Tissue-Tek VIP 6 Service Manual June 2009

Information contained in this service manual is designed for use by properly trained service personnel using appropriate tools and test equipment. If you do not possess the proper training or tools, do not attempt to service this instrument.

© 2010 Sakura Finetek USA, Inc. All Rights Reserved Printed in U.S.A.

Manufactured for: Sakura Finetek USA, Inc., Torrance, CA 90501 U.S.A. Sakura Finetek Japan Co., Ltd., Tokyo, 135-0007, Japan Sakura Finetek Europe B.V., 2408 AV Alphen aan den Rijn, NL Made in Japan

AH9-IF-001-01

Table of Contents Chapter 1

Page

Operating Principles ····································································· 1-1

1-1 Overview ······························································································· 1-1 1-1-1 Tubing System ·························································································· 1-4 1-1-2 Electrical System ······················································································ 1-7 1-2 Operation of Each Part ················································································· 1-7 1-2-1 Rotary Valve ······························································································ 1-7 1-2-1-1 Overview ······························································································· 1-7 1-2-1-1 Components ························································································ 1-8 1-2-1-3 Port Position ························································································· 1-9 1-2-1-4 Operation Flowchart ············································································· 1-11 1-2-1-5 Temperature Control ············································································· 1-12 1-2-2 Gate Valve ································································································ 1-13 1-2-2-1 Overview ······························································································ 1-13 1-2-2-2 Components ························································································· 1-13 1-2-2-3 Valve Positions ····················································································· 1-15 1-2-2-4 Operation Flowchart ············································································· 1-16 1-2-2-5 Temperature Control ············································································· 1-17 1-2-3 Air Unit ······································································································ 1-18 1-2-3-1 Overview ······························································································· 1-18 1-2-3-2 Pressurization Control ·········································································· 1-20 1-2-3-3 Depressurization Control ······································································ 1-20 1-2-3-4 Occurrence of Pump Abnormality ························································ 1-21 1-2-3-5 Pressure Regulator ··············································································· 1-21 1-2-3-6 Solenoid Valves SV4, SV5 ··································································· 1-21 1-2-3-7 Solenoid Valve SV6 ·············································································· 1-21 1-2-3-8 Pressure Control Conditions ································································ 1-22 1-2-4 Exhaust Manifolds and Coupler ······························································· 1-23 1-2-4-1 Overview ······························································································· 1-23 1-2-5 Bottle Illumination ····················································································· 1-25 1-2-5-1 Overview ······························································································ 1-25 1-2-6 Retort Lid Heater ······················································································ 1-27 1-2-6-1 Overview ······························································································· 1-27 1-2-6-2 Current Detection Part ·········································································· 1-28 1-2-6-3 Temperature Sensor Detection Part ····················································· 1-29 1-2-7 Retort Heater ······························································································ 1-30 1-2-7-1 Overview ································································································· 1-30 1-2-7-2 Over-Temperature Protector ································································· 1-32 1-2-7-3 Temperature Sensor Detection Part ······················································· 1-33 1-2-7-4 Temperature Control Method ································································ 1-33 1-2-8 Level Sensor ······························································································· 1-34 1-2-8-1 Overview ······························································································· 1-34 1-2-8-2 Ultrasonic Sensor ··················································································· 1-36 1-2-9 Oven Heater ······························································································· 1-37 1-2-9-1 Overview ································································································· 1-37

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1-2-9-2 Over-temperature Protector ································································· 1-39 1-2-9-3 Temperature Sensor Detection Part ····················································· 1-39 1-2-9-4 Temperature Control Method ································································ 1-39 1-2-10 Cleaning Xylene Heaters ·········································································· 1-40 1-2-10-1 Overview ································································································· 1-40 1-2-10-2 Over Temperature Protector ··································································· 1-42 1-2-10-3 Temperature Sensor Detection part ····················································· 1-42 1-2-10-4 Temperature Control Method ································································ 1-42 1-2-11 Control Box ································································································· 1-43 1-2-11-1 Overview ······························································································· 1-43 1-2-11-2 CPU Board ···························································································· 1-44 1-2-11-3 Heater Driver Board ··············································································· 1-50 1-2-11-4 LCD Unit ······························································································· 1-52 1-2-11-5 Touch Panel Unit ·················································································· 1-53 1-2-11-6 LCD Relay Board ·················································································· 1-54 1-2-11-7 Interface Board ····················································································· 1-55 1-2-11-7-1 Ethernet (LAN) ············································································· 1-56 1-2-11-7-2 Serial Port ····················································································· 1-56 1-2-11-7-3 External Output/Alarm ···································································· 1-57 1-2-11-7-4 UPS Input ····················································································· 1-61 1-2-12 Bulk Reservoir ···························································································· 1-62 1-2-12-1 Overview ································································································· 1-62 1-2-13 Retort Lid Interlock ···················································································· 1-64 1-2-13-1 Overview································································································ 1-64

