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Stat Fax 3300

Service Manual

Copyright 2004 Awareness Technology Inc. 01/2008 Doc. 3300 Rev. G

TABLE OF CONTENTS
1. INTRODUCTION ................................................................................................................................... 1 1.1 APPLICATIONS ...................................................................................................................................... 1 1.1.1 Intended Use ................................................................................................................................ 1 1.1.2 Summary of the Instrument .......................................................................................................... 1 1.2 SPECIFICATIONS .................................................................................................................................... 2 1.3 WARNING MARKINGS ........................................................................................................................... 5 1.3.1 Safety Symbols ............................................................................................................................. 5 1.3.2 Safety Terms................................................................................................................................. 5 1.4 SAFETY PRECAUTIONS .......................................................................................................................... 5 2. PRINCIPLES OF OPERATION ........................................................................................................... 8 2.1 POWER REQUIREMENTS ........................................................................................................................ 8 2.2 PARTS AND CONTROLS ......................................................................................................................... 9 2.3 GENERAL LAYOUT.............................................................................................................................. 11 2.3.1 The Chassis ................................................................................................................................ 11 2.3.2 Front Panel Electronics ............................................................................................................. 11 2.3.3 Main PCB .................................................................................................................................. 12 2.3.4 Photometer Mechanism.............................................................................................................. 14 2.3.5 Flowcell ..................................................................................................................................... 17 2.3.6 Valve .......................................................................................................................................... 17 2.3.7 Vacuum Pump and Pump Control Circuit ................................................................................. 17 2.3.8 Temperature Control.................................................................................................................. 18 2.4 PARALLEL INTERFACE ........................................................................................................................ 18 2.5 AUXILIARY AND OPTIONAL EQUIPMENT............................................................................................. 18 2.5.1 Auxiliary Equipment Interface ................................................................................................... 18 2.5.2 Optional Equipment ................................................................................................................... 18 3. SERVICE PROCEDURES................................................................................................................... 19 3.1 OPENING THE INSTRUMENT ................................................................................................................ 19 3.2 CLEANING THE FLOWCELL ................................................................................................................. 21 3.3 FLOWCELL CONFIGURATION .............................................................................................................. 22 3.4 FLOWCELL ALIGNMENT ...................................................................................................................... 24 3.5 FLOWCELL TUBING REPLACEMENT .................................................................................................... 25 3.6 TESTING FOR LEAKS IN THE FLOWCELL ASSEMBLY............................................................................ 32 3.7 FLOWCELL CELL INSERT REPLACEMENT ............................................................................................ 34 3.8 MAIN PCB AND/OR PHOTOMETER REPLACEMENT .............................................................................. 35 3.8.1 Photometer Replacement ........................................................................................................... 35 3.8.2 Main PCB Replacement ............................................................................................................. 37 3.9 VALVE TUBING REPLACEMENT .......................................................................................................... 38 3.10 EPROM REPLACEMENT ................................................................................................................... 39 3.11 FILTER CHANGE PROCEDURE ........................................................................................................... 41 3.12 LAMP REPLACEMENT........................................................................................................................ 44 3.13 VACUUM ADJUSTMENT .................................................................................................................... 46 3.14 EXHAUST FILTER REPLACEMENT...................................................................................................... 47 4. TROUBLESHOOTING........................................................................................................................ 48 4.1 KEYPAD PROBLEMS ............................................................................................................................ 48 4.1.1 No Keys Function....................................................................................................................... 48 4.1.2 A Row or Column of the Keypad Does Not Function................................................................. 48 4.1.3 The Keyboard and Display Do Not Function............................................................................. 48 4.1.4 Keypad Key Stuck ...................................................................................................................... 48 4.1.5 Password Protection Override................................................................................................... 48

4.2 PHOTOMETER PROBLEMS.................................................................................................................... 49 4.2.1 Lamp Low/Filter Low Message is Displayed............................................................................. 49 4.2.2 Filter Wheel Does Not Rotate .................................................................................................... 49 4.2.3 Filter Wheel Runs at an Uncontrolled Rate ............................................................................... 49 4.2.4 Incorrect Control Readings ....................................................................................................... 50 4.2.5 Poor Linearity............................................................................................................................ 50 4.2.6 Erratic Readings ........................................................................................................................ 50 4.2.7 Lamp failure............................................................................................................................... 50 4.2.8 No sampling ............................................................................................................................... 50 5. CALIBRATION ..................................................................................................................................... 51 5.1 CALIBRATION AND ABSORBANCE LINEARITY ..................................................................................... 52 5.2 RESTORE CALIBRATION DATA ............................................................................................................ 52 5.3 TEMPERATURE CALIBRATION ............................................................................................................. 53 5.4 ABSORBANCE CALIBRATION............................................................................................................... 54 5.5 RESTORE FILTER LABELS ................................................................................................................... 55 6. CONTACT INFORMATION ............................................................................................................... 56 APPENDIX 1 SCHEMATICS................................................................................................................ 57

1. INTRODUCTION
This manual describes service and troubleshooting procedures for 3300 series instruments. This manual is written with the service technician in mind, and contains no information for clinical chemistry analysis, or other applications. For details on instrument operation and specifications, please refer to the Owner's Manual specific to the instrument.

1.1 Applications 1.1.1 Intended Use


This instrument is intended to be used to read and calculate the results of in-vitro clinical diagnostic assays, as well as any other application requiring absorbance or concentration readings at or near the available wavelengths. This general purpose instrument is intended to be used by laboratory professionals capable of selecting the appropriate features and options for each specific clinical application.

1.1.2 Summary of the Instrument

Stat Fax 3300 is designed for the investigation of Biochemistry Enzyme Immuno and Drug Levels from human serum, plasma, or urine. A removable Flowcell installs in the read well to provide extremely rapid fluid sampling with low carryover. A built-in vacuum pump and an external waste bottle with level sensing are supplied standard. When the Flowcell is removed, the instrument accepts standard 12 mm round tubes as well as 1 cm square cuvettes. The design of the instrument includes many features to minimize operator error, such as stable factory calibration, automatic zeroing, complete operator prompting, detailed labeling, pre-programmed calculations, visual and audible feedback, flags and error messages, and minimal maintenance requirements. The operating modes are: Absorbance Mode, Standard Mode, Rate Mode, Factor Mode, Multi-point Mode, and Index Mode. The basic calculations are permanently stored in memory and include several single and multi-point equations. Provisions are made in certain cases for reading specimens in duplicate and/or using the mean reading in calculations. Each calculation mode is described in detail in the Operators Manual. These modes are keyboard selectable and self-prompting to reduce error and simplify operation. System Control The instrument is based on the 8 bit Z180 microprocessor. The software is permanently stored in a M27C1001 EPROM. A battery-backed non-volatile RAM (random access memory) chip (MK48T35) incorporating a real-time clock, (2) 24LC515 EEPROM chips are used to store data such as calibration, test setups, samples, contains 32k of general use RAM, and also maintains the date and time. All digital I/O is accomplished with (2) 8255 Programmable Peripheral Interface. Time intervals and pulse widths are measured using the counter channels of an 8254 programmable timer.

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User-programmable Memory User-programmable memory allows the operator to store and name tests in a numbered test menu. Thereafter, these tests may be readily recalled for later use with minimal set up. Standard curves are also stored in this memory. Test protocols remain stored until either changed or deleted by the user. Instructions for using this memory are given in the Users Test Menu in the Operators Manual.

