APS-1650 Automated Prep Station Operator s Manual

Transcription

1 APS-1650 Automated Prep Station Operator s Manual

2 COPYRIGHT Copyright 2009, 2014 Teledyne Technologies Inc Rev 2 February, 2014 REPRODUCTION All rights reserved. Reproduction or transmission of this document in whole or in part, and by any means without the express written consent of the copyright owner or authorized agent is prohibited. Requests for additional copies of this, or any other CETAC publication, can be filled by contacting an authorized distributor or Teledyne CETAC Technologies Customer Service & Support Industrial Road Omaha, Nebraska 68144, USA Phone (800) (USA only) Phone (402) Fax (402) custserv@cetac.com Web REVISIONS Teledyne CETAC Technologies strives to provide the scientific community with an unparalleled combination of effective technology and continuing value. Modular upgrades for existing instruments will continue to be a prime consideration as designs progress. Teledyne CETAC Technologies reserves the right to revise this document and/or improve products described herein at any time without notice or obligation. Warranty registration entitles the named owner exclusively to manual change pages/new editions as they are published. SAFETY Instruments, accessories, components or other associated materials may not be returned to CETAC if contaminated with biohazard or radioactive materials, infectious agents, or any other materials and/or conditions that could constitute a health or injury hazard to CETAC employees. Call Customer Service and Support if there is any question or doubt relative to decontamination requirements. CAUTION and WARNING statements, as applied in this document, shall be interpreted consistent with the following context: CAUTION applies only to potential property damage conditions; WARNING applies to potential personal injury conditions, in combination with or exclusive of potential property damage. NOTE All user-serviceable components are specifically identified in this document as such; the balance shall be assumed to require the expertise of a factory service technician/engineer for adjustment, repair, replacement, modification, etc. Others not so qualified and performing these actions shall do so at their own risk. Furthermore, never operate the instrument without first reading and understanding the APS-1650 Operator s Manual and ensuring that it is operated safely and properly. ORIGINAL PACKAGING Retain original factory packaging for moves and factory return shipments. Shipping in anything other than the original fitted foam and container can result in incidental damage from which the purchaser will not be protected under warranty.

3 APS-1650 Automated Prep Station Operator s Manual Addendum Notices and Compliance Declarations FEDERAL COMMUNICATIONS COMMISSION (FCC) NOTICE This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a commercial installation. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. Operation of this equipment in a residential environment is likely to cause harmful interference, in which case the user will be required to correct the interference at his own expense. MODIFICATIONS The FCC requires the user to be notified that any changes or modifications made to this device that are not expressly approved by CETAC may void the user's authority to operate the equipment. CABLES Connections to this device must be made with shielded cables with metallic RFI/EMI connector hoods to maintain compliance with FCC Rules and Regulations. CANADIAN NOTICE This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus as set out in the interference-causing equipment standard entitled "Digital Apparatus." ICES-001 of the Department of Communications. AVIS CANADIEN Cet appareil numerique respecte les limites de bruits radioelectriques applicables aux appareils numeriques de Classe A prescrites dans la norme sur le materiel brouilleur: "Appareils Numeriques," NMB-001 edictee par le ministre des Communications. POWER CORD SET REQUIREMENTS The power cord set supplied with your instrument meets the requirements of the country where you purchased the instrument. If you use the instrument in another country, you must use a power cord set that meets the requirements of that country. AD-1

4 APS-1650 Automated Prep Station Operator s Manual Addendum Notices and Compliance Declarations This equipment is designed for connection to a grounded (earthed) outlet. The grounding type plug is an important safety feature. To reduce the risk of electrical shock or damage to the instrument, do not disable this feature. CAUTION To reduce the risk of fire hazard and electrical shock, do not expose the unit to rain or humidity. To reduce the risk of electrical shock, do not open the cabinet. All maintenance is to be performed by an Authorized CETAC Service Provider. Protection provided by the equipment may be impaired if the equipment is used in a manner not specified by the manufacturer. CLEANING INSTRUCTIONS To clean the exterior surfaces of the instrument, complete the following steps: 1 Shut down and unplug the instrument. 2 Wipe the instrument exterior surfaces only using a towel dampened with a lab-grade cleaning agent. 3 Repeat step 2, using a towel dampened with clear water. 4 Dry the instrument exterior using a dry towel. Do not allow any liquid to enter the instrument cabinet, or come into contact with any electrical components. The instrument must be thoroughly dry before you reconnect power, or turn the instrument on. ENVIRONMENTAL Operating Temperature: 10 to 30 C Relative Humidity 0% to 95% Altitude 0 to Ft AD-2

5 APS-1650 Automated Prep Station Operator s Manual Addendum Notices and Compliance Declarations AVERTISSEMENT POUR UNE PROTECTION CONTINUÉ CONTRE LES RISQUES D INCENDIE, REMPLACER UNIQUEMENT PAR DES FUSIBLES DE MÊME TYPE ET AMPÈRAGE. AVERTISSEMENT TOUT CONTACT AVEC LES HAUTES TENSIONS PEUT ENTRAINER LA MORT OU DES BLESSURES SÉVÈRES. CE PANNEAU NE DOIT ÊTRE ENLEVE QUE PAR UN RÉPARATEUR QUALIFIÉ. AVERTISSEMENT TOUT CONTACT AVEC LES HAUTES TENSIONS PEUT ENTRAINER LA MORT OU DES BLESSURES SÉVÈRES. CE PANNEAU NE DOIT ÊTRE ENLEVE QUE PAR UN RÉPARATEUR QUALIFIÉ. AVERTISSEMENT TOUT CONTACT AVEC LES HAUTES TENSIONS PEUT ENTRAINER LA MORT OU DES BLESSURES SÉVÈRES. CE PANNEAU NE DOIT ÊTRE ENLEVE QUE PAR UN RÉPARATEUR QUALIFIÉ. AVERTISSEMENT TOUT CONTACT AVEC LES HAUTES TENSIONS PEUT ENTRAINER LA MORT OU DES BLESSURES SÉVÈRES. CE PANNEAU NE DOIT ÊTRE ENLEVE QUE PAR UN RÉPARATEUR QUALIFIÉ. AD-3

6 APS-1650 Automated Prep Station Operator s Manual Addendum Notices and Compliance Declarations WARNING HIGH LEAKAGE CURRENT - ENSURE PROPER GROUNDING AVERTISSEMENT COURANT DE FUITE ÉLEVÉ FORNIR UNE MISE À LA TERRE EFFICACE. Crush Hazard / Pinch Point Keep hands clear of moving parts. X, Y, Z axis movement may crush hand. Puncture Hazard Moving parts can cause severe injury. Do not put hand under the probe assembly! Lifting Hazard Single person lift could cause injury. Use assistance when moving or lifting. Attention Refer to the manual. This symbol indicates that information about usage of a feature is contained in the manual. AD-4

7 APS-1650 Automated Prep Station Operator s Manual Addendum Notices and Compliance Declarations WARNING If the automated prep station is used in a manner not specified by CETAC Technologies, the protection provided the equipment may be impaired. WARNING The power switchs on the rear panels are not the mains disconnect. Mains disconnect is accomplished by disconnecting the detachable power supply cords at the appliance coupler or at the mains plug. Ensure the power cords are easily accessible and removable, in the event of an emergency, which requires immediate disconnection. CAUTION The CAUTION notice denotes a hazard. It calls attention to a procedure, practice, or the like, that, if not correctly performed or adhered to, could result in personal injury. Do not proceed beyond a CAUTION notice until the indicated conditions are fully understood, and met. WARNING This is a Safety Class 1 Product (provided with a protective earthing ground incorporated in the power cord). The mains plug shall only be inserted in a socket-outlet provided with a protective earth contact. Intentional interruption is prohibited. Safety Maintenance The operator should check the detachable power supply cord condition. The equipment should not be operated if the mains inlet is cracked or broken. Any obvious damage to the case, (from a drop or fall), should be checked by service personnel for loose or damaged parts. See individual parts lists for approved replacement parts. AD-5

8 APS-1650 Automated Prep Station Operator s Manual Addendum Notices and Compliance Declarations Safety and Regulatory Information Review this product and related documentation to familiarize with safety markings and instructions before you operate the instrument. WARNING The WARNING notice denotes a hazard. It calls attention to a procedure, practice, or the like, that, if not correctly performed or adhered to, could result in personal injury. Do not proceed beyond a WARNING notice until the indicated conditions are fully understood and met. WARNING Do not operate in explosive atmosphere. WARNING All external I/O terminals allow a maximum current of V. WARNING Ensure that power is disconnected before removal of any covers. WARNING Equipment is not intended for wet locations. Miscellaneous liquids in the equipment could cause hazardous conditions. WARNING Pollution Degree 1. NOTE: For instructions on how to return end-of-life equipment, producer-supplied electrical accessories, or auxiliary items for proper disposal please contact the supplier or importer. In the event a supplier cannot be reached, contact CETAC Technologies customer service department at 1 (800) AD-6