1-3 Each Function Operation Explanation ·························································· 1-65 1-3-1 Pumping-in ································································································ 1-65 1-3-1-1 Overview ································································································· 1-65 1-3-1-2 Operation ······························································································ 1-66 1-3-2 Pumping-out ······························································································· 1-69 1-3-2-1 Overview ································································································· 1-69 1-3-2-2 Operation ······························································································ 1-69 1-3-3 Bottle Check ····························································································· 1-72 1-3-3-1 Overview ································································································· 1-72 1-3-3-2 Operation ································································································ 1-73 1-3-4 Fume Control ···························································································· 1-74 1-3-4-1 Overview ································································································· 1-74 1-3-4-2 Configuration ·························································································· 1-75 1-3-5 P/V Cycle ·································································································· 1-76 1-3-5-1 Overview ································································································· 1-76 1-3-5-2 Operation ······························································································ 1-76 1-3-6 Mixing ········································································································ 1-78 1-3-6-1 Overview ································································································· 1-78 1-3-6-2 Operation ······························································································ 1-79 1-3-7 Solution Manager ······················································································ 1-80 1-3-7-1 Overview ································································································· 1-80 1-3-7 -2 Operation ······························································································ 1-81 1-3-8 Paraffin Melt Check ·················································································· 1-85 1-3-8-1 Melting of Paraffin ·················································································· 1-85

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1-3-8-2

Standby Mode upon Paraffin Solidification after Recovery of Power Following Power Failure ······················································································· 1-85 1-3-8-3 Adding Paraffin and Paraffin Melt Check Operation ···························· 1-87 1-3-8-4 Operation upon Adding Solid Paraffin with System Power Supplied ··· 1-90 1-3-8-5 Automatic Operation While Waiting for Paraffin to Melt ······················· 1-91 1-3-9 Cleaning ···································································································· 1-93 1-3-9-1 Retort Cleaning ················································································· 1-93 1-3-9-2 Warm Water Flush ············································································ 1-94 1-3-9-3 Rinsing ·································································································· 1-95 1-3-10 Solution Exchange ···················································································· 1-96 1-3-10-1 External Drain ······················································································· 1-96 1-3-10-2 External Fill ··························································································· 1-97 1-3-10-3 Fill from Bulk Reservoir ········································································ 1-97 1-3-10-4 Drain & Fill from Bulk Reservoir ··························································· 1-99 1-3-10-5 Automatic Transfer ··············································································· 1-100 1-3-10-6 Paraffin Drain ························································································ 1-101 1-3-10-7 Bulk Reservoir Fill ················································································· 1-102 1-3-11 Bulk Reservoir Fill ····················································································· 1-103 1-3-11-1 Overview ································································································· 1-103 1-3-11-2 Operation ······························································································ 1-104 1-3-12 Drain from Condenser to Condensate Bottle ··········································· 1-105 1-3-12-1 Overview ································································································· 1-105 1-3-11-2 Operation ······························································································ 1-106 1-3-13 Paraffin Drain to Wax Drain Container ····················································· 1-107 1-3-13-1 Overview ································································································· 1-107 1-3-13-2 Operation································································································ 1-108

1-4

Flowchart ······································································································· 1-109

Chapter 2

Service Operations ······································································· 2-1

2-1 Software/Data Update ············································································ 2-1 2-1-1 Software Update ······················································································· 2-1 2-1-2 Data Backup ····························································································· 2-7 2-1-3 Data Update ······························································································ 2-9 2-1-4 Data Exchange between Systems ··························································· 2-12 2-2 Service Settings ····················································································· 2-18 2-2-1 Disabling and Enabling “Ignore Level Sensor” ········································· 2-18 2-2-2 Clearing Level Sensor Error ····································································· 2-23 2-2-3 Resetting Information on Dirty Retort with Paraffin ·································· 2-24 2-2-4 Resetting Information on Reagent in Retort ············································· 2-25 2-3 Memory Reset ························································································ 2-26 2-4 Manual Operations ················································································· 2-28 2-4-1 User Manual Operations ··········································································· 2-28 2-4-2 Service Manual Operations ······································································ 2-31 2-5 Check Program ······················································································ 2-38 2-5-1 Startup Method of Check Program ··························································· 2-38 2-5-2 Screen Configuration ················································································ 2-39 2-5-3 Check Program Function ·········································································· 2-43 2-5-4 Error List ··································································································· 2-75 2-6 Check on External Alarms/External Signal Output ·································· 2-76 - iii -

Chapter 3 System Alarms and Errors ·································································· 3-1 3-1 System Alarms ······················································································· 3-1 3-1-1 Alarm to Inform of Error ············································································ 3-1 3-1-2 Alarm to Indicate Warning ········································································ 3-3 3-1-3 Alarm to Call Operator’s Attention ···························································· 3-8 3-1-4 Notice of the Status of System that Affects Instrument Operation ············· 3-11 3-2 Error Information ···················································································· 3-16 3-2-1 Display of Error Information ······································································ 3-16 3-2-1-1 Error log screen ······················································································ 3-16 3-2-1-2 Error desicription screen ······································································ 3-17 3-2-1-3 Run history screen ················································································ 3-17 3-3 Troubleshooting ······················································································· 3-19 3-3-1 List of Malfunction ····················································································· 3-19 3-3-1-1 Malfunction with error number································································ 3-19 3-3-1-2 Malfunction without error number··························································· 3-131 3-4 Maintenance Information·········································································· 3-180 3-4-1 Export Data Screen ···················································································· 3-180 3-4-2 Solution Usage List····················································································· 3-181 3-4-3 Parts Usage List ························································································· 3-182 3-4-4 Error Log Report ························································································· 3-183 3-4-5 Keystroke Log Report ················································································· 3-184 3-4-6 Temperature Log Report ············································································ 3-189 3-4-7 Retort Pressure Log Report ······································································· 3-190 3-4-8 Part Status Screen······················································································ 3-192

Chapter 4

Disassembly, Repair and Adjustment ··········································· 4-1