1.2 Specifications
Specification Date......................................21 September, 2002 Model Name ..............................................Stat Fax 3300 Spectrophotometer Type ...........................Filter photometer Optical Configuration .................................Single beam with continuously rotating filter wheel Monochromatic or bichromatic reading 8 filter positions Usable Spectral Range..............................330 to 770 nm System Procedures ...................................Open and by stored menu Calculating Modes ....................................Absorbance Single Standard Differential samples Factor Mode Differential samples Multi Standard Mode (up to 7 standards) Multi Standard % Abs (up to 7 standards) Kinetic Mode (consecutively, or simultaneously (Batch)) By Factor or by Standard Fixed Time Kinetic By Factor or by Standard Index Mode Channels ...................................................120 Open Source of Radiation ...................................Tungsten Halogen, 10 Watt, with automatic lamp saver Selection of Wavelength ............................By filter Filter Type..................................................4-cavity interference, long-life ion beam-assisted deposition Wavelength Accuracy ................................+/- 3 nm Filter Location ............................................After sample (heat absorbing filter before sample) Filter Selection ...........................................Automatic by software or via keyboard Wavelengths ..............................................340, 405, 505, 545, 580, 630 nm supplied standard other/additional filters optional Half Bandwidth...........................................< 10 nm 1/100 Bandwidth ........................................14 nm at 340 nm False Radiant Energy Ratio.......................< 0.001 at 340 and 405 nm Cuvette ................................................... 1 cm square, 12 cm round, flow through Supplied Type............................................Flow-through Material......................................................316 stainless, borosilicate windows

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Geometry ...................................................Cylindrical, 2.3 mm dia x 5 mm +/0.05 mm Illuminated Volume ....................................21 l Minimum Read Volume .............................250 l Aspiration/Purge ........................................Vacuum pump at 18 cm of Hg Valve..........................................................Silicone pinch type Cuvette Holder...........................................Thermostatically controlled compartment at 37 C Detector .....................................................Gallium-Arsenide-Phosphide photodiode Signal Processing and Display Display Type ..............................................240x128 Graphic LCD w/ Backlight Scale of Display Absorbance ...............................................-0.5 to 3.5 (flow-through mode) -0.5 to 2.5 (tube or 1 cm cuvette) Concentration ............................................Maximum 999,999 Kinetic Results ...........................................Abs/min with resolution of 0.0002 A/min Zero Compensation ...................................Automatic Range ........................................................-0.5 to 2.5 absorbance Signal Outputs Parallel ......................................................Centronics/IBM-PC compatible Serial .........................................................RS-232 at 9600 baud, 8 data, 1 stop, no parity Bi-Directional Data Input.................................................1) 20 Key Keypad, 2) PS2 101 Keyboard (connector available at back of instrument) Spectrophotometric Inaccuracy Flow-through..............................................< 0.5 % at 1 absorbance, 340/630 nm NADH solution < 1% at 2 absorbance, 340/630 nm NADH solution < 3 % at 3 absorbance, 340/630 nm NADH solution < 0.5 % at 1 absorbance, 405/630 nm PNP solution < 1 % at 2 absorbance, 405/630 nm PNP solution < 3 % at 3 absorbance, 405/630 nm PNP solution Stability ......................................................Better than 0.003 A/hr monochromatic after warm-up Better than 0.001 A/hr bichromatic after warm-up Warm-up Time ...........................................90 seconds photometric 15 minutes for temperature compartment Electronics .................................................Z180 Microprocessor 18 MHz 128k EEPROM 32 K bytes Nonvolatile RAM (NVRAM) Power ........................................................Auto-Switching Power Supply Voltage source: 90 264 VAC Frequency: 50/60 Hz

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Power consumption: 60 watts Installation Category: CAT II Fuses: 2.5A/250V Fast 5-20 mm Glass Fuse, 2.0A/250V Fast 5-20 mm Ceramic Fuse, (2) 6/10 250V Slow Blow 3AG Fuses Dimensions and Weight ............................40cm (L) x 37 cm (W) x 14 cm (H) lid closed (30 cm lid opened), 6.4 kg Space Requirements .................................10 cm clearance on all sides Environmental Conditions for Safe Operation: Indoor Use Altitude up to 2000m. Temperature 5C to 40C. (Although it may be safe to operate in these conditions, it may not be suitable for the performance of the users tests. Check with supplier.) Humidity 85% for temperatures up to 31C decreasing linearly to 50% humidity at 40C. Mains supply voltage fluctuations not to exceed 10% of the nominal voltage. Recommended Operating Temperature ....15-35C Recommended Operating Humidity Between 10 and 85%, non-condensing Design and Instrument specifications are subject to change without notice.

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1.3 Warning Markings 1.3.1 Safety Symbols


Safety symbols which may appear on the product:

WARNING Risk of Shock

Protective Ground (Earth) Terminal

CAUTION Refer To Manual

BIOHAZARD Risk of Infection

FUSE: For continued protection against the risk of fire, replace only with fuse of the specified type and current ratings. Disconnect equipment from supply before replacing fuse.

1.3.2 Safety Terms


These terms may appear on the product: DANGER indicates an injury immediately accessible as you read the marking. WARNING indicates an injury hazard not immediately accessible as you read this marking. CAUTION indicates a hazard to property including the product. Terms which may appear in this manual: WARNING: Warning statements identify conditions or practices that could result in injury or loss of life. WARNING indicates an injury hazard not immediately accessible as you read the marking. CAUTION: Caution statements identify conditions or practices that could result in damage to this product or other property. BIOHAZARD: Biohazards are biological agents that can cause disease in humans. Lab workers handling potentially infectious materials must use universal precautions to reduce the risk of exposure to these agents.

1.4 Safety Precautions


To assure operator safety and prolong the life of your instrument, carefully follow all instructions outlined below. Read Instructions Review the following safety precautions to avoid injury and prevent damage to this instrument or any products connected to it. To avoid potential hazards, use this instrument only as specified. For best results, familiarize yourself with the instrument and its capabilities before attempting any clinical diagnostic tests. Refer any questions to your instrument service provider. Personal Protective Equipment Many diagnostic assays utilize materials which are potentially biohazardous. Always wear protective apparel and eye protection while using this instrument.

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Follow Operating Instructions Do not use the instrument in a manner not specified by the manual or the protection provided by the instrument may be impaired. Use Proper Power Cord Use only the power cord specified for this product and certified for the country of use. Ground the Product This product is grounded through the grounding conductor of the power cord. To avoid electric shock, the grounding conductor must be connected to earth ground. An alternate method is to attach a ground strap from the external grounding terminal on the rear panel of the instrument to a suitable ground such as to a grounded pipe or some metal surface to earth ground. Observe All Terminal Ratings To avoid fire or shock hazard, observe all ratings and markings on the instrument. Consult this manual for further ratings information before making connections to the instrument. Install as Directed The Stat Fax 3300 should be installed on a sturdy, level surface capable of supporting the instruments weight (25 lbs, 11.4 kg) safely for safety and ventilation purposes. The mounting surface should be free of vibrations. Provide Proper Ventilation Refer to the installation instructions for details on installing the product so it has proper ventilation. The instrument should be surrounded by the following clearances: 3 inches (8 cm) around perimeter of unit and 3 inches (8 cm) on top. Do Not Operate Without Covers Do not operate this instrument with covers and panels removed. Use Proper Fuse. Use only the fuse type and rating specified by the manufacturer for this instrument. Use of a fuse with an improper rating may pose a fire hazard. Refer to the Power Requirements section for details on fuse replacement. Avoid Exposed Circuitry Do not touch exposed connections and components when power is present. Avoid Excessive Dust Do not operate in an area with excessive dust. Do Not Operate With Suspected Failures If you suspect there is damage to this instrument, have it inspected by a qualified service person. Do Not Operate in Wet/Damp Conditions. Do Not Operate In An Explosive Atmosphere.

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Keep Instrument Surfaces Clean and Dry Solvents such as acetone or thinner will damage the instrument. Do not use solvents to clean the unit. Avoid abrasive cleaners; the display overlay is liquidresistant, but is easily scratched. The exterior of the instrument may be cleaned with a soft cloth using plain water. If needed, a mild all-purpose or nonabrasive cleaner may be used. A 10% solution of chlorine bleach (5.25% Sodium Hypochlorite) or 70% isopropyl alcohol may be used as a disinfectant. Take special care not to spill liquid inside the instrument. Operating Precautions Be sure to run a sufficient number of controls in each assay. If controls are not within their acceptable limits, disregard test results. Biohazard Precautions

BIOHAZARD WARNING: If any materials are overturned during operation, immediately set the power switch to OFF (0). This material should be treated as potentially biohazardous. Appropriate cleanup and disposal of biohazardous waste should be used.