9 Contents

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11 APS-1650 Automated Preparation System Operator s Manual Contents Contents Preface Who Should Read This Book How to Use This Book Conventions Used in This Book Instructions Menu Items Terminology Notes Cautions Warnings Where to Go for More Information xiii xiii xiii xiv xiv xv xv xvi xvi xvi xvii 1 Introduction Automated Prep Station Standard Components Rack Adapter Plate 1-5 Sample Vial Rack 1-6 Collection Vial Rack 1-6 Flowing Rinse Station 1-6 Z-Drive Assembly Channel Peristaltic Pump 1-8 RS/232 Serial I/O Ports 1-8 Multi-Channel Auxiliary Port 1-8 vii

12 APS-1650 Automated Prep Station Operator s Manual Contents USB Communications Port 1-8 Stirrer Speed Control 1-8 Pump Speed Control 1-8 Auxiliary Speed Control 1-8 Liquid Level Sensor 1-9 External Desktop Power Supply -- Main 1-9 External Desktop Power Supply -- Pump Module 1-9 Sample Probe Kit 1-9 Sample Stirring Kit 1-9 USB Communications Cable 1-9 Rinse Station Tubing Kit 1-9 Pump Module Box 1-9 Pump Module Tubing Kit 1-9 Software CD 1-10 Optional Accessories 1-10 Serial Interface Null Adapter 1-10 Serial Interface Special Adapter Kit 1-10 Sample Probes 1-10 Serial Interface Kit Preparing for Installation Choosing a Location Space Requirements Rinse Solution Requirements Power Requirements Unpacking the APS Installing the Automated Prep Station viii

13 APS-1650 Automated Preparation System Operator s Manual Contents Shipping Fixture Process Mounting the Z-Drive Assembly Attaching the Z-Drive Assembly Attaching the Z-Drive Cable Channel Peristaltic Pump Connecting the Rinse Station Connecting the Pump Module Box Installation / Removal of the Stirring Paddle Installation / Removal of the Stirring Assembly Installation / Removal of the Sample Probe Emptying the Drip Cup Placing the Sample and Collection Racks Establishing External Connections Connecting the APS-1650 to the Power Source Connecting the APS-1650 to an Analytical Instrument Connecting the APS-1650 to the Host Computer Establishing a Serial Communications Interface Establishing a USB Communications Interface ix

14 APS-1650 Automated Prep Station Operator s Manual Contents Determining the COM Port Installing the Instruo Software Calibrating the Liquid Level Sensor Verifying Installation Testing the Interface Checking the Automated Prep Station Components Testing the Sample Probe Using the Automated Prep Station Establishing Optimal Operating Conditions Creating the Lab Environment Replacing Automated Prep Station Components Purchasing Supplies Arranging the Sample Vial Racks Starting the Automated Prep Station Shutting Down the Automated Prep Station Flushing the Rinse Station and Flow Path x

15 APS-1650 Automated Preparation System Operator s Manual Contents 6 Maintaining the Automated Prep Station Cleaning the Automated Prep Station Daily External Cleaning Weekly Cleaning Checking for Leaks Replacing Peristaltic Pump Tubing Replacing the Sample Probe Replacing the Rinse Station Tubing Troubleshooting the Automated Prep Station Power System Problems Interface Problems RS-232 Cable Problems Software Configuration Problems Z-Drive Assembly Problems 7-5 Drip Cup Problems 7-7 DIP Switch Settings 7-8 xi

16 APS-1650 Automated Prep Station Operator s Manual Contents xii

17 Preface

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19 APS-1650 Automated Prep Station Operator s Manual Preface Preface The APS-1650 Automated Prep Station Operator s Manual explains the procedures for installing, using, and maintaining the CETAC APS It also provides information about troubleshooting APS-1650 problems and describes the design of the automated prep station. Who Should Read This Book The primary audience for the APS-1650 Automated Prep Station Operator s Manual consists of analytical chemists and lab technicians. To use this manual effectively, you should have a basic knowledge of chemistry, a basic knowledge of electronic sampling equipment, and at least a beginning level of computer experience. How to Use This Book The APS-1650 Automated Prep Station Operator s Manual contains seven chapters. You should read the chapters sequentially the first time. Thereafter, refer to the chapters separately as needed. The first chapter provides an introduction to the autosampler. Subsequent chapters detail the primary tasks associated with the APS This manual contains the following chapters: Chapter 1, Introduction, provides you with an overview of the APS Automated Prep Stations s function and design. Chapter 2, Preparing for Installation, discusses space and power requirements that must be met before the APS-1650 is installed. It also provides instructions for unpacking the autosampler. xiii

20 APS-1650 Automated Prep Station Operator s Manual Preface Chapter 3, Installing the Automated Prep Station, provides stepby-step procedures for installing the APS-1650 and connecting it to the host computer. Chapter 4, Verifying Installation, explains how to test the communications interface between the APS-1650 and the host computer. It also explains how to check autosampler components and test the sample probe. Chapter 5, Using the Automated Prep Station, describes the tasks you perform during daily operation of the APS Chapter 6, Maintaining the Automated Prep Station, explains daily, weekly, and periodic maintenance tasks. Chapter 7, Troubleshooting the Automated Prep Station, describes how to diagnose and correct APS-1650 problems. These chapters are followed by a glossary of related terms. Conventions Used in This Book This book uses certain conventions to distinguish different types of information easily. This section describes these conventions. Instructions All step-by-step instructions are numbered and in bold, as in the following example. 1) Replace the sample vial racks. Many numbered instructions are followed by more detailed explanations. xiv

21 APS-1650 Automated Prep Station Operator s Manual Preface Menu Items This book uses the following format for referring to menu items: Settings/Communication The text before the forward slash symbol is the name of the menu; the text after the forward slash symbol is the menu choice. This example refers to the Communications Menu choice in the Settings Menu. Terminology This book frequently uses the following terms: Host Computer The computer that controls operation of the CETAC device. Hz ICP-AES ICP-MS ID LED PEEK VAC VDC X-Axis Hertz. An inductively coupled plasma atomic emission spectrometer. An inductively coupled plasma mass spectrometer. Inside diameter. Light-emitting diode. Polyetheretherketone. Volts alternating current. Volts direct current. The left-to-right axis of the autosampler. xv

22 APS-1650 Automated Prep Station Operator s Manual Preface Y-Axis Z-Axis W-Axis The front-to-back axis of the autosampler. The up-and-down axis of the sample probe. The up-and-down axis of the stirring paddle. Notes Notes contain a reminder about the effect of particular actions. They are indicated as follows: Note: This example shows how a note is displayed. Cautions Cautions indicate situations that require immediate attention to prevent harm to the autosampler. Cautions are indicated as follows: CAUTION This example shows how a caution is displayed. Warnings Warnings indicate situations that could cause bodily harm. Warnings are indicated as follows: WARNING This example shows how a warning is displayed. xvi

23 APS-1650 Automated Prep Station Operator s Manual Preface Where to Go for More Information In addition to the APS-1650 Autosampler Operator s Manual, you can refer to the following resources: The software manual for the ICP-AES or ICP-MS instrument you are using CETAC Technologies Customer Service and Support: Toll Free: 1 (800) Direct: 1 (402) Fax : 1 (402) Web: custserv@cetac.com xvii

24 APS-1650 Automated Prep Station Operator s Manual Preface xviii

25 1 Introduction

26 APS-1650 Automated Prep Station Operator s Manual Introduction 1 2

27 APS-1650 Automated Prep Station Operator s Manual Introduction Introduction The APS-1650 Automated Prep Station is designed to be sturdy, reliable, and easy to use. It provides automated sample dilution that enables you to perform other tasks while the APS-1650 operates. The APS-1650 automatically dilutes and stirs up to 90 samples when fully loaded. It contains a microprocessor that allows sequential or random sampling, providing flexibility. The APS-1650 System is typically controlled by a host computer using a serial communications protocol. The computer may be user supplied or acquired from CETAC. Computer requirements are given later in this chapter. A picture of an APS-1650 System (Autosampler plus Dilution Module) is shown below in Figure 1-1. Figure 1 1. APS-1650 Automated Prep Station Front View. 1 3

28 APS-1650 Automated Prep Station Operator s Manual Introduction Automated Prep Station Standard Components Automated Prep Station components are made of corrosion-resistant stainless steel alloys or anodized aluminum. The enclosure and base are made from a high-strength aluminum alloy that is chromated and finished with an epoxy powder coating. The APS-1650 operates reliably under a wide variety of conditions. Components in the sample flow path are made of Polytetrafluoroethylene (PTFE), Polyurethane, and PEEK. When these inert, non-metallic materials are used at temperatures less than 135 C, they can withstand repeated exposure to the following substances: Petroleum oils and derived fuels, kerosene, and hexane. 1 4