4-1 Overview ·································································································· 4-1 4-2 Retort Lid ······························································································· 4-4 4-2-1 Replacing the Retort Gasket ···································································· 4-4 4-2-2 Adjusting the Retort Lid Hook ··································································· 4-5 4-2-3 Replacing the Retort Lid Lever ································································· 4-7 4-2-4 Replacing the Retort Lid Cover ································································ 4-9 4-2-5 Replacing the Hinge Spring ······································································ 4-11 4-2-6 Replacing the Lid Heater ·········································································· 4-13 4-2-7 Replacing the Lid Sensor Board ······························································· 4-15 4-2-8 Replacing the Solenoid ············································································· 4-18 4-2-9 (Deleted) 4-2-10 Maintaining the Latch and Replacing the Latch Collar ····························· 4-20 4-3 Retort ····································································································· 4-23 4-3-1 Replacing the Ultrasonic Sensor ······························································ 4-23 4-3-2 Replacing the Ultrasonic Sensor Board ··················································· 4-26 4-3-3 Disassembling the Retort ········································································· 4-28 4-3-4 Replacing the Fill Tube Heater Unit and Drain Tube Heater Unit ············ 4-35 4-3-5 Replacing the Retort Temperature Sensor and Over-temperature Protector ···················································································································· 4-38 4-4 Paraffin Oven ··························································································· 4-40 4-4-1 Replacing the Oven Door Sensor ····························································· 4-40 4-4-2 Replacing the Oven Door Gasket ····························································· 4-42 - iv -

4-4-3 Replacing the Oven Heater and Temperature Sensor ····························· 4-43 4-5 Paraffin Container ·················································································· 4-49 4-5-1 Replacing the O-ring in the Connection Tube ·········································· 4-49 4-6 Bottle Rack and Base ············································································· 4-51 4-6-1 Replacing and Adjusting the Bottle Rack Door ········································ 4-51 4-6-2 Cleaning the Inside of the Bottle Rack ····················································· 4-53 4-6-3 Replacing the Wax Drain Container Indicator ·········································· 4-56 4-6-4 Replacing the Xylene Heater ···································································· 4-57 4-6-5 Replacing the Reagent Bottle LED ··························································· 4-60 4-7 Wax Drain Container ·············································································· 4-61 4-7-1 Handling the Wax Drain Container ····························································· 4-61 4-7-2 Replacing the Wax Drain Container Sensor ············································· 4-64 4-8 Reagent Bottle ······················································································· 4-66 4-8-1 Cleaning the Bottle Coupler and Replacing the O-ring ···························· 4-66 4-8-2 Replacing the Bottle Cap Gasket and PTFE Sheet ································· 4-68 4-8-3 Cleaning the Reagent Bottle ····································································· 4-69 4-9 Bulk Reservoir ························································································ 4-70 4-9-1 Draining the Bulk Reservoir ······································································ 4-70 4-9-1-1 Draining the bulk reservoir via the retort ·············································· 4-70 4-9-1-2 Draining the bulk reservoir directly ······················································· 4-73 4-9-2 Replacing the Level Sensor ······································································ 4-76 4-9-3 Cleaning and Replacing the Safety Valve (Teflon Ball) ···························· 4-78 4-9-4 Replacing the Bulk Reservoir ··································································· 4-80 4-9-5 Checking the Function of the Level Sensors ············································ 4-84 4-9-6 Cleaning the Bulk Reservoir ····································································· 4-85 4-10 Rotary Valve/Gate Valve ·········································································· 4-87 4-10-1 Replacing the Motor ··················································································· 4-87 4-10-1-1 Replacing the rotary valve motor ·························································· 4-87 4-10-1-2 Replacing the gate valve motor ···························································· 4-90 4-10-2 Maintaining the Rotary and Stationary Disks, Valve Housing and O-rings ···················································································································· 4-92 4-10-2-1 Rotary valve ·························································································· 4-92 4-10-2-2 Gate valve ····························································································· 4-102 4-10-3 Replacing the Cartridge Heater ································································ 4-110 4-10-3-1 Replacing the rotary valve cartridge heater ········································· 4-110 4-10-3-2 Replacing the gate valve cartridge heater ············································· 4-113 4-10-4 Replacing the Over-temperature Protector ·············································· 4-116 4-10-4-1 Replacing the rotary valve over-temperature protector ························· 4-116 4-10-5 Replacing the Temperature Sensor ·························································· 4-120 4-10-5-1 Replacing the rotary valve temperature sensor ··································· 4-120 4-10-5-2 Replacing the gate valve temperature sensor ····································· 4-122 4-10-6 Cleaning the Flow Tubes ·········································································· 4-124 4-11 Exhaust Manifold, Condenser and Trap Bottle ········································ 4-125 4-11-1 Draining, Cleaning and Assembling the Trap Bottle ································· 4-125 4-11-2 Draining the Exhaust Manifolds ································································ 4-128 4-11-3 Cleaning the Bottle Coupler and Replacing the O-rings ·························· 4-130 4-11-4 Cleaning and Replacing the Pressure Sensor ········································· 4-133 4-12 Air Unit ··································································································· 4-136 4-12-1 Pump Replacement ·················································································· 4-136 4-12-1-1 Replacing the air pump ········································································ 4-136 -v-

