Data
Cancel
Button
Figure E-43: Barcode Scanner Test Screen
15. Repeat Step 14 until all labels have been scanned and verified.
Note: Labels can be scanned in succession without clicking any buttons on the screen.
There is no need to click the Cancel button until all labels have been entered.
IMPORTANT: The Barcode Scanner should beep for each label scanned, indicating the label
was read. Displayed data must match the Read Data column in Table E-13 for
every label read. If the Barcode Scanner does not work properly, refer to
Chapter 7, Diagnostics and Troubleshooting Information to troubleshoot the
Barcode Scanner. Troubleshooting procedures for the Barcode Scanner
include:
• Barcode Scanner does not beep

• Barcode Scanner does not auto scan
• Barcode Scanner scans, but nothing is read
16. Click the Cancel button to return to the Select Bottle to Edit/Graph screen.
17. Click the Previous Screen button two times to return to the Main screen.

452501-1EN1
Table E-8: Bottle Counts and Software Version
Bottle Counts:
Software Version: _________
Table E-9: Local and CMOS Date/Time
Description Time
Local Date/Time
CMOS Date/Time
Table E-10: Calculations for Time Spent Replacing CPU PCBA
Description Time
Local Time at Start
Local Time at Finish

CPU PCBA
Table E-11: Calculations for New CMOS Time
Description Time
CMOS Time at Start

CPU PCBA
New CMOS Date and

Time

452501-1EN1
Table E-12: CPU BIOS Version Upgrade Checklist
System Function
Error Codes 2 and 47 are not Present
Video LCD External Function
Printer Function
UPS (Refer to Step 2 in Section E.2.2 and perform

the UPS shutdown test.)
Modem Function
Keyboard Function
Calibrate one Cell in Each Incubator (Refer to

Section 6.7 or Section 6.8.)
Communications with Computer
Table E-13: Barcode Scanner Test Scans
Symbology Name Sample Read Data
CODE 128 Code 128. Test
CODE 39 Code 39. Test
INTERLEAVED 2 OF 5 0123456789
CODABAR $99.95

452501-1EN1
Table E-13: Barcode Scanner Test Scans (Continued)
Symbology Name Sample Read Data
CODE93 Code 93. Test
UPC-A W/2 DIGIT 6099201118

ADD-ON
UPC-A W/5 DIGIT 0802951041

ADD-ON
UPC-E 998875
EAN-13 (JAN-13) 110123456789

452501-1EN1

452501-1EN1
Appendix F: Electrostatic Discharge (ESD)
About this Appendix
This appendix is to establish guidelines for protecting Electrostatic Discharge

Sensitive (ESDS) components, and assemblies containing ESDS components, from
static electricity. Failure to comply with this document could result in damaged or
destroyed components.
Appendix Contents
F.1 Equipment, Materials, or Supplies • F-2

F.2 General Requirements • F-2
F.3 Work Area Preparation • F-2
BacT/ALERT® 3D 60 Service Manual F-1

452501-1EN1
Equipment, Materials, or Supplies Electrostatic Discharge (ESD)
F.1 Equipment, Materials, or Supplies
• Wrist Strap Conductive – bioMérieux P/N 399106-1 or equivalent