29 APS-1650 Automated Prep Station Operator s Manual Introduction Figure 1 2. APS-1650 Diagram Front View. The following standard components are located on the front of the APS and are shipped with the Automated Prep Station. Each item corresponds with a callout in Figure ) Rack Adapter Plate. The sample tray accommodates one raw sample rack and one diluted sample rack. The sample tray sits on 1 5

30 APS-1650 Automated Prep Station Operator s Manual Introduction pegs located in the base unit. The sample tray is removable to allow for easy clean-up. 2) Sample Vial Rack. The sample vial rack holds the raw samples. Depending upon which version of the APS-1650 was purchased, the standard rack configuration will include. a) One 45 position sample rack. b) One 80 position sample rack. c) One 90 position sample rack. Custom rack configurations can be used if desired. See the Instruo Software manual for information on creating custom rack files. 3) Collection Vial Racks. The collection vial rack holds the prepared samples. Depending upon which version of the APS-1650 was purchased, the rack configuration will include a) One 80 position collection rack, or b) One 90 position collection rack. Additional racks can be purchased separately. Custom rack configurations can be used if desired. See the Instruo Software manual for information on creating custom rack files. 4) Flowing Rinse Station. The rinse station is located in the middle of the chassis at the back of the sample base between the sample and collection racks. It comes with tubing used to connect the rinse station to the rinse source and the waste container. The rinse station block includes rinse ports for both the sample probe and the stirring paddle. 5) Z-Drive Assembly. The Z-Drive assembly includes a Z-Axis and W- Axis motor assemblies. The Z-Axis holds the sample probe. The W- Axis holds the stirrer assembly. Note: Stirrer assembly is optional and may not be included in all models 1 6

31 APS-1650 Automated Prep Station Operator s Manual Introduction Figure 1 2. APS-1650 Automated Prep Station Back View. 1 7

32 APS-1650 Automated Prep Station Operator s Manual Introduction The following standard components are located on the back of the APS and are shipped with the Automated Prep Station. Each item corresponds with a callout in Figure ) On-board three channel peristaltic pump. The APS-1650 will be standard with one on-board peristaltic pump. The pump is located in the lower right-hand corner on the back of the Automated Prep Station. The pump moves the rinse solution from the rinse source through the flowing rinse station. In a typical installation, a gravity drain is used to move the solution from the rinse station to waste. 7) Two RS-232 Serial I/O Ports (COM1 and COM2). The serial ports are located on the left side at the back of the Automated Prep Station. The COM1 port is an alternative communications interface between the APS-1650 and the host computer. The COM2 port connects the Automated Prep Station to other external devices. 8) Multi-channel (I/O) Auxiliary Port. The auxiliary port is located on the back, in the center of the APS The auxiliary port is used to connect the Automated Prep Station to other external devices. 9) USB Communications Port. The APS-1650 comes standard with a USB communications port. This port is the standard way to interface the APS-1650 with the host computer. 10) Stirrer Speed Control. The Stirrer speed is controlled by software. It should be set to default. 11) Pump Speed Control. The pump speed is controlled by software. It should be set to default. 12) Auxiliary Speed Control. The auxiliary speed control is used with the auxiliary peristaltic pump not included with the APS It should be set to default

33 APS-1650 Automated Prep Station Operator s Manual Introduction 13) Liquid Level Sensor. The liquid level sensor is an optical sensor used to determine the level of the raw sample. When properly calibrated the sensor prevents the probe from going to deep into the sample; reducing the amount of rinse required. The following standard components are also shipped with the APS-1650: o o o o o External Desktop Power Supply - Main. The input rating is AC 100V-240V, 3.2 A, with an output of DC 28V, maximum 4.6 A. External Desktop Power Supply --- Pump Module. The input rating is AC 100V-240V, 1.9 A, with an output of DC 24V, maximum 3.33 A. Sample Probe Kit. The kit includes the sample probe. The sample probe ships in the Z-Drive assembly. Sample Stirring Kit (Optional). The kit includes the sample stirrer. The sample stirrer ships in the Z-Drive assembly. USB Communications Cable. The APS-1650 uses a USB cable for communication with the host computer. Rinse Station Tubing Kit. The kit includes rinse tubing, drain tubing, and peristaltic pump tubing required for operation of the flowing rinse station. Pump Module Box. The pump module box houses the syringe pump, air pump, rinse pump, and solenoid valve used for sample preparation. The module can be connected through USB or Serial interface. Pump Module Tubing Kit. The kit includes tubing, connectors, filters, and sipper tubing for the pump module box to perform sample preparation

34 APS-1650 Automated Prep Station Operator s Manual Introduction Software CD. The software CD contains this Operator s Manual, the Spare Parts catalog, Instruo Software used for operating the APS-1650, alignment software, USB drivers, and additional documentation. Optional Accessories If you are doing a specialized type of analysis or are connecting the APS to a host computer that uses a non-rs-232 communications protocol, you may need optional accessories in addition to the standard components included with the Automated Prep Station. The following accessories are available for the APS-1650: o o o o Serial Interface Null Adapter. The null adapter replaces one DB9F port adapter at the host computer. It is used for computers with DCE-AT style serial ports. Serial Interface Special Adapter Kit. The adapter kit replaces one or both standard serial port adapters with unwired DB9M, DB25M, and DB25F adapters for special applications or host computers with serial ports not conforming to the RS-232 standard. Serial Interface Kit. The kit includes two DB9F port adapters for host computers with normal AT-style DTE serial ports, and a meter modular cable. Sample probes. The APS-1650 ships standard with a bevel tipped stainless-steel sample probe. Early versions of the APS-1650 may have shipped with a square tipped probe

35 APS-1650 Automated Prep Station Operator s Manual Introduction Note: Contact CETAC Technologies if you need additional accessories not listed, need added features to integrate the APS-1650 Automated Prep Station into your application, or have unique requirements. Research and development of new features and accessories for the APS Automated Prep Station, often inspired by customer requests, is a continuing activity at CETAC Technologies. 1 11

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37 2 Preparing for Installation

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39 APS-1650 Automate Prep Station Operator s Manual Preparing for Installation Preparing for Installation Installing the APS-1650 requires preparation. Before you install the automated prep station, you should evaluate the physical arrangement of the laboratory to choose a suitable location. Once you choose a location, you must carefully unpack the automated prep station prior to beginning the installation. This chapter discusses what requirements must be met when you choose a location for the autosampler. It also describes how to unpack the APS before installation. Choosing a Location Choosing a location for the APS-1650 involves evaluating the lab environment for the availability of space and power. For the automated prep station to function optimally, the location you select must meet specific requirements associated with each of these items. The following sections discuss space and power requirements. Space Requirements The recommended minimum footprint for countertop installation of the APS-1650 including the Pump Module Box is 110 x 70 x 70 centimeters. When evaluating a location, keep in mind rinse solution, diluents, and waste containers and host computer positioning. The APS-1650 will also need two grounded electrical outlets within 1.2 meters. Rinse Solution Requirements For most applications, kerosene is used for rinse agent in the APS Place the rinse agent source within two meters of the APS

40 APS-1650 Automated Prep Station Operator s Manual Preparing for Installation Ensure that there is a liquid waste receptacle within two meters of the APS The waste receptacle inlet should be at least 30 to 60 centimeters lower than the autosampler rinse station outlet to ensure proper gravity drainage. Power Requirements Place the APS-1650 within 1.2 meters of a power outlet. The APS-1650 uses two external desktop power supplies. The input rating for the main power supply is AC 100V-240V 3.2 A with an output of DC 28V, maximum 4.6 A. The input rating for the pump module box power supply is AC 100V-240V 1.9 A with an output of DC 24V, maximum 3.3 A. Ensure that you position the APS-1650 so that the location where the power supply cord plugs into it is easily accessible (is not blocked) and can be quickly disconnected if needed. The power supply socket is on the back of both the automated prep station and the pump module box near the power switch. Connect the power supplies to the unit first and then connect a line cord to the power supply. Do not apply power to the power supply until ready to operate. WARNING The APS-1650 is intended to operate from an AC power source that will not apply more than 240V AC between the supply conductors and ground. A protective ground connection by way of the grounding connector in the power cord is required for safe operation. 2 4

41 APS-1650 Automate Prep Station Operator s Manual Preparing for Installation Unpacking the APS-1650 Automated Prep Station The APS-1650 is shipped in a wooden crate to minimize damage during shipment. Supplies and accessories are shipped in a second cardboard box banded on top of the wooden crate. If the APS-1650 is shipped or removed from storage during cold weather, allow the packaged equipment to attain room temperature before opening and exposing to warm, humid air. It is usually sufficient to provide four to eight hours for this purpose. CAUTION If condensation forms on or inside the automated preparation station, allow it to dry thoroughly before connecting it to a power source and operating it. Failure to do so may cause equipment damage. Note: Do not throw away the factory packaging. Keep it for possible future use. This is one of the warranty conditions. Inspect external packaging upon receipt for holes, tears, smashed corners, or any other outward signs of damage from rough handling or abuse during shipment. Inspect all items during unpacking and notify the carrier immediately of any concealed damage. Remove the crate cover by removing the screws marked with red circles. There are typically eight screws holding the cover in place. Save the screws and cover for future use. Inside the crate there will be multiple cardboard boxes and bags containing additional items. Remove these and set aside. Locate the packing checklist from the shipping container, and check off items against it. Leave accessories in the packing until you are ready to install them on the automated prep station. 2 5