4-12-1-2 Replacing the Valve/Diaphragm and Diaphragm Seat ························· 4-138 4-12-2 Disassembling, Cleaning and Replacing the Solenoid Valve ···················· 4-143 4-12-2-1 Disassembling and cleaning the solenoid valve ·································· 4-143 4-12-2-2 Replacing the solenoid valve ································································ 4-146 4-12-3 Adjusting the Regulator (Replacement of Diaphragm and O-ring) ·········· 4-147 4-13 Operation Panel Cover and Control Box ················································· 4-149 4-13-1 Removing and Installing the Compact Flash Memory Card ····················· 4-149 4-13-2 Replacing the CPU Board ········································································ 4-151 4-13-3 Replacing the Heater Driver Board ·························································· 4-154 4-13-4 Replacing the Control Panel Unit ····························································· 4-156 4-13-5 Replacing the LCD Relay Board, Power Indicator Board and Inverter ···· 4-160 4-13-6 Replacing the Switching Power Supply, Cooling Fan and Other Components ···················································································································· 4-164 4-13-7 Replacing and Cleaning the Touch Panel Protection Sheet ···················· 4-168 4-13-8 Correcting the Touch Panel ······································································ 4-171 4-13-9 Replacing the Battery ··············································································· 4-174 4-13-10 Installing the Uninterruptible Power Supply ·············································· 4-176 4-14 Top Plate ································································································ 4-182 4-14-1 Cleaning the Top Plate ·············································································· 4-182 4-15 Fume Control Unit and External Drain/Fill Ports ····································· 4-183 4-15-1 Cleaning the Fume Control Unit ······························································· 4-183 4-15-2 Replacing the Exhaust Fan ······································································ 4-185 4-15-3 Replacing the One Touch Coupler ···························································· 4-188 4-16 Exterior Panels ······················································································· 4-192 4-16-1 Removing and Installing the Exterior Panels ··········································· 4-192

Chapter 5

Disassembly Diagrams and Parts Lists ·········································· 5-1

5-1 5-2 5-3 5-4 5-5 5-6 5-7 5-8 5-9 5-10 5-11 5-12 5-13 5-14 5-15 5-16 5-17 5-18 5-19 5-20

Retort Lid ································································································· 5-4 Retort ······································································································ 5-6 Paraffin Oven ··························································································· 5-9 Paraffin Container ···················································································· 5-12 Bottle Rack and Base ·············································································· 5-14 Wax Drain Container ··············································································· 5-16 Reagent Bottle and Condensate Bottle ···················································· 5-18 Bulk Reservoir ························································································· 5-20 Rotary Valve and Gate Valve ··································································· 5-22 Fume Manifold, Condenser and Trap Bottle ············································· 5-24 Air Unit ···································································································· 5-26 Control Panel Cover and Control Box ······················································ 5-28 Top Plate, Right and Left Frames ····························································· 5-30 Fume Control Unit and External Drain/Fill Port Unit ································· 5-32 Exterior Panels ························································································ 5-34 Tubing ····································································································· 5-36 Labels ······································································································ 5-38 Accessories ····························································································· 5-40 Options ···································································································· 5-42 Schematic Diagram ················································································· 5-44

Chapter 6

Instrument Configuration ······························································ 6-1 - vi -

Chapter 7

Electric Circuit Diagrams

CPU Board Circuit Diagram Heater Driver Board Diagram LCD Relay Board Diagram Operating Panel LED Board Diagram US Board Diagram Right Side Relay Board Diagram Lid Sensor Board Diagram Gate Valve Positioning Board Diagram Rotary Valve Positioning Board Diagram Left Side Relay Board Diagram Interface Board Diagram Bottle LED Diagram LCD FPC Diagram

Chapter 8

Options ························································································· 8-1

8-1 8-2

Seismic Anchorage ················································································ 8-1 Exhaust Duct Hose ················································································ 8-2

Chapter 9

Specifications ················································································ 9-1

Appendix 1 Control Files 1 2

Overview ························································································································ 1 Types of Control Files ·································································································· 2 2-1 Executable Program Files ················································································· 2 2-2 Product File (PRODUCTS.CSV)········································································· 2 2-3 User Setting Files ······························································································ 2 2-4 Operation Files ·································································································· 3 2-5 Factory Setting Files ························································································· 4 2-6 History Files ······································································································· 4 2-7 Log Output Files ································································································ 5 3 How to Restore the Internal CF Card for the System ·················································· 6 3-1 Determining the Need for Reformatting a CF Card ·········································· 6 3-2 Structure of the CF Card Set in Drive B ······························································ 6 3-3 CF Card Reformatting Procedure ····································································· 11 3-3-1 Notes ·········································································································· 11 3-3-2 Backing Up the Files in the Current CF Card ············································· 11 3-3-3 Preparing a Set of Factory Setting Files for Restoration ··························· 11 3-3-4 Preparing a New CF Card (Reformatting a CF Card) ································ 11 3-3-5 Creating a New CF Card ············································································ 12

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VIP 6 Service Manual Pending Corrections No

Revision

Page Section

Title

1

AH9-IF-001

5-7

2

AH9-IF-001

1-10 1-2-1-3 Port Position

3

AH9-IF-001

1-11 1-2-1-4 Operation Flowchart

4

AH9-IF-001

1-12 1-2-1-4 Operation Flowchart

5

AH9-IF-001

1-11 1-2-1-4 Operation Flowchart

5-5 Bottle Rack and Base

Last Updated: 2009-12-10

Incorrect Correction Part Code for item #35 (Thermistor) is A6-60- The correct Part Code for item #35 3043. (Thermistor) is A6-60-3046. LED ON pattern for Port18 is PC1, PC2, PC3, LED ON pattern for Port18 is PC1, PC2, PC3, PC5 PC4 All EC42s and EC40s in the flowchart are EC42 should be EC43. EC40 should be incorrect ECs. EC42. EC42 described in the first paragraph is not The correct EC is EC43. the correct EC. "Also, the rotary valve turns by 17.14 degrees "Also, the rotary valve turns by 17.14 from one port to the next port (34.34 degrees from one port to the next port degrees between ports 19 and 20)." (34.34 degrees between ports 17 and 18)."