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2. PRINCIPLES OF OPERATION
This section of the manual describes the operation and the interaction of the plate reader's main systems. Most systems are controlled by the Z180 on the main circuit board.

2.1 Power Requirements


The Stat Fax 3300 contains an auto-switching power supply. Voltage source: .........................................90 264 VAC Frequency: .......................................50/60 Hz Power consumption: ..................................60 watts Installation Category: .................................CAT II Fuse: .........................................................2.5A/250 V Slow Blow / 2.0A/250V Slow Blow A "dead" instrument may result from a blown fuse. However, a blown fuse may indicate a problem on the main PCB or power supply. If there is no voltage present at J6, check the fuse located at the back left corner of the power supply and remove it with a fuse puller, or carefully pry it out with a small screwdriver. Install a 250V 2A slow blow fuse. Use only the recommended fuse. Do not substitute other rating! If voltage is present at J6, check for input voltage on voltage regulators VR2, VR3, and VR4. For 110-120 V units used in the US, use a UL listed cord set consisting of a minimum 18 AWG, Type SVT or SJT three conductor cord, maximum 3 meters (10 feet) in length, rated 10 A, 125 V, with a parallel blade, grounding type attachment plug. For 220-240 V units used inside the US, use a UL listed cord as above, except rated 250 V, with a tandem blade, with grounding type attachment plug. The cord set provided by the manufacturer meets these requirements. For other locations, use the power cord certified for the country of use. Safety Grounding - Do not alter or defeat the safety grounding methods provided. To avoid the risk of electric shock, the third prong of the AC power plug must be connected to conductive parts internal to the equipment. Internal fasteners to grounding points are marked by the IEC 417 symbol 5019. DO NOT loosen or remove these fasteners or connections. An alternate method of grounding is provided by connecting the grounding terminal located on the rear panel to a suitable ground. To avoid electric shock, the power cord protection ground conductor must be connected to ground.

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2.2 Parts and Controls


The following photographs identify major parts and controls of the Stat Fax 3300

C B

D A E

Figure 2.2-1 Overall view

K I J H G

M N O

Figure 2.2-2 Rear view

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R T P S U

Figure 2.2-3 Waste Bottle Assembly

Reference Figures 2.2-1, 2.2-2, and 2.2-3:


A. Flowcell B. Waste Bottle (See Detail in Fig. 2.3) C. Internal Printer D. Graphical LCD Display E. Key Pad F. Heat Block G. Power Cord Connector H. Power Switch I. Parallel Port J. Heat Block Connector K. Serial Port L. External Keyboard Connector M. Sensor Jack N. Vacuum Fitting (Blue) O. Waste Fitting (Black) P. Waste Bottle Q. Bottle Cap Assembly (white cap and rubber stopper) R. Waste Full Sensor Wires S. Waste Tube (Black Fitting) T. Exhaust Filter U. Sensor Lead V. Vacuum Fitting (Blue) W Sample Bar

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2.3 General Layout 2.3.1 The Chassis


The chassis consists of two main components: Cover. The cover is a pressure formed fire-retardant ABS enclosure meeting UL specification 94V-0. It is attached to the main chassis with 2 #4 self-tap screws. The display panel is attached to main cover (see Figure 2.2-1). The LCD display, the interface circuit board, and the keypad are all included in this assembly. Base. The base supports the rear electronic deck, and is the foundation for the plate transport and photometer mechanisms.

2.3.2 Front Panel Electronics


The display: The LCD is driven directly off of the Z180 bus. Address decoding is done on the main board. The keypad: The keypad consists of a 5 X 4 membrane keypad. Ports PB0 through PB7 provide the key scan output. The keys are connected as shown in the drawing. Scanning is performed from PB0 to PB7 outputs and reading from PC0 to PC3 inputs. Port Buffer Board: Contains the parallel, serial, and external keyboard ports. A cable runs from this board to the Main PCB. The ports use an 8255 located on the Main Board.

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2.3.3 Main PCB


Under normal circumstances, there are no adjustments to be made to the main PCB. Circuit failures are highly unlikely, but if they occur, it is recommended that the repairs be performed by factory authorized technicians. There are ten test points on J8 which provide access to a number of vital signals. The instrument can be observed in operation with an oscilloscope. Typical test point waveforms are shown in Figure 2.3.4-2. The current configuration (after Revision Level L artwork) of the Surface Mount Main PCB is as follows:

Figure 2.3.3.1 Surface Mount Main PCB Configuration (Rev. L artwork)

The 7-segment LED on the Main PCB was replaced by discrete diodes: D4, D12, D13, D14, and D17 with Revision level L. Figure 2.3.3-1 displays functions as shown and is further described below:

Diode D4 D6 D12 D13 D14 D17

Label SAMPLE POWER VACUUM VALVE CELL HEAT TUBE IN

Function Indicates when the sample sensor is closed +15V available on the Main PCB and processor is active. Indicates a signal to turn on the pump A signal to open the pinch valve is present The heating elements in the photometer cell block are energized. Detects a test tube or Flowcell inserted into the photometer.

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NOTE: Prior to REV L art work (Surface Mount) this was the configuration of the Main PCB:
Pump

Tube Detect

Sample Sensor

Valve Action

Cell Heat

Power
Figure 2.3.3-2 - Functions indicated by 7-segment LED

The 7-segment LED on the Main PCB displays functions as shown in Figure 2.3.3-2 and is further described below: Pump Sample Sensor switch Cell heat Tube detect Power Valve action Indicates a signal to turn on the pump. Indicates when the sample sensor switch is closed. The heating elements in the photometer cell block are energized. A test tube or Flowcell is inserted into the photometer. +15V available on Main PCB. A signal to open the pinch valve is present.

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2.3.4 Photometer Mechanism

The Stat Fax 3300 uses a single channel silicon diode detector to read the light signal from a 6-volt gas-filled lens-end tungsten lamp. The continuously rotating filter wheel contains four fixed wavelength interference filters, and is located inside the photometer housing underneath the microwell plate. This arrangement greatly reduces problems due to ambient light and allows for an open frame structure of the plate transport system. The photometer is operated under microprocessor control. The filter wheel is electronically controlled via a TDA7275A speed control chip to four revolutions per second. Infrared opto switches provide commutation (filter identification) using the holes in the edge of the filter wheel. One pair provides a count pulse, and the other provides a home indication. Figure 2.3.4-1 shows the photometer mechanism. Figure 2.3.4-2 illustrates the photometer and absorbance conversion signals (filter count, home, sample and hold, filter peaks and comparator output waveforms). The photometer mechanism consists of four elements: The filter wheel and rotation mechanism: The filter wheel is rotated by a small DC motor connected to the wheel by a rubber belt. The wheel speed is electronically controlled to four revolutions per second. As the wheel turns, the filters mounted in it pass between the light source and the photo detector, the reading is taken when the filter passes through the light beam. Filter wheel position detection system: Optical gates (beam interrupt switches) are used to control the filter wheel speed and take readings. Normally the infrared light from the LCD side of the gate is blocked, but when the small holes in the filter wheel pass by, the light passes through and the microprocessor receives a signal. There are two sets of holes. One set consists of several holes, one at each filter. When one of these holes is detected, the filter is lined up, and a reading is taken. The other set is only one hole and it is used primarily for synchronizing the filter count. Light source: The light source consists of the lamp with its built-in lens, the diffuser, and the aperture block. The light, originating at the lamp, passes through the diffuser, then through the sample plate, the aperture block, and then into the photometer. This area under the spot of light is known as the read site. The connection to the lamp and filter wheel motor is the junction PCB with an IDC (insulation displacement connector.) Optical detection system: This system consists of a photometer PCB on which is mounted: a light sensitive photodiode and the operation amplifier. The optical system is connected to the junction PCB using a 14-pin (2 x 7) header cable assembly.