• Soldering Iron, electrostatically shielded with a ground tip
• Fluke 87 multimeter or equivalent
F.2 General Requirements
You are responsible for ESD awareness and practices.
• You are required to wear a grounded wrist strap prior to, and while, handling
ESDS components or assemblies. The wrist strap shall make constant
contact with your bare wrist and not be placed over shirt sleeves or gloves.
• Keep static-sensitive assemblies inside antistatic packages when not in use.
• Prior to carrying an ESDS component or assembly, always place it completely
inside an antistatic bag. (Do not partially wrap the ESDS component or
assembly with an antistatic bag.)
• Discard any antistatic bag with holes or other visible damage.
• If you need to ship an ESDS component or part, package it in appropriate
antistatic packaging. (For example, antistatic tubes, carriers or conductive
bags.) If possible, mark the outside of the package as containing ESDS
components.
• Do not staple antistatic bags containing ESDS components. To seal the bag,
fold the open end of the bag and apply tape to the outside.
• Do not place paper or other foreign items inside the antistatic packages. If
documentation needs to be kept with the ESDS component, tape it on the
outside of the package.
• All tools should be static free, where possible.
• Probing of circuits containing ESDS components with ungrounded
instrumentation (VOM, DVM, etc.) or similar type equipment is prohibited,
except when battery-operated or plastic-cased instruments must be used, or
when required measurement must be obtained with a piece of test equipment
that is isolated from ground.
F.3 Work Area Preparation
At a system or instrument location, prior to handling or installing ESDS components,

perform the following:
1. Remove all static generating material (polyethylene film, Styrofoam, paper, etc.)
from the work area.
2. If possible, ground the assembly into which the ESDS components are to be
installed.
F-2 BacT/ALERT® 3D 60 Service Manual

452501-1EN1
Electrostatic Discharge (ESD) Work Area Preparation
3. Verify the proper functioning of wrist strap and cord as defined below.
• Using a multimeter, measure the resistance from the wrist strap to the end of
the cord. Discard and replace the wrist strap if the resistance is less than
800k ohms or greater than 1.2M ohms.
4. Put the grounding wrist strap on, and clip the cord end to a chassis ground point
of the instrument/module you will be repairing.
IMPORTANT: When working on ESDS equipment, you must discharge through a grounded
wrist strap. Do not allow your skin to come into contact with the instrument
chassis until after you connect the wrist strap alligator clip to a known chassis
ground point.
BacT/ALERT® 3D 60 Service Manual F-3

452501-1EN1
Work Area Preparation Electrostatic Discharge (ESD)
F-4 BacT/ALERT® 3D 60 Service Manual

452501-1EN1
Glossary
A-D CONVERTER A device that transforms analog electrical signals to a digital format by
using a logarithmic function.
ACCESSION A sample collected from a patient during a single event.
ACCESSION ID Synonym for accession number.
ACCESSION NUMBER A number that uniquely identifies the sample or patient specimen.
AGITATION The rocking motion of the racks within the Incubation Chamber. Required
in order to produce the growth of Microbes.
AGITATION MOTOR The device within the Incubation Chamber that produces agitation
(Step-5).
ANONYMOUS BOTTLE A bottle that has been placed in an Incubation Chamber without going
through the formal bottle loading process. Bottles loaded anonymously
must eventually be identified and assigned a bottle ID. Anonymous bottles
cannot be moved to another cell without being identified and assigned a
bottle ID.
ASTM Acronym for American Society for Testing and Materials
AUDIBLE ALARM The field technician sets the coarse adjustment of volume and frequency
with the use of jumpers. Fine setting of volume specified by the user to flag
positive bottles, instrument failure, or an operator error.
BacT/ALERT® bioMérieux's automated instrumentation to screen test specimens for the

presence of microbes.
BacT/LINK® The version of BacT/ALERT® 3D 60 software that includes the LIS option.
BARCODE READER Used to scan accession numbers or bottle barcode labels and identifies
bottles when loading or unloading.
BLOWER Device within the Electronics Drawer that circulates warm air in the
Incubation Chamber for the incubation process.
BOTTLE GRAPH A line graph that plots the microbial activity in a blood culture bottle over
time.
BOTTLE ID Usually a barcode that uniquely identifies a single blood culture.
BOTTLE TYPE BacT/ALERT® bottle with a specific type of culture medium (i.e.: FAN®
Aerobic).
BUTTON BAR The user can freely move to any screen at any time by selecting (clicking)
the appropriate button from the vertical column of buttons that is always
visible on the right-hand side of the display.
CAUTION A step or action that could easily result in damage to the instrument, or an
incorrect result.
CENTRIFUGATION A technique employing the quantitative application of centrifugal force. A

centrifuge is a rotating device employing this technique, used for
separating liquids of different specific gravities or for separating
suspended particles in a liquid solution.
BacT/ALERT® 3D 60 Service Manual Glossary-1