42 APS-1650 Automated Prep Station Operator s Manual Preparing for Installation Once the packing checklist has been verified, remove the base unit from the crate and set on the surface planned for operation. WARNING The APS-1650 base unit weighs approx. 30 kg or 66 lbs. Two people are required to lift the unit. Always use proper form when lifting. 2 6

43 3 Installing the Automated Prep Station

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45 Installing the APS-1650 APS-1650 Automated Prep Station Operator s Manual Installing the APS-1650 The APS-1650 Automated Prep Station is designed for easy installation. Installation consists of two parts: assembling the automated prep station and connecting it to the host analytical instrument. The APS-1650 can be installed with minimal effort. The only items that will be needed are a Ball Point Allen Wrench set, which is included in the APS-1650 kit, and a screwdriver. You can remove thumbscrews with tools if necessary, but do not tighten them with anything other than your fingers. To install the automated prep station, you must complete the following tasks. Each of these tasks will be discussed in detail later in this chapter. 1) Removal of carriage shipping fixture. 2) Mounting the Z-Drive assembly. 3) Connect the rinse station. 4) Assemble the sample vial racks. 5) Establish external connections. 6) Connect the autosampler to the host computer. WARNING The APS-1650 base unit weighs approx. 30 kg or 66 lbs. Two people are required to lift the unit. Lifting should be done with a person situated on either side of the instrument. Ensure the AC power is off before proceeding with installation. Shipping Fixture Process Depending on when the APS-1650 was shipped, there may, or may not be a fixture securing the Y-Arm during shipment. If the unit has a shipping fixture, it is an Y shaped bracket holding the Y-Arm in the far left position. Using a Philips screwdriver, remove the screw, remove the bracket, and replace the screw. The bracket should be stored with the packaging for future use. 3 3

46 APS-1650 Automated Prep Station Operator s Manual Installing the APS-1650 Figure 3-1 Shipping Fixture in place Mounting the Z-Drive Assembly The Z-Drive assembly must be attached to the autosampler arm to allow movement and function of the sample probe. Figure 3-1 illustrates the Z-Drive assembly components. Attaching the Z-Drive Assembly to the Autosampler Arm 1) Carefully unpack the Z-Drive assembly. 2) Identify the four screws and the Allen Wrench. 3) Located the two mounting pins on the assembly. 4) Place the pins in the corresponding holes in the mounting block, while holding it stable. 5) Insert the screws one at a time, while continuing to hold the assembly stable. 6) Be careful not to tighten the screws too much. Note: The screws are going into plastic and the plastic threads can be easily stripped if the screw is tightened too much. 3 4

47 APS-1650 Automated Prep Station Operator s Manual Installing the APS-1650 Figure 3-2 Mounting of Z-Drive Assembly Installation of the Z-Drive 15-Pin Cable 1) Attach the end without the ferrite block to the 15-pin connection port on the back of the Z-Drive assembly and tighten screws. 2) Attach the end with the ferrite block to the 15-pin connection port on the rear (in the center) of the unit, and tighten the screws. Warning: The Z-Drive 15-Pin Cable must be connected before applying power to the unit. Connecting or disconnecting the Z-Drive cable while power is applied WILL cause catastrophic damage to the unit and possibly harm the user. 3 5

48 APS-1650 Automated Prep Station Operator s Manual Installing the APS-1650 Single 3-Channel Peristaltic Pump The APS-1650 is equipped with a 3-channel peristaltic pump on the back side of the unit. In a typical installation one channel of the pump is used to move rinse solution into the flowing rinse station. Gravity drain is typical, but the additional channels can be used for a pumped drain setup if desired. Connecting the Rinse Station The cabinet-mounted rinse station is located to the right of center on the chassis. Typically, a solution from the kerosene family is used as the rinse solution and is pumped into the rinse station by the on-board 3- channel peristaltic pump. Since the inlet of the rinse station is at the bottom of the rinse station, the rinse solution flows from the bottom to the top of the stirrer paddle reservoir. Up-flow rinsing is the most effective method for decontaminating the stirrer paddle between samples. Reversing the connections and the rinse solution flow reduces the effectiveness of the rinse station and can cause cross-contamination and unsatisfactory performance. The rinse solution flows from the stirrer paddle reservoir to the drain (rinse out) reservoir within the rinse station. The waste rinse then drains from the rinse station by means of a gravity drain which is the standard arrangement for draining the rinse station. The sample probe is also rinsed within the rinse station, but the rinse solution used to cleanse the probe is pumped from the pump module box through the probe. The rinse solution is combined with air bubbles to create a scrubbing effect for more efficient rinse inside the probe. The rinse solution and air bubbles are forced through the probe into the small opening in the rinse station which is then forced up around the probe to cleanse the external surface prior to overflowing into the drain (rinse out) reservoir within the rinse station. 3 6

49 APS-1650 Automated Prep Station Operator s Manual Installing the APS-1650 To connect the rinse station, complete the following steps and refer to Figure 3-2: Note: Portions of the tubing assembly described in steps 1-5 below may have been completed in advance at the factory. 1) Connect the rinse solution to the on-board peristaltic pump tubing (Figure 3-3) a) Connect the 42 inch (107 cm) length of 1/8 inch (3.2 mm) ID Superthane tubing to the top inside channel of the Viton pump tubing. Note: Superthane tubing is rigid and can be hard to connect. To aide in making good connections, slightly stretch the tubing using needle nose pliers. Dip the tip of the connector in isopropyl alcohol to lubricate before making the connection. Press the tubing into the connector in one fluid motion. b) Insert the 18 inch (46 cm) Sipper tube to the other end. The sipper tube can now be inserted into the rinse solution container. 2) Connect the peristaltic pump to the rinse station (Figure 3-3) a) Connect the 42 inch (107 cm) length of 3/16 inch (4.7 mm) Superthane tubing to the bottom inside channel of the Viton pump tubing. b) The rinse station is attached to the chassis by a bracket. It must be removed to attach the rinse tubing. Remove the rinse station from the bracket by removing the thumbscrew. c) The APS-1650 has a removable rack adapter tray. Lift the tray out of the base and set aside. d) Route the rinse tubing through the top hole on the left side of the base pan to the rinse station. Connect the tubing to the rinse in port of the rinse station. (Port Y in Figure 3-2) e) The tubing can be trimmed to length if desired. 3) Connect the drain (rinse out) side of the rinse station to the waste reservoir (Figure 3-3) a) Connect the 66 inch (168 cm) length of 3/16 inch (4.7 mm) Superthane tubing to the drain (rinse out) channel of the rinse station. (Port AA in Figure 3-2) b) The waste container can be located on either side of the APS The shortest distance to the waste container will produce the best results. Route the drain tubing through the bottom hole in the base pan nearest to the waste container. Trim the tubing so it easily reaches the waste container, but will remain above the fluid level. Insert the end into the waste container. 3 7

50 APS-1650 Automated Prep Station Operator s Manual Installing the APS-1650 c) Attach the rinse station to the mounting bracket using the thumb screw. Ensure the tubing is routed low in the base pan up against the chassis. d) Replace the rack tray ensuring the tubing is not pinched and the tray is fully seated. Connecting the Pump Module Box The Pump Module Box can be positioned to the left or the right of the base unit. When deciding on a position, keep in mind positioning of the rinse solution container, diluent container, and electrical outlets. Note: Portions of the tubing assembly may have been assembled in advance at the factory. 1) Connect the air tubing (Figure 3-3) a) Locate the peek 4-way fitting and attach it to the Z-Drive using the two 3/32 inch allen screws and allen wrench provided. The check valves should be pointed to the front and rear of the unit. The top and bottom ports should not have check valves attached. b) Connect the 54 inch length of green peek tubing to the Air Out port on the Pump Module Box. Note: The tubing should stick out past the end of the ferrule when making the connections of the air tubing. If the air line is flush with the ferrule air leaks will occur causing poor rinse and an increase in carryover. c) Connect the other end of the peek tubing to the rear port on the peek 4-way fitting on the Z-Drive. 2) Connect the rinse out tubing (Figure 3-3) a) Connect the 4 inch (10 cm) length of polyurethane tubing to the Rinse Out port on the Pump Module Box. Connect the other end of the tubing to one of the top ports in the Tee-fitting. b) Connect the 60 inch (152 cm) length of polyurethane tubing to the other top port of the Tee-fitting. Connect the other end of the tubing to the front port on the peek 4-way fitting on the Z- Drive. c) Connect the 36 inch (91 cm) length of Superthane tubing to the bottom port of the Tee-fitting. Connect the other end to the 18 inch sipper tube. This tube can be placed in the rinse solution container. 3 8