6 7 8 9 10

Created: 9/2/2009 Printed: 3/22/2010 10:56 AM

1/1

W. Wong

Chapter 1 Operating Principles

Chapter 1 1-1

Operating Principles

Overview

Tissues (cassettes containing fixed/coverslipped tissues) are placed in stainless tissue baskets and the baskets are placed in the retort. After the baskets have been placed the retort lid is closed. Parameters are entered according to messages, buttons and icons displayed on each screen, after which the user can start auto operation by operating a button or icon. In the auto operation mode, reagent is supplied to the retort (this action is hereinafter referred to as “pumping in”) or drained from the retort (hereinafter referred to as “pumping out”) from/to the reagent tanks sequentially at the pre-defined intervals to fix, dehydrate and replace tissues. Thereafter, paraffin that has been heated in the paraffin oven is pumped in to the retort to permeate paraffin through the tissues. Reagent and paraffin pumped in to the retort are controlled at the pre-defined temperatures, and also a mixing function is provided whereby the P/V cycles for pressurizing/depressurizing the retort are repeated at specified intervals, along with pumping in/out of reagent, to process the tissues more effectively. In the pumping-in phase, the retort is depressurized and reagent is supplied from the selected reagent tank. In the pumping-out phase, the retort is pressurized and reagent is returned to the selected reagent tank. The retort is pressurized/depressurized by closing the reagent circuit connected to the retort and increasing/decreasing the retort pressure. This is implemented by operating one air pump and multiple solenoid valves in the air circuit, as well as the rotary valve and gate valve in the reagent circuit. Tissues are taken out from the retort and the remaining paraffin in the retort is drained to the final paraffin tank, after which a series of cleaning/drying steps are performed using xylene and alcohol to wash off paraffin attached to the retort. To manage reagent, functions are also provided to drain used reagent to an external container, measure the amount of reagent supplied from an external container using the level sensors installed in the retort, and supply reagent to a specified reagent bottle.

- 1-1 -

Chapter 1 Operating Principles

1-1-1

Tubing System

Note: Circled numbers indicate tube numbers.

Fig. 1-1-1.

Tubing Diagram

Fig. 1-1-1 shows a tubing diagram of the system. Take note that the reagent tanks, paraffin containers and waste paraffin container that can be selected by the rotary valve, two bulk reservoirs affixed to the system, external drain/fill ports, etc., are referred to as “ports,” where each port is assigned a port number (Pnn) and name. Each port is connected to a tube denoted by the same number. Note that port numbers are different from station numbers shown on the screen. With this system, process reagent bottles are indicated as P1 to P10 (Station Numbers: Sta. 1 to 10), paraffin containers as P11, P12, P14 and P15 (Station Numbers: Sta. 11 to 14), waste paraffin container as P13 “Wax Drain” (Station Number: Sta. 15), retort cleaning reagent bottles as P16 “Cleaning XL” (Station Number: Sta. 16) and P17 “Cleaning Al” (Station Number: Sta. 17), bulk reservoirs as P18 “Bulk Left” (Station Number: Sta. 19) and P19 “Bulk Right” (Station Number: Sta. 20), and one external drain/fill port as P20 “Drain/Fill” (Station Number: Sta. 18). For your information, accumulated liquid generated by condensation of air gas in the tubing is drained to the condensate bottle “Condensate” during operation. The tubing system is divided into the following units:  Retort

A container used to process tissues.

 Paraffin oven

A unit that stores paraffin containers containing molten paraffin. Two types of paraffin containers are housed in the oven according to the required paraffin replenishment function, where only station 14 (P15) is larger than others.

 Tank rack

A unit that stores the process reagent bottles, retort cleaning reagent bottles, waste paraffin container, and condensate bottle.

 Rotary valve

A valve used to select each port.

 Gate valve

A valve used to connect and disconnect each reagent port to/from the retort. - 1-2 -

Chapter 1 Operating Principles

 Access door

When the access door on the left side of the retort at the front is opened, the fume control unit and external drain/fill ports can be accessed.