452501-1EN1
Glossary
CALIBRATION Test rod used to calibrate cells. There are four separate standards used to
STANDARD calibrate the cells. Each standard is identified by the number of rings
around the end of the standard.
CARET The text entry position indicator that appears in the form of a vertical line
indicating where new text entry will appear. The caret always appears in
the current prompt.
CELL Holds and monitors each culture bottle. Each cell is numbered from one
through 60.
CELL FLAG Secures bottles in cells. Aids in cell diagnostics and with bottle loading and
unloading determinations.
CELL INDICATOR LIGHT Illuminates to show the location of positive, negative, or anonymous
bottles as well as to show where new bottles should be placed/removed.
An indicator light is adjacent to each cell.
CHAMBER The Incubation Chamber contains three racks (60 cells in total) for a total
capacity of 60 culture bottles.
CHECK BUTTON Icon on operator's screen used to accept an input or selection by the
operator.
CLICK Pointing to an item, and then quickly pressing and releasing the mouse
button.
CPU Acronym for Central Processing Unit.
CURSOR A marker for the active site where input would be directed.
D-A CONVERTER A device that transforms digital signals to an analog electrical format by
using a logarithmic function.
DATA SIGNAL Contained within the ModSig PCBA and routes all signals within the
DISTRIBUTION Instrument.
DC POWER SUPPLY Device that produces the required DC voltages used within the Instrument.
DIMMED BacT/ALERT® 3D 60 disables (dims or grays) user interface (i.e.: menu

items, buttons, text fields) that are unavailable due to security restrictions
or due to the current context of the software. Disabled user interface items
are not selectable.
DISABLED Describes a user interface item (i.e.: menu item, button, text entry field)
that is not currently selectable by the user. Disabled user interface items
are usually displayed in gray.
DOS Disk Operating System (MS-DOS® is used).
ELECTROSTATIC Component that is easily damaged by static electricity. These components

SENSITIVE DEVICE (ESD) are usually associated with PCBAs.
ENABLED The opposite of disabled.
ESD Acronym for Electrostatic Sensitive Device.
EXECUTABLE A software program that can be started from the operating system's
command prompt.
EXTERNAL SPEAKERS External devices typically used to produce alarm sounds remotely and
connected via an external port on the rear of the Instrument.
Glossary-2 BacT/ALERT® 3D 60 Service Manual

452501-1EN1
Glossary
FIELD Refers to an area on the screen where variable text is displayed.
FIRMWARE In computer terms, firmware is the internal software code that a system
uses to operate.
GENERIC BOTTLE ID A bottle ID that does not indicate one of the pre-defined bottle types.
GRAPHICAL USER A method of user/computer interfacing where the user communicates with
INTERFACE (GUI) the computer by manipulating graphical screen images.
GRAYED See DIMMED. Refers to user interface items that are not selectable.
HEATER Device within the Incubation Module that produces the required heat for
the Incubation process.
HOSPITAL ID Text screen (usually a barcode) that uniquely identifies a patient.
INCUBATION CHAMBER The chamber within the Instrument that holds the racks and incubates
BacT/ALERT® 3D 60 bottles. It may also be referred to as the Incubation
Module.
INDICATOR LIGHT OR An identifier for an indicated cell that lights up to indicate location of a
LAMP particular bottle or bottle type. They are located in the racks adjacent to
the cells.
ISOLATION Isolates and protects the BacT/ALERT® 3D 60 from facility power.