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Figure 2.3.4-1 - Photometer Mechanism

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Figure 2.3.4-2 - Photometer and absorbance conversion signals

Use the home signal to trigger an oscilloscope to observe the test points J8 as shown above. Each filter peak is sampled and held (U15 Pin 1) and simultaneously converted from an analog signal to a digital absorbance by an exponential capacitor decay circuit (U14 Pin 7) and one of the 16 bit counters in U16 Pin 11. (See the photometer schematic.) The photometer output is proportional to the power of the light signal whereas the width of the positive phase of the pulse at the counter chip is proportional to the absorbance. The resistance (TP1) across the log cap (simple RC decay) determines the base of the log (10 for absorbance) and is used to adjust the low end absorbance calibration (gain). Another potentiometer (TP3) is used to null the offset voltages in the circuits and serves to adjust the hi-end absorbance indications.

CAUTION: Do not turn trim pots. Refer to the Calibration Section.

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2.3.5 Flowcell
If proper care is taken to clean the Flowcell between uses, especially after highly proteinaceous liquids have been sampled, the Flowcell itself should require little or no maintenance. The Flowcell should be cleaned regularly as described in the section entitled Cleaning the Flowcell. If the Flowcell tubing has become damaged or the Flowcell is clogged, reference the service procedure Flowcell Tubing Replacement. Erratic readings (excessive dither) may be a result of trapped air in the Flowcell. This can be caused by improper installation of, or failure of the Flowcell tubing or coupling tubes. Refer to the Flowcell Tubing Replacement section. Check the insertion depth of the Flowcell tubes into the coupling tubes. Ensure that a leakfree seal is made and that no tubes are kinked or pinched off.

2.3.6 Valve
The valve uses a short length of silicone tubing. If the valve operates but no sample is drawn up, the pinch valve tubing may be blocked. To check for clogged valve tubing, unscrew the Flowcell vacuum line from the Luer fitting. Activate and hold Sample Sensor Optical Switch and listen for aspiration. If you hear aspiration, the valve is operating, but the Flowcell is clogged. If you do not hear aspiration, the valve tubing is clogged. Refer to the Valve Tubing Replacement section.

2.3.7 Vacuum Pump and Pump Control Circuit


The vacuum pump and pump control Circuit should require no maintenance. If the vacuum pump runs continuously, you probably have a leak in the vacuum side. Check the waste bottle cap and fittings. Check that the tubing is firmly seated on barbs and all fittings are tight. Turn the fittings only until finger-tight; do not over tighten the plastic Luer fittings. If the waste bottle is located at a higher or lower level than the instrument, such as on a shelf, or if the instrument is used at very high altitudes, the vacuum trim pot may require adjustment. See the Vacuum Adjustment section. If the vacuum pump is taking longer to achieve full vacuum (runs much longer than usual, but otherwise works), the exhaust filter is likely clogged and should be replaced. In the event that the exhaust filter gets wet due to a waste bottle spill, it must be replaced. Reference the Exhaust Filter Replacement section for instructions on replacing the exhaust filter.

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2.3.8 Temperature Control


The temperature control system is very stable and ordinarily does not require adjustment or recalibration. In the event calibration must be verified or reestablished, refer to the section titled Temperature Calibration.

2.4 Parallel Interface


The locations of the parallel port and the RS 232 serial port on the rear deck of the unit are shown in Figure 2.2-2. The parallel interface is industry standard Centronics compatible. The cabling is the industry standard parallel printer cable. Below is the pin out list for the parallel port on the Stat Fax 3300: Pin # 1 2 3 4 5 6 7 8 9 11 12 16 19-25 Function Strobe Data0 Data1 Data2 Data3 Data4 Data5 Data6 Data7 Busy Paper Out Initialize Ground Direction To Printer To Printer To Printer To Printer To Printer To Printer To Printer To Printer To Printer From Printer From Printer To Printer

2.5 Auxiliary and Optional Equipment 2.5.1 Auxiliary Equipment Interface


Parallel Port: The Stat Fax 3300 can send results out to a printer with a parallel port. The Stat Fax 3300 has a 25-pin female connector on the back of the hatch cover. This connector is a standard parallel port. A standard parallel cable normally used to connect a PC to a parallel printer can be purchased from any computer store. See Section 2.4 Parallel Interface for pin outs. Serial Printer: The Stat Fax 3300 can print its results out to an Epson compatible serial printer using the included serial interface port. The data is sent at 9600 baud, No Parity, 8 data bits, and 1 stop bit. The connection requires a standard serial cable. External Heat Block: The Stat Fax 3300 comes standard with an External Heat Block. The External Heat Block maintains its temperature at 37.5 C and is connected to the rear of the Stat Fax 3300. When active, the temperature is displayed on screen.

2.5.2 Optional Equipment

External Keyboard. The Stat Fax 3300 can also be operated using an External Keyboard attached to the port on the rear panel.

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3. SERVICE PROCEDURES
3.1 Opening the Instrument
Refer to Figure 3.1 Instrument Interior. The cover is hinged at the rear panel, and can be raised to allow access to the inside of the instrument. Disconnect the power cable, the tubing, and the sensor lead from the rear panel. Locate and remove the two cover screws from the underside, one on each side (shown with arrows in Figure 3.1). Gently lift the front of the cover upward, taking care to clear the photometer. Prop the cover open with a suitable object. Do not force the cover backwards. Damage to the cover or fittings may result. To reinstall the cover, reverse the procedure. Carefully lower the cover until it seats on the chassis, taking care to clear the incubation block and the Flowcell Luer fitting.

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MAIN PCB

Power Supply

Pump

Valve Photometer Fan

Cover Screw

Cover Screw

Figure 3.1 Instrument Interior (internal view with cover lifted)

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3.2 Cleaning the Flowcell


The Flowcell should be cleaned when the instrument will not be used for an extended period, e.g. over night, end of shift, and when storing the Flowcell. Proper cleaning will help to prevent clogging of the Flowcell tubing and valve tubing. Cleaning is extremely important to obtaining accurate, repeatable results. If reagent, serum, or other proteinaceous fluid is allowed to dry in the Flowcell, it is extremely difficult to remove and its presence can affect test results. To clean the Flowcell: 1. Purge with air for at least 5 seconds. 2. Aspirate several ml of Flowcell cleaning solution. Allow the solution to remain in the Flowcell for 3 minutes. 3. Aspirate 15 ml of distilled water then purge with air for 5 seconds. 4. Aspirate 0.1N hydrochloric acid (HCl). Allow the solution to remain in the Flowcell for 3 minutes. 5. Purge with at least 15 ml of deionized water. 6. If the Flowcell is to be removed for storage, purge with air until no more fluid can be seen flowing into the waste bottle. Otherwise, leave the Flowcell filled with water.

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3.3 Flowcell Configuration


Flowcell Configuration offers two choices; read tubes and cuvettes, or to activate the Flowcell with options to change the aspirate (sample) volume, and read and store water reference values.

Flowcell Configuration:
From the TOOLS menu (F4) access the Flowcell Configuration screen by pressing: The screen will display:

Prompt/Response:
F4 TOOLS Numeric Key 2 Current Flowcell STATUS =

Current Flowcell STATUS = ON Current Aspiration VOLUME = 500 L

OFF

The current status of the Flowcell will be highlighted (ON or OFF). Press the F1 key to toggle the Flowcell Mode ON

ON/OFF

VOLUME

CAL MENU

OK

Press the F1 key to toggle the Flowcell Mode ON The screen will display the current aspiration volume. To change the volume, press: The display will prompt: ASPIRATION VOLUME 0 = 750 1 = 600 2 = 500 3 = 450 4 = 400 5 = 350 6 = 300 7 = 250

F1 Current Aspiration VOLUME = F2 VOLUME Enter Aspiration Volume: Make a selection from the seven volume choices. Press ENTER (F4) to accept. Press CLEAR (F3) to entry. Press QUIT (F1) to return to the Main Menu.