 Fume control unit In this unit, all exhaust gases generating from the air tubes/reagent bottles, as well as exhaust gases in the oven/tank rack, are sucked in at once and passed through the activated carbon filters using air blown by a fan, to cause the exhaust gases to be adsorbed to the filters.  External drain/fill ports A connection port that supplies and drains reagent to/from a reagent bottle through the retort “Drain/Fill” (Station Number: Sta. 18), as well as connection ports that fill reagent to the right and left bulk reservoirs “Bulk Left” (Station Number: Sta. 19) and “Bulk Right” (Station Number: Sta. 20), are available.  Bulk reservoirs Storage containers capable of replenishing retort reagent are provided inside the right and left side panels of the system, where the left bulk reservoir is connected to the connection port for “Bulk Left” (Station Number: Sta. 19), while the right bulk reservoir is connected to the connection port for “Bulk Right” (Station Number: Sta. 20). Specified reagent, etc., can be pumped in to/out of the retort storing tissues using the gate valve and rotary valve. This is made possible by depressurization and pressurization achieved by the air pump and multiple solenoid valves in the air unit. The retort has four level sensors to detect the levels at 2.7 liters, 3.5 liters and 4.2 liters from the bottom, as well as the top overflow level. These sensors are used to fill reagent to a specified level so that the tissues are submerged in reagent. One feature of this system is that a specified amount of reagent can be supplied from an external container to P1 to 10 (Station Numbers: Sta. 1 to 10) and P16 and 17 (Station Numbers: Sta. 16, 17) through the external drain/fill port P20 (Drain/Fill) (Station Number Sta. 18), and used reagent can also be drained to an external container. If the specified level in the retort is not reached during the process, reagent can be replenished to the retort from a specified bulk reservoir. In the system preparation steps, an external tube is connected to the left bulk reservoir via the connection port for “Bulk Left” (Station Number Sta. 19), and to the right bulk reservoir via the connection port for “Bulk Right” (Station Number Sta. 20), to allow for reagent supply from an external container. This system consists of pressurized tubing circuits and uses large amounts of reagents having very adverse effects on the human body, etc. Accordingly, air generated by depressurization, pressurization, etc., is converted into reagent mist by the condenser and tentatively accumulated in the trap bottle, and the air accumulated in the trap bottle is discharged to the condensate bottle during operation. The condensed exhaust gases, gases in the reagent bottles, gases generated in the oven and odorous gases in the tank rack are guided by the intake fan of the fume control unit and cleaned by the activated carbon filters, and then released to atmosphere. For your information, these exhaust gases can be discharged through a duct, etc., by installing an optional duct connection adapter (used for both 38-mm and 75-mm ducts).

- 1-3 -

Chapter 1 Operating Principles

1-1-2

Electrical System

Fig. 1-1-2-1 shows an electrical diagram.

Fig. 1-1-2-1

Table 1-1-2-1 Symbol

Name

PCB1

CPU board

PCB2

Heater driver board

PCB3

LCD relay board

PCB4

Power indicator board

PCB5

Ultrasonic sensor board

PCB6

Relay board (right)

PCB7

Lid sensor board

PCB8

GV positioning board

PCB9

RV positioning board

PCB10

Relay board (left)

PCB11

Interface board

Electrical Diagram

List of Printed Circuit Boards

Function A printed circuit board mainly consisting of a CPU, used to control the system by means of software. A printed circuit board used to control the heaters. A printed circuit board used to control the display through the LCD and touch-panel controller. A printed circuit board equipped with power indicators. A printed circuit board used to relay inputs from the four ultrasonic sensors in the retort. A printed circuit board used to relay signals from the bulk reservoir level sensors, temperature sensors, etc. A printed circuit board on which the relays for wires connected to the retort lid heater and lock, as well as the lid sensor, are mounted. A printed circuit board equipped with the four photo-sensors that determine gate valve positions. A printed circuit board equipped with the six photo-sensors that determine rotary valve positions. A printed circuit board used to relay signals from the bulk reservoir level sensors, bottle LEDs, etc. A printed circuit board equipped with the connectors for external alarm output, LAN, serial communication and UPS.

- 1-4 -

Chapter 1 Operating Principles

Table 1-1-2-2 Symbol

Name

PLUG

Power Cord

CP

Circuit protector

NF

Noise filter

SP

Switching power supply

USB LCD(TP) INV LAN RS232C

PI8 L1 Pump

USB connector LCD module with touch panel Inverter LAN interface connector RS232C interface connector Alarm output connector, terminal block Terminal block for power-failure signal input Speaker CF card slot Pressure sensor Waste paraffin container sensor Oven door sensor Waste paraffin container indicator 2.7l ultrasonic sensor 2.5l ultrasonic sensor 4.2l ultrasonic sensor Ultrasonic sensor for overflow position Overflow sensor for left bulk reservoir High level sensor for left bulk reservoir Low level sensor for left bulk reservoir Overflow sensor for right bulk reservoir High level sensor for right bulk reservoir Low level sensor for right bulk reservoir Lid closed positioning sensor for retort Locked positioning sensor for retort Lid solenoid Air pump

SV1

Solenoid valve for pressurization

SV2

Solenoid valve for depressurization

ALARM UPS BZ CN8 PS LS1 LS2 LD1 US1 US2 US3 US4 PI1 PI2 PI3 PI4 PI5 PI6 PI7

SV3 SV4 SV5 SV6

Solenoid valve for opening line to atmosphere Solenoid valve for filling left reservoir Solenoid valve draining right reservoir Solenoid valve for draining condensate