TRANSFORMER
KEYBOARD Provides for an alternate means of input for bottle IDs, accession
numbers, hospital IDs, and names. Serves as a backup input device
should the mouse or Barcode Reader fail.
LABORATORY Name for a customer maintained computer system (usually a mainframe)

INFORMATION SYSTEM that collects information from laboratory instruments within the lab.
(LIS)
LCD MONITOR A Liquid Crystal Display device that is used to display video images of
software and firmware functions. Typically called a Flat Panel Display.
LIS Acronym for Laboratory Information System.
METAL OXIDE VARISTOR An electronic device that provides inline surge protection for internal
(MOV) circuitry of the Instrument.
MODSIG A PCBA that serves as a control interface for data communications

between all of the internal and external devices/peripherals of the
Instrument.
MOV Acronym for Metal Oxide Varistor.
MICROBE Microorganism or simply put, a germ.
MOMENTARY BUTTON An Instrument display screen button which remains activated (appears to
be pressed) only as long as the corresponding screen area is being
clicked.
MONITOR A device upon which video images are displayed.
MS-DOS® Acronym for Microsoft Disk Operating System (DOS).
MYCO Abbreviation for Mycobacteria.

452501-1EN1
Glossary
MYCO CONVERSION Rack configuration designed to grow and detect Mycobacteria. This
conversion disables the agitation process, which is not required for the
growth of Mycobacteria.
NEGATIVE Describes a culture bottle that has no evidence of microbial activity.
NOTE Any step or actions that may need further clarification or explanation.
NVRAM (Non Volatile Random Access Memory that is capable of retaining data when power is
RAM) removed from the system.
OPTION A member of the set of possible valid entries for the current field.
PCBA Acronym for printed circuit board assembly.
PEM Acronym for Power Entry Module.
PM Acronym for preventive maintenance.
POP UP Synonym for display screen dialog.
POSITIVE Describes a culture bottle that has evidence of microbial activity.
POWER CONNECTOR A fitting to attach the alternating current (AC) power cord.
POWER ENTRY MODULE Device on the Instrument that contains the fuse(s) and facility voltage
(PEM) setting selection. It also contains the power connector.
POWER PANEL Panel within the Instrument that contains the DC Power Supply, relays,
and isolation transformer.
PREVENTIVE Routine maintenance procedures that are accomplished annually by the

MAINTENANCE (PM) service technician. These maintenance procedures ensure proper
operation of the instrument and help in reducing major outages.
PRINTER PORT Printer interface port (parallel) on the Instrument for producing hard copy
reports concerning bottle status.
PRINTED CIRCUIT BOARD A fiberboard containing the necessary electronic components that are
(PCBA) interconnected via soldered paths to create a working circuit assembly.
PROMPT A text entry field that appears on a display screen. The primary purpose
for a prompt is for data entry. Read-only prompts are not selectable and
are dimmed. User entries into a prompt are checked for validity according
to the value range internally assigned for that prompt.
QUAD SERIAL PCBA PCBA within the Instrument that provides for the communication between
the Incubation Chamber and the rest of the equipment.
QUICK REFERENCE Outlines instructions for system operation and describes specific fault
CARDS codes. Found in the Operator’s Manual and may be conveniently
relocated by the customer.
RACK Contains 20 cells, each of which can hold and monitor an individual culture
bottle. Racks gently rock to agitate bottles, unless they are set up for MB.
RACK LEVELING Bracket on the rear of the rack assembly providing for a means of the
BRACKET agitation arm to make contact with the rack.
RAM An acronym for Random Access Memory. RAM is volatile memory (unless
it is the special NVRAM).
REFERENCE See THERMOMETER.