Enter Aspiration Volume: QUIT CLEAR ENTER

NOTE: When reading sample in Flowcell Mode, remember to have more sample than the aspiration volume selected. Attempting to aspirate the exact amount of sample may result in poor results due to air mixing with sample. User technique, the shape of the bottom of vessel being used, and the location of the tube during sampling can affect this process.

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Flowcell Configuration: (Continued)


Select the CAL MENU by pressing F3 The screen will display: FLOWCELL CALIBRATION

Prompt/Response:
F3 CAL MENU FLOWCELL CALIBRATION

Enter Menu Number: 1 = Read Water Reference 2 = Flowcell Alignment Enter Menu Number: QUIT A short description of each option follows below. Select the numeric key that corresponds with the option desired.

NOTE: These options may only be used if the Flowcell is active. Press: Numeric Key 1 Read Water Reference: The instrument references water instead of air when reading with the Flowcell. These reference values are stored in non-volatile memory and used whenever the Flowcell is active and until new values are read. This should be done before Flowcell Alignment. In order to insure good blanks when using the Flowcell, conduct Read Water Reference on a regular basis; time intervals depend upon instrument usage and when encountering unexpected (very high, very low) blank values. Numeric Key 2 Flowcell Alignment: NOTE: This option is not necessary under normal operating conditions. Necessary when a new Flowcell is used, or if a lamp replacement has occurred. Conduct Read Water Reference before and after Flowcell Alignment. The Flowcell should be active but NOT inserted into the read well. Press F3 PRINT RESULT to print the current reading. Insert the Flowcell into the read well. Submerge the end of the tubing into a container of water and activate the Sample Bar. Continue with the interruption of the beam until water starts to flow into the Waste Bottle. This will decrease the likelihood of air bubbles interfering with an accurate reading.

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Flowcell Configuration: (Continued)

Prompt/Response:

Numeric Key 2 Flowcell Alignment: (Continued) This reading should be slightly over half of the original reading. If it is not, the Flowcell must be adjusted. If the displayed value is less than 50% of the reading with the Flowcell removed, purge and remove the Flowcell. Adjust the set screw with the hex wrench supplied. Turn the set screw 1/4 turn in either direction and replace the Flowcell. Sample water again. If the value increases, turn the set screw in the same direction. If the value decreases, turn the setscrew in the opposite direction. Repeat until the value is >50%. When complete, press QUIT to return to the main prompt. New water values must be read as described above in Read Water Reference.

Function Key F1 QUIT to return to Main Menu

3.4 Flowcell Alignment


Note that Flowcell alignment is not necessary under normal operating conditions. However, it is necessary to perform Flowcell alignment when a new Flowcell is used, or if a lamp replacement has occurred. Conduct Read Water Reference before and after Flowcell Alignment. The Flowcell alignment instructions can be found above in Section 3.3 Flowcell Configuration.

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3.5 Flowcell Tubing Replacement


The Flowcell utilizes 1.2mm I.D. Teflon tubing for the Inlet (sample) and Exit tubes. Replacement tubing is included with the tubing kit. Follow this procedure to replace the Flowcell tubing. Materials/tools required: Tubing kit Tweezers Phillips screwdriver Isopropyl alcohol

Inlet (sample) tube

Exit tube

Figure 3.5A Flowcell Lift and remove the Flowcell out of the read well.

Flowcell handle Flowcell upper body

Flowcell lower body assembly

Figure 3.5B Flowcell

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Remove the two flathead screws from the retainer plate to remove the Flowcell handle (reference Figure 3.5B and 3.5C)

Flowcell handle

Remove the retainer plate from the Flowcell handle by removing the two flathead screws.
Retainer plate

Figure 3.5C Remove the flathead screws on the retainer plate

Inlet tubing

Exit tubing

Tube support

Flowcell handle

Figure 3.5D Remove Exit tubing Remove the Exit tubing (reference Figure 3.5D) at the metal tube and pull it through the Flowcell handle. Slip the Inlet tubing out and away from the Flowcell handle. Remove the two pan head screws with split lock washers from the underside of the retainer plate (reference Figure 3.5E) and slide off the retainer plate.

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Remove the two pan head screws with split lock washers from the underside of the retainer plate.

Figure 3.5E Remove two pan head screws with split lock washers

Remove the upper cell body from the lower cell body assembly by removing the two flat head machine screws from both sides of the upper cell body (see Figure 3.5F). Once the screws are removed, pull the upper cell body apart from the lower cell body assembly.

Remove screws from both sides

Upper cell body Lower cell body assembly

Figure 3.5F Remove the lower cell body assembly

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Remove the four flathead screws from the cell retainer plate (reference Figure 3.5G).

Remove the four flathead screws from the lower cell body retainer plate.

Figure 3.5G Lower cell body assembly Once the cell retainer plate is removed, lift off the cell window and the seal to access the metal cell insert. Grasp the cell insert and lift it out from the lower cell body. Remove the Inlet (sample) tubing from the steel tube on the cell insert. Remove the ground contact sleeve from the metal tube. Locate the Inlet (sample) tubing from the tubing kit. Carefully press the end of the Inlet tubing (the swaged end) onto the short steel tube of the cell insert. Reassemble the lower body assembly following the illustration shown in Figure 3.5H. Read the tip that follows for immobilizing the glass cell window to make reassembly easier.

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Useful T I P for reassembling the lower cell body assembly:

Ensure that an o-ring is inserted into the cell retainer plate (reference Figure 3.5H). Position an o-ring, a glass cell window, a Teflon seal, the cell insert, and the remaining Teflon seal into the lower cell body per Figure 3.5H. While holding the remaining glass cell window by its edge with tweezers, dip the remaining glass cell window in isopropyl alcohol (this will help immobilize the cell window for ease in placement) and place it in position on the underside of the cell retainer plate. Insert two of the screws into the cell retainer plate at opposing corners and set the cell retainer plate into position and tighten the screws. Install the remaining two screws. Once the lower cell body is assembled, attach the upper cell body to the lower cell body assembly by slipping the Inlet tubing and metal cell insert through the center hole of the upper cell body. Push the two pieces together until they are flush. Reinstall the two flathead machine screws to each side of the upper cell body to hold the upper cell body and the lower body cell assembly together (reference Figure 3.5F and Figure 3.5I).

Insert flat head screw on both sides and tighten


Figure 3.5I Upper cell body and lower cell body assembly Slide the Inlet tubing and metal insert through the center hole on the retainer plate (reference Figure 3.5E).

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Figure 3.5H illustrates the process of assembling the Flowcell lower body once it has been taken apart for inlet (sample) tube replacement or for cell insert replacement.

Figure 3.5H Flowcell lower body assembly

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Reinstall the two pan head screws with split lock washers to attach the retainer plate to the assembly (Figure 3.5J). Insert the ground contact sleeve over the metal cell insert tube (reference Figure 3.5J) pressing it into place until the ground contact sleeve is at the height of about 1/8.

Underside of retainer plate with the two pan head screws with split lock washers in place Metal cell insert for exit tube with ground contact sleeve in place

Figure 3.5J Flowcell lower body assembly Feed the Exit tube through the hole provided in the Flowcell handle (reference Figure 3.5D). Feed the Inlet tube into the Inlet (sample) tube support via the hole provided inside the Flowcell handle. Attach the Exit tubing to the metal cell insert (reference Figure 3.5D). Carefully, without kinking the tubing, snug the Exit tubing and the Inlet tubing into place such that the retainer plate can be fastened to the Flowcell handle. CAUTION: Handle carefully. Do not pinch the tubing. Reinstall the two flathead machine screws (reference Figure 3.5C) to hold the retainer plate and assembly to the Flowcell handle. Follow the process for testing for leaks in the Flowcell assembly.