M1

Rotary valve motor

M2

Gate valve motor

FAN1

Cooling fan

FAN2

Fume fan

SSR Bottle LED

Solid state relay Bottle led unit

Electrical Units

Function This cable receives the power from the commercial power source. Since the power-supply voltage and applicable safety standards vary from one country to another, a different cable is used in each country. This protector serves as a main power switch, and also has a function to cut off the power upon occurrence of short-circuit, etc. This filter eliminates noise between the system and commercial power source. This power supply converts the AC power-supply voltage to DC power-supply voltages of 24 VDC and 5 VDC. It also insulates the system from the commercial power source. An interface that connects a USB memory device to the system. This module provides a 10.4” color LCD and resistance-membrane touch panel. A DC-AC converter for turning on the cold cathode tube in the 10.4” color LCD. A RJ45 LAN connector. A connector for establishing serial communication. A connector and terminal block for outputting alarms indicating power failure and various errors to an external device. A terminal block for notifying the system of power failure when an uninterruptible power supply (UPS) is used externally to the system. A speaker for generating an alarm sound, key click sound, etc. A connector that houses a CF card in which the system software, etc., is stored. This sensor measures the retort pressure. A proximity sensor that detects whether or not a waste paraffin container is set. A proximity sensor that detects opening of the oven door. A red indicator indicating that paraffin has been drained. An ultrasonic sensor that detects the 2.7-L level. An ultrasonic sensor that detects the 3.5-L level. An ultrasonic sensor that detects the 4.2-L level. An ultrasonic sensor that detects the 4.5-L level. An optical level sensor located at the overflow position in the left bulk reservoir. An optical level sensor located at the high level position in the left bulk reservoir. An optical level sensor located at the low level position in the left bulk reservoir. An optical level sensor located at the overflow position in the right bulk reservoir. An optical level sensor located at the high level position in right left bulk reservoir. An optical level sensor located at the low level position in right left bulk reservoir. An optical sensor that detects that the retort lid lever is at the closed position. An optical sensor that detects that the retort lock lever is at the locked position. A self-holding solenoid for locking/unlocking the lid. An air pump for pressurizing/depressurizing the retort. A solenoid valve positioned on the discharge side of the air pump and switched when pressurizing the line. A solenoid valve positioned on the suction side of the air pump and switched when depressurizing the line. A solenoid valve positioned on the valve manifold to open and close the air circuit to/from atmosphere. A solenoid valve switched when depressurizing/supplying from the left bulk reservoir. A solenoid valve switched when depressurizing/supplying from the right bulk reservoir. A solenoid valve switched when discharging condensate in the condensate bottle to the condensate bottle. A 2-phase stepping motor with reducing gears. This motor is used to turn the rotary disk. A 2-phase stepping motor with reducing gears. This motor is used to turn the rotary disk. A fan that cools the interior of the control box. A fan in the fume control unit, used to forcibly discharge odorous gases from the system. A solid-state relay used in the heating control of retort heaters. A unit that illuminates the reagent bottle to facilitate checking of reagent level from the back of the bottle.

- 1-5 -

Chapter 1 Operating Principles

Table 1-1-2-3

Temperature Control Units

Temperature-controlled location

Heater symbol

Thermost at symbol

Temperature sensor symbol

TH1

TC1

TH1

Retort lid heater

TH2

TC2

TH2

Retort front heater

TH3

TC3

TH3

Retort heater, other

TH4

None

TH4

Fill tube heater

TH5

None

TH5

Drain tube heater

TH6 TH7 TH8 TH9 TH10 TH11

TC6 TC7 TC8 TC9 TC10 TC11

TH6 TH7 TH8 TH9 TH10 TH11

Gate valve hater Rotary valve heater Paraffin station 11 heater Paraffin station 12 heater Paraffin station 13 heater Paraffin station 14 heater

TH12

TC12

TH12

Oven top board heater

TH13

TC13

TH13

Xylene heater

1-1-2-1

Description A heater for preventing bedewing on the retort lid. Only this heater is driven by 24 VDC. A heater provided on the front side of the retort. It also heats the level sensors. A heater not located on the front side of the retort. A tube heater provided between the side face at the top of the retort and the gate valve. A tube heater provided between the side face at the bottom of the retort and the gate valve. A heater that heats the GV housing. A heater that heats the RV housing. A heater positioned at the bottom of oven station 11. A heater positioned at the bottom of oven station 12. A heater positioned at the bottom of oven station 13. A heater positioned at the bottom of oven station 14. A heater for the tube holding block at the oven top board A heater positioned at the bottom of the xylene station.

Explanation of Electrical System

This system is available in three models, each corresponding to one of three power-supply voltage specifications. Table 1-1-2-4 Power-supply Voltage Specifications Model Power-supply voltage Rated input VIP6-J0 AC 100V 50/60 Hz 12 A VIP6-A1 AC 115V 50/60 Hz 12 A VIP6-E2 AC 230V 50/60 Hz 6A The system supplies the power using the power cable connected through the inlet at the back of the system. The power switch located on the right side face of the control box can be used to supply and cut off power to/from the system. The power-supply voltage supplied to the system is directed via the noise filter to the switching power supply that generates safe, low voltages and also to the heater driver board. The switching power supply generates 24-VDC power to drive devices and 5-VDC power used for control. These voltages output from the switching power supply are supplied to the CPU board first, and then to the various devices according to the software. On the CPU board, the microcontroller loads the software from the CF card set in the CF card slot on the CPU board, and then starts the software. Inputs and outputs to/from the LCD, touch panel, etc., are implemented via the LCD relay board, while each heater is temperature-controlled via the heater driver board. Except for the heaters, all devices are driven by the power output from the switching power supply. Among the heaters, the lid heaters are driven by 24 VDC, while all other heaters are driven by the AC power-supply voltage.