THERMOMETER

452501-1EN1
Glossary
SCROLL BUTTON A button that allows selection of numerical or symbolic values by clicking
arrows above or below a window that shows the selected character. While
an arrow is being clicked, the center portion shows one character from
among the available list of choices.
SELECT To choose a screen option with a pointing device.
SLIDEBAR SWITCH A rectangular icon device which moves between ON and OFF (symbolized
by 1 and 0, respectively) when the corresponding end of the rectangle is
clicked.
SLOER Acronym for Standard Laboratory Operating Environment Requirements.
THERMOMETER An independent, NIST-Traceable temperature monitoring device.
TITLE BAR The horizontal bar at the top of a window that contains the title of the
window, screen, or dialog box.
TOGGLE BUTTON A button that becomes active (appears to be clicked) after the
corresponding screen area is clicked, and continues to be active until it is
clicked again.
UP/DOWN SCROLL Icon that is used to select a numerical value of 0 to 9. More than one
BUTTON button is available for larger numbers.
UPS Uninterruptible Power Supply.
USER INTERFACE The methods by which the computer and user can communicate.
WARNING Identifies actions that can result in injury or death to personnel performing
a procedure (or persons that may be nearby).
WAVEFORM From the lab technician’s perspective, this is another name for a bottle
graph. For the Field Engineer, it could mean either the same as above, or
more commonly the picture presentation on an oscilloscope display.
Zip® DRIVE Disk drive within the Instrument providing for a means of loading software
and backing up data.

452501-1EN1
Glossary

452501-1EN1
Index
A temperature 6-2
Cell
Accessing the Configuration Screen 3-31
incubator 3-20
Adjust
Cell Flag
power supply 6-25
incubator 3-20
Agitation Motor 3-18
Cell Indicator Lamp
Alignment and Adjustment Procedures 6-1 incubator 3-20
APC Back-UPS Model 650 Battery Chapter Organization 1-3
replacement 5-114
Chassis-mounted Components 3-17
Assembly Descriptions 3-3
Cleaning Agent Hazards 1-9
B Click 1-4
COMM Port
Backup description 3-4
controller module DOS 4-13
Commands 1-4
data 4-11
Compact Flash Adapter PCBA 3-16
BacT/ALERT® 3D 60
data backup 4-2
assembly descriptions 3-3
data backup restore 4-5
modem configuration 2-32
replacement 5-33
power down 4-2
power up 4-2 Compact Flash Disk 3-15
Barcode Loopback Component
controller module 3-51, 7-66 replacement 5-1
Barcode Scanner Component Replacement 5-1
description 3-3 Important Information 5-5
instrument improvements E-39 Components
Battery module 3-5
CPU BIOS Configuration and Operation Option Data
replacement 5-23 re-enter 5-13
Blower 3-18 Configuration Screen 3-30
replacement 5-86 access 3-31
Blower Assembly checkboxes 1-6, 3-32
replacement 5-84 Connector Locations
Blower Motor Capacitor CPU PCBA D-2
replacement 5-86 inlet thermistor PCBA D-10
Bottle Holder Cover ModSig PCBA D-6
replacement 5-95 ModSig PCBA fuses D-8
outlet thermistor PCBA D-10
Bottle Retainer Assembly
power entry module D-13
replacement 5-107
quad serial PCBA D-9
solid state relays D-12
C step-5 PCBA D-9
calibrate module temperature screen, diagram terminal strip TB1 D-11
6-3 UPS D-5
Calibration Controller Module
3D 60 software barcode loopback 3-51, 7-66
single cell 6-15 barcode scanner
Cal 10 A software instrument improvements E-39
single cell 6-19 CPU BIOS
single slug 6-8 version update E-19
BacT/ALERT® 3D 60 Service Manual Index-1