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3.6 Testing for Leaks in the Flowcell Assembly


Test for leaks when the Flowcell has been disassembled and reassembled as for tubing or cell insert replacement. The Flowcell should be active but NOT inserted into the read well until stated to do so.

Testing for Leaks in the Flowcell Assembly:


From the TOOLS menu (F4) access the Flowcell Configuration screen by pressing numeric key 2

Prompt/Response:
F4 TOOLS Numeric key 2 Flowcell Configuration Current Flowcell STATUS =

The screen will display:

Current Flowcell STATUS = ON Current Aspiration VOLUME = 500 L

OFF

The current status of the Flowcell will be highlighted (ON or OFF). Press the F1 key to toggle the Flowcell Mode ON

ON/OFF

VOLUME

CAL MENU

OK

Press the F1 key to toggle the Flowcell Mode ON Select the CAL MENU by pressing F3 The screen will display:
FLOWCELL CALIBRATION 1 = Read Water Reference 2 = Flowcell Alignment Enter Menu Number: QUIT

F1 F3 CAL MENU FLOWCELL CALIBRATION

Enter Menu Number: Numeric key 2 Flowcell Alignment

Select Flowcell Alignment by pressing numeric key 2 NOTE: These options may only be used if the Flowcell is active.

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Testing for Leaks in the Flowcell Assembly:


Perform an air voltage reading (the Flowcell should be active but NOT inserted into the read well) by pressing the Sample Bar. Press F3 to print the result and press Enter. Press LINE FEED twice to advance the paper feed so that the reading is visible. Install the Flowcell into the photometer. Snug the Exit tubing into the Flowcell Luer fitting (do not over tighten). Fill the Flowcell with water by placing the Inlet (sample) tube into a container of deionized water. Press and hold in the Sample Bar until there are no air bubbles visible in the Exit tube feeding into the Waste bottle. This reading displayed should be slightly over half of the original reading. If it is not, see the following scenarios to correct the problem: 1) Check to see that the Inlet (sample) tubing is not kinked behind the retainer plate in the Flowcell handle. Remove the two flathead screws from the retainer plate under the Flowcell handle. Ensure that the tubing is not kinked as this will hinder its ability to aspirate. Reinstall the retainer plate to the Flowcell handle. Perform the reading again. If the reading is not > 50% of the original reading see the step below. 2) Disassemble the Flowcell as detailed in Section 3.5 Flowcell Tubing Replacement. Ensure that the o-rings, glass cell windows, and seals are seated properly. Ensure that the swaged end of the Inlet (sample) tubing is securely attached to short steel tube of the cell insert. Reassemble the Flowcell and perform the reading again. When complete, press QUIT to return to the main menu.

Prompt/Response:
F3 PRINT RESULTS ENTER

LINE FEED LINE FEED

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3.7 Flowcell Cell Insert Replacement


The Flowcell may be disassembled for extensive cleaning or replacement of the cell insert. To replace the cell insert, follow the instructions on disassembling the Flowcell in Section 3.5 Flowcell Tubing Replacement. Once the lower cell body assembly is disassembled, remove the cell insert and install the new cell insert. Assure the correct orientation is used when installing the new cell insert by following the illustration in Figure 3.5H. Reassemble the Flowcell following the instructions in Section 3.5 Flowcell Tubing Replacement. Use the procedure provided to check for possible leaks in the Flowcell. After assembly, complete the procedure in Section 3.4 Flowcell Alignment to restore optical alignment.

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3.8 Main PCB and/or Photometer Replacement 3.8.1 Photometer Replacement


1. Open the instrument. Refer to Figure 3.1. Locate the photometer. Unplug cables from the main PCB.

2. NOTE: For ease of relocating for reassembly, mark the chassis with a pencil along the front and side edges of the photometer subassembly as shown below.

3. Locate the two #6 screws holding the photometer assembly to the chassis. From the bottom of the instrument, remove these screws, washer, and the speed nuts from inside the instrument.

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4. Install the replacement photometer subassembly to the chassis by replacing the two #6 self tap screws with internal tooth lock washers through the chassis base and the photometer mounting slots and into the speed nuts. Line up photometer with locating marks made in step 2. Connect the cables removed in step 1. NOTE The internal tooth lock washer must make electrical contact (ground) with the chassis base for low noise operation.

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NOTE: Screw locations shown at black circles.

Figure 3.6.2 Main PCB NOTE: Screw locations shown above with black circles

3.8.2 Main PCB Replacement


1. Open the instrument. Refer to Figure 3.1. Locate the Main PCB. Unplug cables from the main PCB and disconnect the wires from the Power Supply. 2. Refer to Figure 3.6.2. Remove the four screws securing the Main PCB. Secure the replacement PCB in the same fashion as the removed PCB. 3. Reconnect Power Supply Wire Harness. Plug in all remaining cables.

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3.9 Valve Tubing Replacement


It is not recommended to replace any tubing while the instrument is performing properly. However, the short length of silicone tubing used in the sampling valve may become clogged or worn with age. A replacement is included in the tubing kit. Set the power switch to OFF (O). Open the instrument as described in Section 3.1 Opening the Instrument. Refer to Figure 3.1. Locate the valve. Refer to Figure 3.9. Pull back the pinch bracket and remove the valve tubing from the valve body. Disconnect the valve tubing from the fittings at both ends. Install the replacement tubing to the valve body in a similar manner. Push the tubing over the tubing barbs until seated. Be especially careful not to kink, stretch, or tension the tubing. Lower the cover and replace the screw.

Pull towards the front of the instrument to free tubing

Figure 3.9 Valve Tubing Replacement

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3.10 EPROM Replacement


1. Firmware update consists of one EPROM to be installed in the instrument as follows: Access the circuit board by turning off the instrument, disconnecting the power cord and removing the cover as shown in Section 3 Service Procedures. 2. Locate the EPROM socket (see Figure 3.10.2) and push the small blue levers outward at both ends of the socket (see Figure 3.10.3). This frees the EPROM for easy removal and insertion. 3. If necessary, gently bend the pins of the new EPROM so that the pins are perpendicular to the EPROM (see Figure 3.10.1). Hold the EPROM by the body and bend the pins against a flat surface such as a table to bend all the pins the same amount. Do not over bend the pins, since they are easy to break if bent too far.

Figure 3.10.1 - Correct Alignment of EPROM Pins 4. Install the EPROM with the notch oriented as shown in the label on the EPROM socket. The notch should face toward the left side of the instrument. Figures 3.10.2 and 3.10.3 display the location of the EPROM on the Main PCB and an enhanced view of the EPROM label showing the direction of the arrow for proper orientation. 5. Reinstall the cover and power cord. Turn the instrument back on.

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EPROM Replacement (Continued)

Figure 3.10.2 - Location of EPROM on Main PCB

Note the direction of the arrow on the EPROM label for proper orientation.

Figure 3.10.3 Enhanced view of the EPROM

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3.11 Filter Change Procedure


Refer to Figure 3.11.2 Photometer Illustration for this procedure. Materials/tools required: Replacement filter with neutrals and retainer Phillips screw driver Flat blade screw driver (small) Awl with blunt tip (or similar for prying) Wooden dowel (or similar for pressing) 7/16" diameter

1. Disconnect the unit from the AC power source and detach the power cord. Open the instrument (see Section 3, Service Procedures). Set the cover out of the way. 2. Locate the photometer. Unplug the 4 pin lamp/motor cable from the interconnect printed circuit board (PCB). Using the flat blade screw driver, unplug the gray cable from the interconnect PCB. NOTE: Do not remove the spacers from the photometer. Removing or altering their position on the photometer will require the unit be realigned per the procedure in the service manual. Do not move the lamp or the lamp bracket. 3. IMPORTANT: Refer to Figure 3.1. Follow the procedure in Section 3.8 Main PCB and/or Photometer Replacement for removing the photometer. 4. Remove the four 6-32 screws retaining the photometer cover. Set the cover aside. Remove the two 4-40 screws securing the photometer PCB. Remove the drive belt from the filter wheel. Using the blade screwdriver, remove the filter wheel shaft. Remove the wheel. Remove the shaft taking care not to misplace the nylon spacer/washers.