- 1-6 -

Chapter 1 Operating Principles

1-2

Operation of Each Part

1-2-1

Rotary Valve

1-2-1-1

Overview

The purpose of the rotary valve is to provide a reagent passage between a specific station and the retort. The rotary valve has positions corresponding to respective stations, to provide a reagent circuit connecting the gate valve to each station. A total of 20 stations are available. For your information, the station numbers shown and manipulated on the software screen are called “stations,” while the tube numbers assigned mechanically to the rotary valve are called “ports.” Note that numbers do not always match between “stations” and “ports.” Table 1-2-1-1 Rotary Valve Station Numbers Station Sta.1 Sta.2 Sta.3 Sta.4 Sta.5 Sta.6 Sta.7 Sta.8 Sta.9 Sta.10 Sta.11 Sta.12 Sta.13 Sta.14

Port P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 P11 P12 P14 P15

Connected to Reagent bottle at the far left on the upper level Reagent bottle second from the left on the upper level Reagent bottle third from the left on the upper level Reagent bottle fourth from the left on the upper level Reagent bottle fifth from the left on the upper level Reagent bottle at the far left on the lower level

Sta.15

P13 (Wax Drain)

Sta.16 Sta.17 Sta.18 Sta.19

P16 (Cleaning XL) Reagent bottle at the far right on the upper level P17(Cleaning AL) Reagent bottle at the far right on the bottom level External drain/fill port (center) P20 (Drain/Fill) Left bulk reservoir P18 *Bulk Left)

Sta.20

P19 (Bulk Right)

Reagent bottle second from the left on the lower level Reagent bottle third from the left on the lower level Reagent bottle fourth from the left on the lower level Reagent bottle fifth from the left on the lower level Oven at the far left Oven second from the left Oven third from the left Oven fourth from the left Reagent bottle sixth from the left on the upper level

Right bulk reservoir

Application For process reagent For process reagent For process reagent For process reagent For process reagent For process reagent For process reagent For process reagent For process reagent For process reagent For paraffin For paraffin For paraffin For paraffin Waste paraffin container Xylene for cleaning Alcohol for cleaning External drain/fill For storing new reagent (for filling purposes only) For storing new reagent (for filling purposes only)

The rotary valve allows for direct access to a given station by specifying the applicable station. When accessing a station, stations 19 and 20 are not passed, except when station 19 or 20 is directly specified, in order to prevent reagent from mixing into stations 19 and 20 that are bulk reservoirs. When accessing station 1 from station 17 (containing alcohol for cleaning), for example, the motor is operated in the reverse direction (= turned in the direction of decreasing port numbers) until station 1 is accessed.

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Chapter 1 Operating Principles

1-2-1-2

Components

The rotary valve mainly consists of the component units listed below. Table 1-2-1-2 No. 1

Name RV housing

2

RV fixed disk

3

RV rotary disk

4

RV positioning disk

5

RV positioning board

6

Stepping motor

Rotary Valve Components

Function This housing connects the reagent circuit to the reagent tank, gate valve, etc. The RV housing has a temperature control function. This disk is made of ceramics, and has ports arranged in a circle concentric to the common port at the center. A disk made of ceramics, connecting a given port on the fixed disk to the common port at the center. The RV rotary disk is turned by a drive motor and stopped at a specified port position. A disk with grooves used to indicate the current position of the rotary disk. It has a concentric double structure, where the inner circle defines the port number, while the outer circle defines the stopped position. A printed circuit board on which six photo-sensors are mounted. The port position is detected by this board in combination with RV positioning disk 5. A stepping motor with rotary gears, having a resolution of 7,200 steps. This motor is used to move the RV rotary disk at a specified position.

6

3

4 2

1

Fig. 1-2-1-1

- 1-8 -

Rotary Valve

Chapter 1 Operating Principles

1-2-1-3

Port Position

The port position is determined by the six photo-sensors detecting different positions on the grooves provided in RV positioning disk 6. RV positioning disk 6 has the inner groove and outer groove as shown in the figure below. The RV positioning board is shown below.

PC1

PC5

PC6

Positioning board Positioning disk

* When viewed from the motor

Fig. 1-2-1-2

RV Valve Positioning

- 1-9 -

Chapter 1 Operating Principles

Table 1-2-1-3 Port position

*

Port Positions and Photo-sensor Illumination Conditions Illumination conditions of LEDs on CPU board

R:PC1

R:PC2

R:PC3

R:PC4

R:PC5

R:PC6

1

OFF

OFF

OFF

ON

ON

OFF

2

ON

OFF

OFF

OFF

ON

OFF

3

OFF

ON

OFF

OFF

OFF

OFF

4

ON

OFF

ON

OFF

OFF

OFF

5

OFF

ON

OFF

ON

OFF

OFF

6

OFF

OFF

ON

OFF

ON

OFF

7

ON

OFF

OFF

ON

OFF

OFF

8

OFF

ON

OFF

OFF

ON

OFF

9

OFF

OFF

ON

OFF

OFF

OFF

10

OFF

OFF

OFF

ON

OFF

OFF

11

OFF

OFF

OFF

OFF

ON

OFF

12

ON

OFF

OFF

OFF

OFF

OFF

13

ON

ON

OFF

OFF

OFF

OFF

14

OFF

ON

ON

OFF

OFF

OFF

15

OFF

OFF

ON

ON

OFF

OFF

16

ON

OFF

OFF

ON

ON

OFF

17

ON

ON

OFF

OFF

ON

OFF

18

ON

ON

ON

OFF

ON

OFF

19

OFF

ON

ON

ON

ON

OFF

20

OFF

OFF

ON

ON

ON

OFF

Note that when each LED is illuminating, it means that the corresponding sensor is sensing light. The above patterns are feasible only when “R: PC6” is OFF (= PC6 is sensing light).

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