452501-1EN1
Index
CPU PCBA Digital Reference Thermometer

replacement 5-16 replacement 5-88
DOS backup 4-13
Digital Reference Thermometer Battery
modem loopback 3-53, 7-67
replacement 5-89
power event log 3-54, 7-68
software 3-60, 7-72 Display Configuration Screens 3-30
view files 3-55, 7-69 Display Output Area
Zip® drive test 3-51, 7-64 navigation buttons 3-37
Controller Module Diagnostic Tests 7-64 Drawer Assembly
Controller Module Diagnostic Values 3-51 replacement 5-90
Conventions Drawer Switch Magnet

typographic 1-4 replacement 5-110
usage 1-4 Drawer/Heater
CPU BIOS Battery incubator 3-49, 7-61
replacement 5-23
CPU BIOS Version Update E-19
E
CPU Configuration Data Electrical Grounding 1-8
restore 5-13, 5-22 Electronics Drawer 3-6
CPU PCBA 3-6 Electrostatic Discharge (ESD) F-1
BIOS and jumper settings reference E-13 Equipment Description 3-3
connector locations D-2
ESD Precautions 1-9
Final Checks 5-15
initial checks 5-16 Existing Hardware 1-10
instrument improvement E-2
replacement 5-7, 5-16 F
Fan
D replacement 5-76
Data Backup 4-11 Fan Assembly 3-19
compact flash adapter PCBA 4-2 Fault/Status Code Troubleshooting 7-16
restore
compact flash adapter PCBA 4-5
Fax Modem
replacement 5-111
Data Backup Restore 4-13
Field Engineer Password 2-30, 4-16, 4-20, 4-23
DC Power Supply 3-5
replacement 5-70 Finding Topics 1-3
Decontamination Procedures B-1 Flag Check
incubator 3-47, 7-59
Diagnostic Buttons 3-33
Fuse Replacement 1-9
Diagnostic Procedures
incubator 7-52
G
Diagnostic Screens
overview 3-38 Gas Spring Assembly
replacement 5-105
Diagnostic Test Screens, Buttons, and Values
3-32 Genus and Species Names 1-4
Diagnostic Test Selection Screen
access 7-52 H
Diagnostics and Troubleshooting Hardware
introduction 7-3 existing 1-10
Diagnostics and Troubleshooting Information
7-1
Index-2 BacT/ALERT® 3D 60 Service Manual

452501-1EN1
Index
Hazardous Voltages 1-9 Keyboard Entry 1-4

Health Risks 1-9
Heater 3-18 L
replacement 5-80 LED Check
Heating Element 1-10 incubator 3-49, 7-62
How To Use this Manual 1-1 Link Assembly
replacement 5-97
I LIS
loopback 3-83, 7-77
Important Information 5-5
message log 3-87, 7-80
Incubation Chamber 3-20 message stats 3-87, 7-79
Incubation Module port stats 3-85, 7-78
loopback method 7-53 LIS Diagnostic Tests 7-77
Incubator LIS Module Diagnostic Values 3-83
cell 3-20
Loopback
cell flag 3-20
LIS 3-83, 7-77
cell indicator lamp 3-20
diagnostic values 3-40 Loopback Method
drawer/heater 3-49, 7-61 incubation module 7-53
flag check 3-47, 7-59 incubator 3-40
LED check 3-49, 7-62
loopback method 3-40 M
message log 3-44, 7-56
Manual
message stats 3-43, 7-55
typographic conventions 1-4
port stats 3-42, 7-54
usage conventions 1-4
rack 3-20
reading log 3-46, 7-58 MB Conversion 6-4
temperature log 3-45, 7-57 Message Log
Industry Bottle Barcodes incubator 3-44, 7-56
activate 2-25 LIS 3-87, 7-80
Initial Checks Message Stats

CPU PCBA 5-16 incubator 3-43, 7-55
LIS 3-87, 7-79
Inlet Thermistor PCBA
connector locations D-10 Metal Oxide Varistor
replacement 5-52 replacement 5-65
Installation Checklist C-1 Micro Switch

check 6-29
Instrument Components 3-1
Modem Configuration
Instrument Icon 7-17
BacT/ALERT® 3D 60 2-32
Instrument Improvement Modem Loopback
CPU PCBA E-2
controller module 3-53, 7-67
Instrument Improvements E-1 ModSig PCBA 3-8
barcode scanner E-39
CPU BIOS version E-19
replacement 5-36
Intended Audience 1-2 ModSig PCBA Fuse(s)
K replacement 5-41
Keyboard 3-93 Module
description 3-4 components 3-5
replacement 5-109