Figure 3.11.1 - Filter Wheel

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5. Locate the filter to be removed (see Figure 3.11.1). 6. There are two means of filter retention in field use; silicone glue or a retaining ring. If a retaining ring is used, carefully pry two to three of the retaining ring teeth away from the filter until the ring is dislodged and remove the ring and filter. If silicone glue is present, remove the silicone and push the filter from the wheel using the eraser end of a pencil or other soft blunt object and any residual glue should release. Remove any neutral or screen disks that may remain in the filter cavity. 7. Locate the neutral filters and/or screens that were included with the replacement filter and drop them first into the cavity. Next insert the filter with the mirror side down. Place the replacement retainer over the filter so that the tabs are angled away from the filter and press in place with a 7/16 diameter wooden dowel or similar object. 8. Reinstall the filter wheel on the bracket taking care not to pinch any washers under the shoulder of the shaft. Tighten the shaft. Replace the belt. Replace the photometer PCB taking care to center the board around the shaft. Tighten the two 4-40 screws. Replace the optical cover taking care to position the gray cable in the slot of the cover. Do not pinch the cable under the cover. Insert the three 6-32 screws and snug up. Do not over tighten. 9. Reinstall the photometer assembly as per Section 3.8. 10. If necessary refer to the lamp alignment procedure in the service manual. 11. Plug the cover cable back into the main PCB. Replace the cover but do not install the cover screws. If an updated EPROM was included with the filter replacement kit, install it now referring to the EPROM replacement sheet. 12. Attach the power cord and connect the unit to the AC power source. Turn the unit on. The displayed numbers represent the voltages of the installed filters. All voltages should be between 2 and 10 volts. To terminate this mode, press Clear as required. NOTE: If the filter voltage is not in the range specified in the previous step, check lamp alignment. If the lamp alignment is properly set, the neutral density filters may need to be changed. Add neutrals to lower the voltage. Remove neutrals to increase the voltage. Never adjust the trim pots on the main PCB to obtain the correct voltage. Refer to Section 4 Troubleshooting as needed. 13. Detach the unit from the AC power source. Replace the two cover screws. Refer also to Section 3.12 Lamp Replacement and Section 4 Troubleshooting.

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Remove Screws

Remove Connectors Red Wire

Remove (3) screws holding photometer to the base. Belt Filter Wheel Shaft Filter Retainer

Remove retainer (if used), filter, and neutrals with soft, blunt object.

Two Nylon Washers Install replacement neutrals, filter, and retainer using 7/16 dowel.

One Nylon Washer

Figure 3.11.2 - Photometer Illustration

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3.12 Lamp Replacement


The lamp should be replaced only if it fails to light, or several filter voltages are reported as low. To replace the lamp, follow the procedure below.

CAUTION: Turn the power OFF and unplug the instrument


Open the instrument as described in Section 3.1 Opening the Instrument. Locate the photometer and the lamp at the right side of the photometer. Refer to Figure 3.12-1 Lamp Replacement. The figure shows the right side view of the photometer assembly.

CAUTION: Lamp is HOT. Allow the lamp to cool before handling. Avoid handling with bare skin.
Loosen but do not remove the two center lamp connector screws. Remove the lamp by lifting upward. Use a pair of pliers or tweezers to handle the new lamp. Avoid handling with bare skin. Insert the lamp leads into the connector until they hit bottom. Refer to Figure 13.12-2, for proper lamp alignment. The lamp filament must be centered on the lens and the lamp body must be parallel with the lens bracket. While holding the lamp in alignment, tighten the lamp connector screws. Set the power switch to ON. Observe the projection of the light from the lamp onto the cell holder (behind the lens). Refer to Figure 3.12-2 for spot alignment. The spot should be small and centered on the oval hole in the cell block (behind the lens). If the spot is not centered, use the adjustment screws to position the spot. The vertical adjustment screw raises and lowers the lamp bracket. The lamp bracket is slotted at the horizontal adjustment screw, so that the lamp bracket can be moved. The horizontal adjustment screw serves to lock down the lamp bracket. Insert a borosilicate 12 mm tube filled with plain water into the read well. Do not use a soda-lime glass tube, since it does not transmit at 340nm. Press F4 (TOOLS). Press 4 and ENTER. Press 1 and Enter. The display shows the voltages for each filter.

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Figure 3.12-1 - Lamp Replacement

X
Correct Incorrect Figure 3.12-2 Proper Lamp Alignment

X
Incorrect

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3.13 Vacuum Adjustment


For the purpose of adjusting the vacuum perform the following: With the Waste bottle assembly connected properly to the instrument (reference Section 2.2 Parts and Controls), disconnect the vacuum line at the blue fitting at the rear of the instrument; connect this vacuum line with the blue luer to the vacuum gauge; connect the vacuum gauge to the back of the instrument at the blue fitting forming a tee (Figure 3.13-1).

Vacuum gauge

Pressure side of waste bottle

Instrument rear panel

Figure 3.13-1 Vacuum gauge connection Set Flowcell Mode On via the TOOLS menu F4 Select Flowcell Configuration numeric key 2 Toggle the Flowcell Status ON via the F1 key Select F4 OK Press and release the Sample bar. The vacuum gauge should read 7.0 0.5. If not, adjust trim pot TP2 until the reading on the vacuum gauge is within the acceptable range. When the reading on the vacuum gauge is within the acceptable range, remove it and connect the vacuum line to the instrument at the blue fitting. Perform Self Check by selecting the TOOLS Menu F4; select Diagnostics Menu numeric key 4; select Self Check numeric key 6, and check that the vacuum system reading displayed is OK, select F1 to Quit.
System Diagnostics: EEPROM OK NV RAM OK Vacuum System OK Aspiration Valve OK Photometer OK ______________________________________ QUIT REPEAT ENTER

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3.14 Exhaust Filter Replacement


To replace the exhaust filter: Set the power switch to OFF (O). Carefully release pressure from the Waste bottle. Before uncoupling the exhaust filter from the Inlet tubing, note the orientation of the wording (INLET) on the exhaust filter. The side of the exhaust filter with the wording (INLET) should face away from the blue vacuum fitting (see Figure 3.14-1). Pull the tubing from the fittings on the filter. Install the new filter with the INLET side pointing away from the blue vacuum fitting. Push the tubing on the fitting until seated.

Exhaust filter Inlet wording

Vacuum fitting (blue)


Figure 3.14-1 Exhaust Filter

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4. TROUBLESHOOTING
Presented below are some possible problems and their solutions.

4.1 Keypad Problems 4.1.1 No Keys Function


If on power up the LCD functions, the interconnection between the main circuit board and the keyboard interface is OK. If the unit beeps briefly immediately at power-up and no keys function, either the cable is not plugged in correctly, the key tail is shorted, or there is a stuck key. Unplug the keypad to determine if it is malfunctioning. Check that the tracks are covered down to the insertion point. If the covering has been damaged, insulate it with clear tape. If the problem still persists, massage over the keypad until the beeping starts. If necessary, stick the key with a pin to equalize the air pressure inside. If necessary, replace the keypad. If the tracers on the key tails are missing conductive material at the end that plugs into the interface PCB, the insulation may be trimmed back 1mm at a time to expose fresh contact material. Check that the key tails are properly inserted and covered to 1/4" from the end as discussed in Section 4.1.1. If a row (horizontal) does not function, check that the low level on the appropriate line of Port B can be transmitted to the desired line of Port C. Reference schematic. It is highly unlikely that a component has failed. It is more likely that a plated through hole on the interface board has failed. Trace the circuit on the board, and replace if necessary. The problem is probably the connection between the keyboard interface and the main board. Make sure that the 14 pin cable is plugged in correctly on both ends. A keypad with a stuck key will be ignored by the firmware so that an external keyboard can be used. A series of thirty beeps will be emitted, and the keypad will be disabled. To override the password protection, power-up the instrument while pressing the numeric 5 key on the internal keyboard for a short duration, such as five beeps. NOTE: To avoid the stuck key scenario, it is Important that the key be pressed for a very short duration, such as five beeps maximum. The password control window will display the status of the password; the status can be changed from ON to OFF.