51 3) Connect the rinse in tubing (Figure 3-3) APS-1650 Automated Prep Station Operator s Manual Installing the APS-1650 a) Connect the 36 inch (91 cm) length of Superthane tubing to the Rinse In port on the Pump Module Box. Connect the other end to the out port on the red in-line liquid filter. b) Using a 1 inch (2.54 cm) length of Superthane tubing, connect the in port on the in-line liquid filter to the 18 inch (46 cm) sipper tube. This tube can be placed in the rinse solution. 4) Connect the diluent (Figure 3-3) a) Connect the 36 inch (91 cm) length of Superthane tubing to the right port of the syringe pump valve. Connect the other end of the tubing to the 18 inch sipper tube. This tube can be placed in the diluent container. b) Connect the 62 inch (158 cm) length of polyurethane tubing to the left port of the syringe pump valve. Connect the other end of the tubing to the the bottom port on the peek 4-way fitting on the Z-Drive. 5) Connect the probe (Figure 3-3) a) Connect the 8-5/8 inch (22 cm) length of polyurethane tubing to the top port of the 4-way fitting on the Z-Drive. Connect the other end of the tubing to the bevel tipped probe. AA Rinse Station Drain R 4-Way Fitting DD Tee-Fitting S Check Valve (Inlet) EE In-Line Liquid Filter T Peek Tubing GG Restrictor Sapphire X Polyurethane Tubing JJ Check Valve (Outlet Y Rinse Port (IN) N Superthane Tubing Z Viton Tubing Table 3-1 APS-1650 Tubing Diagram 3 9

52 APS-1650 Automated Prep Station Operator s Manual Installing the APS-1650 Figure 3-3 APS-1650 Tubing Diagram 3 10

53 APS-1650 Automated Prep Station Operator s Manual Installing the APS-1650 Installation of the Paddle to the Stirring Assembly 1) While holding the top part of the assembly in one hand, and the paddle in the other, insert the paddle into the stirring assembly. To remove, pull the paddle out. Installation and Removal of the Stirring Assembly 1) With the power off, manually push the rear block on the Z- Drive assembly half of the way down. 2) Insert the stirring motor and secure with thumb screw. 3) Plug the cord into the front of the Z-Drive assembly. Do not wrap the cord around the Z-Drive assembly. 4) To remove the stirring assembly, simply reverse the directions for installation. Warning: Always power down the unit before plugging in / unplugging the stirring motor. Installation and Removal of the Sample Probe 1) To install the sample probe, slide the probe into the front block on the Z-Drive and secure with the thumb screw. When installing, make sure the bottom of the sample probe is even with the end of the stirring paddle. 2) If the Liquid Level Detector is used, slide the sensor up the probe and secure approximately one inch above the tip of the probe. Secure with the set screw. Secure the wires to the probe with cable wraps. Note: The level sensor block is plastic. Do not over tighten the screw when securing to the probe. Note: Anytime the liquid level sensor or probe has been repositioned, the liquid level sensor requires calibration. See Calibrating the Liquid Level Sensor later in this chapter. 3 11

54 APS-1650 Automated Prep Station Operator s Manual Installing the APS ) To remove the sample probe, simply reverse the directions for installation. Emptying the Drip Cup The APS-1650 uses two drip cups; One for the stirrer and one for the sample probe. 1) With the power off and the Z-Drive in the up position, (the drip cup is underneath the stirrer and the sample probe), lift up on the cup. 2) Empty the drip cup, clean it and then return it to the cup holder. Placing the Sample and Collection Racks Depending upon the version of the APS-1650, the sample vial racks may come assembled and ready for use. Some versions of sample vial racks are shipped unassembled. However, you can easily assemble them without using tools. Once you assemble the sample vial racks, place them in the sample tray before proceeding with the installation. WARNING Before loading or unloading any sample vial racks on the sample tray, park the sampling arm and probe in the home position by cycling the power on and off. The home position is the initial position at power up. Never attempt to load, unload or reposition the sample vial rack or sample vial while the APS is operating. There are two types of racks used with the APS The Sample Rack and the Collection Racks. The Sample Rack holds the raw samples and is positioned to the left of the rinse station. The Collection Rack holds the diluted samples and is position to the right of the rinse station. 1) Place the sample vial rack on the sample tray to the left of the rinse station, aligning the holes on the sample rack to the pegs on the sample tray Correctly placed sample vial racks will not move more than +/- 1mm in either a left/right or forward/backward direction unless you lift them. 2) Place the collection vial rack on the sample tray to the right side of the rinse station aligning to the attachment points.

55 APS-1650 Automated Prep Station Operator s Manual Installing the APS-1650 Collection vial racks vary in models and attach in different fashions. Some attach to pegs in the sample tray while others sit in holes on the sample tray. Regardless of the model rack purchased, the rack should be level and stable on the sample tray. 3) Fill the racks with the appropriate vials. WARNING Establishing External Connections The next step in the installation process involves connecting the APS Automated Preparation Station to the power source and to a host computer. The following sections explain how to establish these connections. Connecting the Automated Prep Station to the Power Source A voltage-specific external desktop power supply is supplied with each APS-1650 Automated Preparation Station. Use only the external desktop power supply or an exact replacement. To connect the automated prep station to a power source, plug the external desktop power supply cord into the power connector located on the back panel of the autosampler. Then, plug the power supply s power cord into a VAC +/-10%, 50/60Hz utility power outlet. Connecting the APS-1650 Automated Preparation Station to the Host Computer You cannot operate the APS-1650 Automated Preparation Station until you establish a communications interface between the autosampler and the host computer. The APS-1650 supports the following two communications protocols: The USB interface is the standard configuration. A virtual COM port is created when using the USB interface. The connection works like a standard RS-232 serial port with the host PC software. Device drivers for the USB interface are included on the Software CD. The serial (RS-232) protocol is an optional configuration. There are two RS-232 serial ports on the APS-1650, and a serial interface kit is shipped with the autosampler. Either interface is acceptable for either device. Check your host computer for available terminals when making your decision. When interconnecting any computing devices, keep the communications cables away from sources of electromagnetic or 3 13

56 APS-1650 Automated Prep Station Operator s Manual Installing the APS-1650 Radio Frequency (RF) interference, such as electric motors, transformers, fluorescent light ballasts or RF energy sources. Establishing an RS-232 Serial Communications Interface The optional serial interface kit includes two interface cables equipped with two modular port adapters each. Use the interface kit to establish a serial communications interface with the host computer. To do so, complete the following steps: 1) Plug one end of the cable into the host computer s serial (COM) port. Finger-tighten both screws of the cable adapter. Note: If a host computer serial port with a DB9F, a DB25M or a DB25F connector (9-pin D-submini receptacle or 25-pin D-submini plug or receptacle) must be used, use the mating connector from the CETAC Technologies universal port adapter kit. You can order the adapter kit from CETAC Technologies, or purchase an adapter locally to convert the serial port to DB9M. Do not use a null modem adapter. 2) Connect the other end of the cable to the APS-1650 COM1 port. Finger-tighten both screws of the cable adapter. 3) Plug one end of the second cable into the host computer s serial (COM) port. Finger-tighten both screws of the capable adapter. 4) Connect the other end of the cable to the Pump Module Box COM1 port. Finger-tighten both screws of the cable adapter. Establishing a USB Communications Interface The APS-1650 Automated Preparation Station is supplied with a USB cable. A cable may also be obtained from any computer store or purchased separately through CETAC. Complete the following steps for the USB interface: 1) Power up both the computer and the APS ) Plug one end of the cable into the host computer s USB port and the other end to the APS-1650 USB port. 3) The computer screen should display New Hardware Found on the screen. Insert the CETAC Installation CD and open the USB drivers. Follow the instructions on the screen. 3 14

57 APS-1650 Automated Prep Station Operator s Manual Installing the APS ) Connect the second USB cable to the host computer and the Pump Module Box. Power on the Pump Module Box. Determining the COM Port being used by the host computer The operating system on the host computer automatically assigns a communications port to each device. 1. Open the Device Manager a. Right clicking on My Computer and select Manage. b. In the Computer Management window, select Device Manager. c. Scroll to the line Ports (COM & LPT). Click on the + sign to expand the contents. 2. Displayed is a listing of all the communications ports on the host computer. (Figure 3-4) 3. Note these settings because they will be required to connect with the Instruo Software to operate the APS Figure 3-4: Communication Ports In Figure 3-4, we can see this computer has two serial ports (COM1, COM2) and one USB port (COM8). 3 15