452501-1EN1
Index
Mouse 3-93 Q
Moving Parts 1-9
Quad Serial PCBA 3-7
N replacement 5-27
Navigation Buttons Quick Reference Card 3-94
display output area 3-37 description 3-4
O R
Operation Buttons 3-34 Rack
Operator Panel incubator 3-20
description 3-3 Rack Controller PCBA 3-21
Operator Panel Screens 3-30 Reading Log
Optics 6-8 incubator 3-46, 7-58
Organization of the Manual 1-2 Reflective Standard Discs
replacement 5-116
Outlet Thermistor PCBA
connector locations D-10 Requirements
replacement 5-50 system setup 2-2
Restore
P CPU configuration data 5-22
data backup 4-13
Port Stats
Restore CPU Configuration Data 5-13
LIS 3-85, 7-78
S
Post Service Validation 5-124
Power Entry Module Safety Summary 1-7
connector locations D-13 Scandisk Output 3-88, 7-75
fuses Schematics and Diagrams D-1
replacement 5-74
screen
Power Entry Module Fuse(s) calibrate module temperature 6-3
replacement 5-74
Select 1-6
Power Event Log
Setup System 2-1
Single Cell Calibration
Power Panel Assembly 3-17
3D 60 software 6-15
Power Supply Cal 10 A software 6-19
adjust 6-25
Single Slug Calibration 6-8
DC power
replacement 5-70 Slide Bar 3-37
metal oxide varistor SLOER Form C-4
replacement 5-65
Software
solid state relay
association tables 3-62, 7-74
replacement 5-67
audit trail 3-81
transformer
replacement 5-62
bottle processing tables 3-63, 7-74
configuration tables 3-83
Power Supply Assembly 3-25
Power Supply Data 3-27 debug 3-61, 7-72
Printer Port modem activity log 3-62, 7-74
description 3-4 operating system exception log 3-62, 7-73
Purpose of this Manual 1-2 software exception log 3-62, 7-73

452501-1EN1
Index
Solid State Relay View Files

replacement 5-67 .APF files 3-55, 7-71
Solid State Relays .BID files 3-55, 7-70
connector locations D-12 .BTF files 3-55, 7-71
.LOG files 3-55, 7-71
Specifications A-1
Step-5 Drive Agitation Linkage Assembly PLDSTORE.DAT files 7-72
replacement 5-100
Step-5 Motor W
replacement 5-45
Warnings, Cautions, and Information 1-6
Step-5 PCBA 3-11
replacement 5-43
Z
Symptomatic Troubleshooting 7-4 Zip® Drive 3-15
replacement 5-55
System Control
test 3-51, 7-64
description 3-3
System Power Panel Assembly
replacement 5-60
System Power Supply 6-2
System Setup 2-1
requirements 2-2
T
Temperature
verification 4-14
Temperature Calibration 6-2
Temperature Log
Terminal Strip TB1
Transformer 3-18
replacement 5-62
Troubleshooting
Fault/Status Code 7-16
Symptomatic 7-4
Typographic and Usage Conventions 1-4
U
UPS
domestic model
battery replacement 5-114
replacement 5-112
User Input 1-6
V
Verification
incubator temperature 4-14

452501-1EN1
Index

452501-1EN1
Recommended Changes
You can improve this manual by recommending improvements using the
Recommended Changes to Service Documentation Form. Fill it out as shown on the
sample shown below and send it to the e-mail, fax number, or address shown in the
table below.
Recommended Changes to Service Documentation Forms can be accessed by

double-clicking the paperclip next to the sample form.
Note: The Recommended Changes to Service Documentation Forms may only be used for
service documentation for the VITEK® 2, VITEK® 2 Compact, BacT/ALERT 3D®, and
PREVI™ Isola product lines.
Fax Number E-mail Address Mail Address
314-739-8689 patricia.stelbrink@na.biomerieux.com bioMérieux