58 APS-1650 Automated Prep Station Operator s Manual Installing the APS-1650 Installing the Instruo Software The Instruo software is designed to control the APS-1650 Automated Prep Station operations. Follow these instructions for installation. 1) Minimum Hardware Requirements Windows 2000 (Service Pack 3)/Windows XP (Service Pack 2) 128MB for Windows 2000, and 256MB for Windows XP Video running 1024x768 with 256 colors Pentium 600MHz for Windows 2000, 1GHz for Windows XP 2 free COM or USB ports Internet Explorer 6 or higher 2) Installation a. A software CD ships with each unit from CETAC. Insert this CD into the host computer. Note: If you are unable to locate the software CD, contact CETAC Technologies Customer Service at b. Locate the file on the CD named setup.exe and double click. c. Follow the instructions on the screen. d. Go to Start/Programs/Instruo/Instruo Manual to open the manual for the Instruo Software. Read it. Print a copy and keep it with this manual for future reference. Calibrating the Liquid Level Sensor The Liquid Level Sensor is an IR (infrared) light sensor. The sensor sends an IR light beam down to the sample. The light reflects off the sample and is read by the IR sensor to determine the distance to the liquid sample. The IR laser and detector are mounted on the back side of the base unit. The IR light travels through two fiber optic wires to the sensor head mounted to the probe. If the sensor has been moved on the probe, or the probe height has changed (or probe replaced) since the last calibration, the Liquid Level Sensor should be re-calibrated. In addition, calibration should be completed if the probe depth in the sample is too high or too low. The Liquid Level Sensor cannot be used with all rack configurations. It was designed for use with the 45 position sample rack and bottles. The 3 16

59 APS-1650 Automated Prep Station Operator s Manual Installing the APS-1650 Liquid Level Sensor should be turned off or removed when used with the 80 or 90 position sample racks. To turn the Liquid Level Sensor off, refer to the DIP Switch Usage in Chapter 7 Trouble Shooting the Automated Prep Station. Note: Samples with a dull, non-reflective surface may not reflect the IR light and could be problematic for the Liquid Level Sensor to make a correct read. Reflective surfaces between the Liquid Level Sensor and the sample such as the lip of the sample tube may also cause issues with correctly reading the sample level. CETAC Technologies recommends using sample bottles with 30mm opening with no lip at the top. 1) Verify the Liquid Level Sensor height on the probe is correct. Refer to Installation and Removal of the Sample Probe earlier in this chapter. 2) Place a clear liquid sample (water works), and a clean red colored sample, such as transmission oil in the sample rack. 3) Using the Manual Controls in the Instruo software, navigate the probe to the clean sample. Move the probe down 2mm into the clear sample. 4) Locate the Liquid Level Detector on the rear of the unit and open the plastic lid. 5) Set the sensitivity a) There should be two numbers on the detector. One red number and one green number. Press an arrow button on the detector twice. The green light should now be flashing. b) Using the arrow buttons, match the green number to the red number. An exact match is difficult. Plus or minus 30 is an acceptable range. 6) Raise the probe out of the sample. 7) In the Instruo Software, mark the box Level Sensor Enabled 8) Add 15mm to the probe depth and tell the probe to go down. a) The probe should stop in roughly the same position (2mm below the surface) b) If the probe goes too deep or too shallow, start over at step 5. 9) With the Liquid Level Sensor box still checked in the Instruo software, move the probe to the clean red sample and go down 15mm below the surface. a) The probe should stop roughly 2-7mm into the sample. b) If the probe goes too deep or too shallow, start over at step 5. 10) The liquid level sensor is now calibrated. In the Instruo Method, the Sample Probe Depth Uptake can be set to 135mm. The Liquid Level Sensor will detect the sample surface and stop 2mm into each sample regardless of the sample volume. 3 17

60

61 4 Verifying Installation

62

63 APS-1650 Automated Preparation Station Operator s Manual Verifying Installation Verifying Installation Once installation of the APS-1650 Automated Preparation Station is complete, it is important to verify that you have installed it correctly. Attempting to use it before ensuring that it is installed correctly may result in damage to the autosampler. Verifying installation of the autosampler consists of two parts: Ensuring that the communications interface between it and the host computer is working. Ensuring that the sample probe and stirring assembly function properly. This chapter explains how to test the above items before using the autosampler. Note: The procedures given in this chapter are for use in a Windows environment. Testing the Interface If the communications interface between the automated prep station and the host computer is not established correctly, the autosampler will not function. Before you test the interface, ensure that the communication port connectors are properly attached between the host computer and the automated prep station. 4 3

64 APS-1650 Automated Preparation Station Operator s Manual Verifying Installation Note: The following procedures assume that you started the Windows operating system and the Program Manager window is showing. To test the communications interface, complete the following steps: 1) Start the host computer and go to the main Windows screen. 2) Turn on power to the automated prep station. 3) Click the start button in the lower left corner of the Program Manager window. a) A selection list will appear. 4) Select rograms/accessories/communications/hyperterminal and double-click. a) The HyperTerminal window appears (Figure 4 1). Figure 4 1. Example of HyperTerminal Window. 4 4

65 APS-1650 Automated Preparation Station Operator s Manual Verifying Installation 5) Double click on the Hyperterminal icon. a) The Connection Description box appears (Figure 4 2). Figure 4 2. Connection Description Box. 6) Type the name COM_test for the connection and choose an icon from the list given, and click OK. The phone number box appears (Figure 4-3). 4 5

66 APS-1650 Automated Preparation Station Operator s Manual Verifying Installation Figure 4-3. Phone Number Box. 7) Select Direct to COM in the Connect Using box. Click OK. The COM Properties box appears (Figure 4-4). Figure 4-4. COM Properties Box. 4 6

67 APS-1650 Automated Preparation Station Operator s Manual Verifying Installation 8) Change the bits per second to 9600, set the data bits to eight, the parity to none, the stop bits to one, the flow control to none, and click OK. 9) Select File/Properties. The COM_Test Properties box appears. 10) Select Settings on the COM_Test Properties box and click on the ASCII setup button on the lower right of the box. The ASCII setup box appears (Figure 4-5). Figure 4-5. ASCII Setup Box. 11) In the ASCII Setup box, select the following items: a) Echo typed characters locally. b) Append line feeds to incoming line ends. c) Wrap lines that exceed terminal width. d) Click OK. 4 7

68 APS-1650 Automated Preparation Station Operator s Manual Verifying Installation 12) Click OK on the COM_Test Properties box. 13) Type the command home at the cursor in the upper left of the main HyperTerminal screen and press Enter. The autosampler resets, with the sample probe moving out and back into the home position. If the autosampler does not reset, see Chapter 7, Troubleshooting the Automated Prep Station. 14) Now change the COM port to the correct port used by the Syringe Module Box, reconnect through HyperTerminal, and type the command ver. The Syringe Module Box will return a status. If nothing is returned, see Chapter 7, Troubleshooting the Automated Prep Station. Checking the Automated Prep Station Components The following components may be damaged during shipping or installation: the sample probe, the peristaltic pump tubing, and the rinse station and tubing. It is important that you check these components for damage before you operate the automated prep station. To do so, complete the following steps: 1) Shut down and unplug the system. 2) Visually inspect the sample probe, peristaltic pump tubing, and rinse station and tubing for leaks or signs of damage. If you detect a leak or other damage to an autosampler component, you must replace it. For more information, see the appropriate section in Chapter 6, Maintaining the Automated Prep Station. 4 8

69 APS-1650 Automated Preparation Station Operator s Manual Verifying Installation Testing the Sample Probe The sample probe must descend into the center of each sample vial to ensure satisfactory sample uptake. Rough handling in shipment can disturb the autosampler s cabinet-to-base alignment. If it is incorrectly aligned, the sample probe will not function properly. It is therefore important to test the sample probe before you actually run samples with the autosampler. Note: Before testing the sample probe, ensure that you have installed all system components correctly. Also, ensure that you have securely tightened all thumbscrews and connected the communications cable from the host computer to the COM1 port on the automated prep station. Testing the sample probe involves observing the operation of the sample probe. To do so, complete the following steps: 1) Turn the autosampler power switch on and verify that the LED power indicator is on. The LED power indicator is green in color. The indicator is located behind the Z-Drive assembly when it is in the home position. 2) Using the Manual controls in the Instruo control software, command the probe down 40 in the home position. In small increments, experiment sending the probe to go deeper and deeper until the probe goes into the port on the rinse station. If at any point it is obvious the probe is going to hit the rinse station instead of the port, stop and contact Customer Support. 3) Repeat step 3 for the stirring paddle. Note: If the autosampler alignment is not correct, contact CETAC Technologies Customer Service and Support or an authorized representative. 4 9

70 APS-1650 Automated Preparation Station Operator s Manual Verifying Installation 4 10

71 5 Using the Automated Prep Station

72 APS-1650 Automated Preparation Station Operator s Manual Using the Automated Prep Station 5 2

73 APS-1650 Automated Preparation Station Operator s Manual Using the Autosampler Using the APS-1650 The APS-1650 Automated Prep Station is both reliable and easy to use. Before using it, however, ensure that your lab environment provides operating conditions that will prolong the life of the APS Once the proper operating conditions are met, you can arrange the sample vial racks and start the autosampler sequence run. When you finish using the autosampler, you may need to flush the rinse station and flow path before shutting the system down. This chapter explains how to create the proper operating conditions for using the APS-1650 Automated Prep Station. It also explains how to arrange the sample vial racks, start and shut down the unit, and flush the rinse station and flow path. Establishing Optimal Operating Conditions The APS-1650 Automated Preparation Station operates reliably even under less than ideal conditions. It is not, however, indestructible. Malfunction or damage can occur if specific operating conditions are not met. Meeting these conditions requires that you create the proper lab environment, replace autosampler components that wear out under normal use, and purchase the appropriate supplies for use with the automated prep station. The following sections explain how to meet these conditions. Note: Damage or malfunction that results from unsatisfactory operating conditions may constitute misuse and abuse and be excluded from warranty coverage. 5 3

74 APS-1650 Automated Preparation Station Operator s Manual Using the Automated Prep Station Creating the Lab Environment To create satisfactory operating conditions in your lab environment, follow these guidelines: Operate the APS-1650 in a conventional lab environment where the temperature is F (10 35 C), the humidity is 20 70% non-condensing, and the unit is not exposed to excessive flammable or corrosive materials. Avoid rough handling of the APS If possible, do not expose the autosampler to vibration or shock. Protect the autosampler from long-term exposure to condensation, corrosive materials, solvent vapor, continual standing liquids, or large spills into the autosampler cabinet or arm. Exposures of this type can damage the drive mechanisms as well as the electronics. Observe the same general electrostatic discharge precautions as with any other integrated circuit electronic devices. Low humidity environments, especially when combined with static-generating materials, require maximum care. WARNING Discharge static buildup and ground to the autosampler base or cabinet before performing any maintenance. Do not touch or short-circuit bare contacts, COM1, DILUTOR, or auxiliary ports. Avoid using the APS-1650 if strong electromagnetic interference, radio frequency interference, or radioactivity is present. Interference fields can cause erratic operation of the unit. The APS will not function properly if the level of radioactivity is above background. 5 4

75 APS-1650 Automated Preparation Station Operator s Manual Using the Autosampler Replacing Auto Sampler Components The following APS-1650 components wear out under normal use and must be replaced periodically. Peristaltic pump tubing Sample probe Drip Cup Control Rod Springs in the Z-Drive Assembly If you fail to replace these components when they deteriorate, the autosampler will not function properly. For information about replacing autosampler components, see Chapter 6, Maintaining the APS Purchasing Supplies Because the life-span of the sample vials varies, you should maintain an adequate supply of spare vials. When you need to purchase additional supplies, it is extremely important that you choose the appropriate sizes and materials. When you purchase sample and/or standards vials, make sure they meet the following requirements: The diameter of the sample vial matches the rack size you are using. The height does not exceed 125 millimeters. The material is compatible with the samples you are analyzing or the reference standards you are using. This requirement also applies to the peristaltic pump tubing. WARNING Use of mismatched sample vials and sample vial racks may result in malfunctions or sample spills. Be sure your vials meet the given requirements. 5 5

76 APS-1650 Automated Preparation Station Operator s Manual Using the Automated Prep Station To order additional supplies, refer to the CETAC Accessories and Supplies Catalog for the APS-1650 Automated Preparation Station which can be found on the installation CD or Arranging the Sample Vial Racks You can change the arrangement of the sample vial racks to meet your needs. The APS-1650 accommodates one sample vial rack of 45, 80, or 90 positions each. It accommodates one sample collection rack of 80, or 90 positions each. The automated prep station physically accepts any and all size combinations and arrangements of sample vial racks. However, you can use racks of mixed sizes only if the Instruo software enables you to do so. A custom rack file may need to be created to work with the rack of your choice. For more information about placing sample vial racks in the sample tray, see Chapter 3, Installing the Autosampler. For more information on working with custom rack solutions, see the Instruo Software Manual. CAUTION Incorrectly defining the sample rack layout can result in sample spills, damage to the unit, and invalid analysis results. Starting the Automated Prep Station Once you arrange the sample vial racks and ensure that the arrangement is correctly defined in the software, you can start the autosampler and let it run until the sampling sequence is finished. To do so, complete the following steps: 5 6

77 APS-1650 Automated Preparation Station Operator s Manual Using the Autosampler 1) Ensure that the rinse station is properly connected. For more information about proper connections, see Chapter 3, Installing the Autosampler. 2) Turn the APS-1650 Automated Preparation Station power switches on. The green LED indicator along the autosampler X-Axis lights up when the power is on. The green LED on the Syringe Module will also light up when power is on. 3) Open the Instruo Software and load the desired Method and Sequence. Refer to the Instruo Software Manual with question on Method and Sequence setup. 4) Purge air from the system a) Ensure rinse and diluent uptake tubing and drain tubing are inserted into the correct containers. b) Using the Direct Controls in Instruo, Purge the Rinse and Syringe Pump until all air is removed from the tubing. Refer to the Instruo Software Manual as needed. 5) In the Instruo software, execute the sequence. The APS-1650 runs until it reaches the end of the sampling sequence. 5 7

78 APS-1650 Automated Preparation Station Operator s Manual Using the Automated Prep Station Shutting Down the Autosampler To shut down the autosampler, complete the following steps: 1) Drain the rinse system by removing the rinse solution uptake tubing from the rinse solution source. Using the Direct Hardware Control in Instruo, let the peristaltic pump run until all solution drains from the tube attached to the rinse station outlet. 2) Using the Direct Hardware Control in Instruo, empty the syringe pump. 3) Release the pressure shoe on the peristaltic pump. Releasing the pressure shoe decreases wear on the pump tubing. 4) Shut down the Instruo software. 5) Turn off the APS-1650 power switch and the power switch on the Syringe Module Box. Flushing the Rinse Station and Flow Path Generally, you can operate the APS-1650 without flushing the rinse system. Under normal circumstances, you can simply drain the rinse system prior to shutting down the autosampler. However, you need to flush the rinse station and flow path during initial startup of the APS Automated Prep Station after installation. Flushing the rinse system during initial startup of the APS-1650 Automated Prep Station removes any contaminants that could cause interference during sample analysis. To flush the rinse station and flow path, complete the following steps: 5 8

79 APS-1650 Automated Preparation Station Operator s Manual Using the Autosampler 1) Insert the rinse uptake tubing into the rinse solution or Isopropyl alcohol. 2) Run the rinse solution through the rinse station and flow path for 5 to 10 minutes. Once you flush the rinse system, you can proceed with the sampling sequence or drain the rinse system as part of the shutdown procedure. 5 9

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81 6 Maintaining the APS-1650 Automated Preparation Station

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83 APS-1650 Automated Preparation System Operator s Manual Maintaining the Automated Prep Station Maintaining the APS-1650 Automated Preparation Station Routine maintenance of the APS-1650 consists of daily and weekly cleaning of specific autosampler components. Routine maintenance also includes checking APS-1650 components for leaks or other damage. Additional periodic maintenance tasks may be required, including replacement of the following autosampler components: peristaltic pump tubing, sample probe, locking springs in the Z-Drive Assembly, rinse station tubing, and sample tray. This chapter explains how to clean the APS-1650, inspect it for leaks, and replace damaged components. WARNING Discharge static buildup and ground to the autosampler base or cabinet before performing any maintenance. Do not touch or short-circuit bare contacts, COM1, Dilutor, or auxiliary ports. Cleaning the Automated Prep Station Cleaning the APS-1650 is the primary maintenance task you perform. Failure to do so regularly causes increased wear and reduces the automated prep station s life. You must clean the APS-1650 both daily and weekly to prevent damage and extend its life. It is especially important to clean up spills and remove contaminants, such as abrasives, from the autosampler s moving parts. It may also be necessary to chemically neutralize spills. The following sections explain daily and weekly cleaning procedures. 6-3

84 Daily External Cleaning Use of the APS-1650 often results in spills on autosampler components such as the sample tray. Good maintenance requires that you clean the autosampler daily. To do so, complete the following steps: 1) Shut down and unplug the autosampler. For information about shutting down the Autosampler, see Chapter 5, Using the Autosampler. 2) Wipe the sample base, rack adapter plate, autosampler cabinet, pump module box, and Y-arm using a towel dampened with a lab-grade cleaning agent. CAUTION Do not allow the cleaning agent to come into contact with the lead screws. Also, never lubricate either of the two lead screws. 3) Repeat step two, using a towel dampened with clean water or Isopropyl alcohol. This process removes any remaining contaminants. 4) Dry the sample base, rack adapter plate, autosampler cabinet, pump module box, and Y-arm using a dry towel. The APS-1650 must be thoroughly dry before you turn the autosampler power on. Weekly Cleaning Although cleaning it daily removes spills and contaminants from most of the automated prep station components, it is necessary to clean the APS-1650 more thoroughly once a week. To do so, complete the following steps: 6-4