Attn: PL&D RCSD Attn: PL&D RCSD
595 Anglum Rd
Hazelwood, MO 63042
Recommended Changes to Service DATE: 12JUN09

Documentation Recommended
TO: FROM:
Fax No. 123-456-7899 John Doe Changes to Service
55 bioMérieux Way
Anytown, CA, 123456 USA
Documentation
MANUAL NUMBER REVISION DATE MANUAL TITLE Form
510726-4EN1 07/2006 VITEK® 2 and VITEK® 2 XL Integrated System
Service Manual
CHAPTER SECTION PAGE FIGURE TABLE RECOMMENDED CHANGES AND REASON
NO. NO. NO. NO. NO. (Provide exact wording of changes, if possible.)
2 2.3.2 2-4 2-2 The black plastic card part number is listed
incorrectly. It should be XXXXX-XX.
SAMPLE
NAME AND JOB TITLE TELEPHONE NO. SIGNATURE
John Doe
John Doe, Field Service Engineer 123-456-7890
FOR PL&D USE ONLY

Date Received TTP # Entered By Date Entered
03/2010

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452501-1EN1

For Internal Use Only

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Consult Instructions for Use

Contains sufficient for <n> tests

Fragile, handle with care

Caution, consult accompanying documents

Electric shock warning

Potential pinch-point warning

Upper limit of temperature

Lower limit of temperature

In Vitro Diagnostic Medical Device

Authorized Representative in the European Community

Separate collection for waste electrical and electronic

Keep away from sunlight

Protect from light

Both direct and alternating current

Three-phase alternating current

Earth (ground) terminal

Protective conductor terminal

Frame or chassis terminal

ON (only for a component of the system equipment)

OFF (only for a component of the system equipment)

Equipment protected throughout by double insulation or

Potential tip over/crush hazard

List of Figures ................................................................................................. xiii

List of Tables .................................................................................................. xxv

1 How to Use this Manual ............................................................................. 1-1

2 System Setup.............................................................................................. 2-1

BacT/ALERT® 3D 60 Service Manual v

2.4 BacT/ALERT® 3D 60 Unpacking Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

3 Instrument Components............................................................................ 3-1

vi BacT/ALERT® 3D 60 Service Manual

3.7.1 Diagnostic Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

4 Operating Procedures................................................................................ 4-1

5 Component Replacement .......................................................................... 5-1

BacT/ALERT® 3D 60 Service Manual vii

5.4.3 CPU PCBA (P/N 750-0070-01) Installation . . . . . . . . . . . . . . . . . . . 5-20

viii BacT/ALERT® 3D 60 Service Manual

5.19 Power Supply Solid State Relay(s) Replacement . . . . . . . . . . . . . . . . . . . . 5-67

BacT/ALERT® 3D 60 Service Manual ix

5.33.1 Step-5 Drive Agitation Linkage Assembly Removal. . . . . . . . . . . . 5-100

6 Alignment and Adjustment Procedures................................................... 6-1

7 Diagnostics and Troubleshooting Information ....................................... 7-1

x BacT/ALERT® 3D 60 Service Manual

7.2 Symptomatic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

B Decontamination Procedures ...................................................................B-1

C Installation Checklist .................................................................................C-1

D Schematics and Diagrams.........................................................................D-1

BacT/ALERT® 3D 60 Service Manual xi

D.1.2 CPU PCBA (P/N 750-0070-902) . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3

E Instrument Improvements ......................................................................... E-1

F Electrostatic Discharge (ESD) .................................................................. F-1

Glossary .............................................................................................. Glossary-1

Index .......................................................................................................... Index-1

xii BacT/ALERT® 3D 60 Service Manual

Figure 1-1: Checkboxes .................................................................................................... 1-6