85 APS-1650 Automated Preparation System Operator s Manual Maintaining the Automated Prep Station 1) Shut down and unplug the system. 2) Remove the sample tray. 3) Wipe loose particles off the Y-Axis lead screw with a dry, lint-free cloth. The Y-Axis lead screw is a large metal screw located inside the Autosampler arm tubing, as shown in Figure 6 1. Figure 6 1. Z-Drive Assembly on the Autosampler Y-Arm. 6-5

86 WARNING Never lubricate the lead screws. The lead screw nuts are compounded with a dry film lubricant. Oiling the lead screws will cause gumming, galling, and binding of the sample probe assembly. 4) Wipe the automated prep station exterior until it is clean, using a towel dampened with a lab-grade cleaning agent, followed by a towel dampened with clear water. Pay special attention to the slider block and guide rails along the tube of the autosampler arm. 5) Wash the rack adapter plate in a warm detergent solution. Make sure you remove all spills and stains. 6) Rinse the rack adapter plate with water and then dry it. Ensure that the sample tray is thoroughly dry. 7) Replace the rack adapter plate on the autosampler base. Checking for Leaks Several of the automated prep station components have a limited life and will wear out under normal use: the sample probe, the peristaltic pump tubing, and the rinse station and tubing. Standard maintenance procedures require that you periodically check these components for leaks. To do so, complete the following steps: 1) Run the Rinse Pump in the pump module box using the manual controls in the Instruo software until the rinse solution is coming out of the probe. 2) Wait 2 minutes and inspect the probe for drips. 3) Restart the Rinse Pump in the Instruo software. If there is a delay before the rinse solution exists the probe check all fittings for leaks. 6-6

87 APS-1650 Automated Preparation System Operator s Manual Maintaining the Automated Prep Station If you detect a leak or other damage to an autosampler component, you must replace it. For more information, see the appropriate section in this chapter. Replacing Peristaltic Pump Tubing Routine maintenance of the APS-1650 Automated Preparation Station includes replacement of the peristaltic pump tubing. Because of the operating nature of peristaltic pumps, the tubing will probably be the most frequently replaced item on the autosampler. If you use strong bases, acids, or solvents as rinsing agents, the tubing may break down rapidly. To replace the peristaltic pump tubing, complete the following steps: 1) Shut down and unplug the autosampler. 2) Release the pressure shoe on the peristaltic pump and remove the old tubing. Carefully pull or cut the old tubing to remove it. 3) Replace the pump tubing by pushing the new tubing onto the mounting block fittings. Replace the new tubing carefully. Damage can result if you apply too much force. 4) Reconnect the pressure shoe. Replacing the Sample Probe You must replace the sample probe if it is leaking or shows other signs of deterioration. To do so, complete the following steps: 1) Shut down and unplug the autosampler. 6-7

88 2) Remove the Liquid Level Sensor from the probe. 3) Remove the old sample probe and tubing. Be careful not to use excessive force when removing the sample probe. Applying too much force can result in damage to the Z-Drive assembly. 4) Install the new sample probe. 5) Replace the Liquid Level Sensor and calibrate. For information about installing the sample probe an Liquid Level Sensor calibration, see Chapter 3, Installing the Autosampler. Replacing the Rinse Station Tubing If the rinse station tubing is typically exposed to deionized water as a rinsing agent, you do not need to replace it often. However, if you use other rinsing agents, such as acids or solvents, the tubing is likely to deteriorate more rapidly. To replace the rinse station tubing, complete the following steps: 1) Shut down and unplug the autosampler. 2) Disconnect the rinse solution uptake and drain tubing. Apply only a linear force when removing the tubing to prevent the fittings from breaking. 3) Remove the rinse station block by removing the screw from the mounting bracket. 6) Connect the rinse solution uptake and drain tubing. Apply only a linear force when replacing the tubing to prevent the fittings from breaking. 6-8

89 7 Troubleshooting the Automated Prep Station

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91 APS-1650 Automated Prep Station Operator s Manual Troubleshooting the Automated Prep Station Troubleshooting the APS-1650 The APS-1650 Automated Preparation Station is both easy to operate and reliable. However, problems with it may occur. When the autosampler does not function properly, isolate the problem to determine if it originates in the host computer, the analytical instrument, the RS-232 cable, or the autosampler. If you determine the problem is in the APS-1650, check the power system, the communications interface, or the sample probe assembly to find the cause of the problem and resolve it. This chapter explains how to troubleshoot APS-1650 problems. If you cannot solve a problem using the steps given in this chapter, contact CETAC Technologies Customer Service and Support at A complete catalog of accessories and supplies is included on the installation CD, or can be found at Power System Problems A possible cause of APS-1650 malfunction is a problem in the power system. If the autosampler is not functional, there may be no power getting to it. If this is the case, the green LED power indicator will be off. To troubleshoot this problem, complete the following steps: 1) Check the wall outlet and see if the external power supply is plugged in. 2) Ensure the power switch of the external power supply is turned on

92 APS-1650 Automated Prep Station Operator s Manual Troubleshooting the Autosampler Interface Problems Operation of the APS-1650 is directed by the host computer. A malfunction of the autosampler can indicate a problem with the RS-232 cable or with the configuration of the software on the host computer. The following sections explain how to troubleshoot these problems. RS-232 or USB Cable Problems The first step in troubleshooting interface problems is to check the RS-232 cable. To do so, complete the following steps: 1) Check the autosampler power switch to ensure it is on. 2) Check the communications cable to ensure it is plugged in to the correct port on the autosampler. If the cable is plugged in, ensure that it is tightened properly. 3) Check the host computer to ensure that the communications cable is connected to the appropriate COM port. If the cable is plugged in, ensure that it is tightened properly. For more information about connecting the RS-232 cable, see Chapter 3, Installing the Autosampler. Software Configuration Problems If the RS-232 cable is connected properly and the autosampler is still not communicating with the host computer, ensure that the Instruo software is configured correctly. To do so, complete the following steps: 1) Verify communications in Hyper Terminal. If the wrong port or baud rate is selected, change the configuration. For information about changing the software configuration, see Chapter 4, Verifying Installation

93 APS-1650 Automated Prep Station Operator s Manual Troubleshooting the Automated Prep Station 2) Run the Instruo software and ensure that the instrument is functioning properly. Z-Drive Assembly Problems An APS-1650 malfunction may be caused by a problem in the Z-Drive assembly. You can easily determine that a malfunction is related to the Z-Drive assembly if you hear a loud chattering noise when the APS-1650 power switch is on or if the sample probe is not moving. To troubleshoot Z-Drive assembly problems, complete the following steps: 1) Ensure that the Y-Axis slider block and Z-Drive assembly are installed. If the Z-Drive assembly is not installed, follow the instructions provided in Chapter 3, Installing the Autosampler, to install it. If the Z-Drive assembly is already installed, continue with step two. 2) Check the Y-Axis position magnet for damage. The home position magnet is attached to the Z-Drive assembly. If the magnet is damaged or blocked, you must replace or clean the assembly. For information about mounting the Y-Axis slider block on the autosampler are, see Chapter 3, Installing the Autosampler. If the home position flag is undamaged, continue with step three. 3) Ensure the sample probe block and stirrer block move freely up and down the Z-Drive assembly. If the assembly is binding and cannot be corrected, contact customer service. Note: If you cannot free the Z-Drive assembly, you will need to replace it. See Chapter 3, Installing the Autosampler, for information about mounting a new Z-Drive assembly. You can order a new Z-Drive assembly from CETAC Technologies

94 APS-1650 Automated Prep Station Operator s Manual Troubleshooting the Autosampler Drip Cup Problems Should the drip cup swing out too soon, too late, or operate in any other unusual manor, check the locking spring located at the top of the control rod just below the Z-Drive motor assembly. Replace the spring if broken, worn, or damaged. 1) Turn the power off and unplug the power supply. 2) Remove the drip cup. 3) Slide the probe block down to the lower end of its travel. 4) Lift up on the control rod compressing the spring. 5) Rotate the drip cup holder past its normal rotation toward the Y-Arm. 6) Lower the control rod and replace the spring. 7) Press the control rod up compressing the spring. 8) Rotate the drip cup holder back to its original position and release the control rod. 9) Slide the probe block up and down several times to confirm proper operations. 10) Plug in the power supply and turn on the power

95 APS-1650 Automated Prep Station Operator s Manual Troubleshooting the Automated Prep Station Dip Switch Settings The APS-1650 Automated Preparation Station has two banks of DIP switches located under the potentiometers on the rear of the unit. A Philips screw driver is required to remove the panel to gain access. The DIP Switches control various setting as outlined below. Always power off the unit prior to making DIP Switch changes. Small 5-DIP bank (not pictured) Level Sensor Present (APS-1650) Level Sensor NOT Present (1650) Off On 7-- 7