4.1.2 A Row or Column of the Keypad Does Not Function

4.1.3 The Keyboard and Display Do Not Function

4.1.4 Keypad Key Stuck

4.1.5 Password Protection Override

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4.2 Photometer Problems 4.2.1 Lamp Low/Filter Low Message is Displayed


Check that the lamp is illuminated and is properly aligned. Insert a borosilicate 12 mm tube filled with plain water into the read well. Do not use a soda-lime glass tube, since it does not transmit at 340nm. Press F4 (TOOLS). Press 4 and ENTER. Press 1 and Enter. The display shows the voltages for each filter. Make sure that all are greater than 2 volts. If a particular channel is low, the filter may be degrading. Ensure that the lamp is fine and that there is nothing blocking the light path such as dirt or dust. Replace if less than 1 volt. Check that the wire harness that goes from the main circuit board to the photometer is installed properly. If the filter wheel motor is running, but the filter wheel does not seem to be rotating, check the two rubber belts. If the motor is not turning, check that the motor has between +5 and +6 volts across the motor terminals. (Make sure that the reader is attempting to read a plate or running test 186.) If there is no voltage on the motor, check for a high level on ULN2003, pins 1 and 2. Also check that the 7806 has +6 volts on its output terminal. Check that the wheel count pulse is transmitting to the NMI pin of the Z180. It should be a narrow, negative spike. Also check that the wheel home pulse is arriving at the 8255 port, PC6 pin 11. If neither are present and the cables are installed correctly, check the IR LCD pair on top of the photometer housing for 1.2 to 1.5 volts between the black and the white wire. A reading of +5 volts here indicates an open LCD or unterminated return.

4.2.2 Filter Wheel Does Not Rotate


4.2.3 Filter Wheel Runs at an Uncontrolled Rate


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4.2.4 Incorrect Control Readings


Check that the procedures and materials used were valid. Turbid or contaminated reagents may affect absorbance readings. Reading reference dyes can be very helpful in separating instrument problems from reagent problems. Be sure that the appropriate wavelengths were selected for the chromophore being read. Tubes should have no bubbles, condensation, scratches or smudges. If the instrument is several years old, or has been operated in very humid conditions, new optical filters may be needed. The instrument incorporates interference filters of an advanced technology, and will provide extended life in humid environments when compared to standard soft interference filters. However, excessive humidity should be avoided. The instrument will require service to replace the filters.

4.2.5 Poor Linearity

4.2.6 Erratic Readings


One possible source of erratic readings (excessive dither) is trapped air in the Flowcell. This can be caused by improper installation of the Flowcell tubing. Refer to the Flowcell Tubing Replacement section. Check the insertion depth of the Flowcell tubes. Ensure that a leak-free seal is made. The lamp is rated to read over 300,000 tubes, and the lamp saver feature minimizes lamp idle time. Lamp replacement is only indicated when the lamp fails to light, or when the message Lamp output low! is displayed. Press LAMP to turn the lamp on or off. If the lamp fails to light, refer to the section titled Lamp Replacement. If you can hear the valve cycle, but no sample is drawn up, the valve tubing may be blocked. Press and hold PURGE several times. Disconnect the Luer fitting at the rear of the Flowcell. Press PURGE and listen for aspiration. If air is heard entering the fitting, the valve tubing is clear, but the Flowcell is blocked. Refer to the Flowcell Cleaning section and the Flowcell Tubing Replacement section. If the valve clicks but the pump does not run when you activate the Sample Switch, the valve tubing may be stuck closed. If this happens, remove the front cover screw and lift open the cover. Pull the pinch bracket against the spring tension (to open the valve manually). Gently pull the tubing slightly to break the seal. See the section titled Valve Tubing Replacement for a diagram and more information about the valve tubing.

4.2.7 Lamp failure

4.2.8 No sampling

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5. CALIBRATION
This instrument relies on software calibration. All calibration data is stored in serial EEPROM memory. This data is used by the microprocessor to compensate for variations in electronic components and manufacturing. During factory calibration, the calibration data is set and any hardware adjustments are made using precision reference standards. The calibration data is then recorded on a label located on the bottom of the instrument. The factory calibration is very stable and does not drift appreciably over time, making trim pot or other component adjustments unnecessary unless the trim pots are disturbed or calibration-related components replaced. Recalibration of the instrument, software or otherwise, should not be considered until all possible interfering factors have been ruled out. If field calibration is in fact necessary, it should only be performed with the proper reference materials and instruments. In any case, software calibration should be attempted before any trim pot or component replacements or adjustments are considered. The temperature calibration data is stored as offsets which the instrument adds to the sensed temperatures. The absorbance calibration data is stored as a scaling factor, which is the ratio of a known reference absorbance to the instrument's reported absorbance. The calibration data may be printed at any time by selecting test #213. This prints the serial number of the instrument, the date of last calibration, and the stored calibration data for the absorbance and cell temperature. The calibration data is stored with a check sum that is recalculated and compared each time a mode is selected. Failure to recover the calibration data properly (checksum failure) will be indicated on the display and the internal printer: Do Temperature Calibration Test Do ABS Calibration Test The instrument annunciates this condition with multiple beeps. The temperature offset for the read well is then set to 0.0 and the absorbance scaling factor is set to 1.000. In this condition, the maximum temperature error is 1.5 C and the maximum absorbance error is 10%. The calibration data can be restored as described in Restore calibration. The hardware calibration of the instrument in time is based on an 18 MHz ceramic resonator RES1. Calibration in temperature is based on trim pot TP4 and time. Calibration of absorbance is based on C17, a 0.1f polystyrene capacitor, trim pots TP1 and TP3, and time.

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5.1 Calibration and Absorbance Linearity


Each instrument is calibrated during manufacturing using standards that are traceable to the National Institute for Standards and Testing (NIST), and is tested to verify its linearity to 2A. This preset calibration is very stable. Absolute calibration can be verified with the use of NIST filters, or by periodic comparison to a reference instrument that is known to be calibrated to NIST filters. Calibration may be confirmed using a commercially available calibration check set which can be obtained from your distributor. A periodic verification of instrument linearity is advised. Since most lab test results are based upon standards rather than upon absolute absorbances, the linearity of the instrument is the more critical indicator of instrument performance.

CAUTION: DO NOT ALTER ANY POTENTIOMETER SETTINGS Changing these settings will make the factory calibration data invalid. In the unlikely event the calibration data is lost or corrupted, the absorbance factor is set to 1.000 and the temperature offset adjustments for the cell are set to 0.0. Do not enter values other than those recorded on the calibration label unless absolutely necessary.

5.2 Restore Calibration Data


Each unit is electronically calibrated at the factory. The calibration values are entered by the keyboard and stored in nonvolatile memory. The instrument will not accept a change greater than +/- 10% (.900-1.100) for the absorbance factor, nor will it accept a temperature offset change greater than +/- 2.5C. Only minimal calibration adjustments are accepted from the keyboard. Do Temperature Calibration Test Do ABS Calibration Test If either of these messages are printed or displayed, it indicates that the calibration values have been lost. These messages will be printed each time that the instrument is turned on, a mode is selected, or a test is recalled. The instrument will continue to operate, but the calibration must be restored to ensure the accuracy of the instrument. WARNING: DO NOT ALTER ANY POTENTIOMETER SETTINGS ! Changing these settings will make the factory calibration data invalid. In the unlikely event the calibration data is lost or corrupted, the absorbance factor is set to 1.000 and the temperature offset adjustments for the cell are set to 0.0. Do not enter values other than those recorded on the calibration label unless absolutely necessary.

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Follow these steps to restore the electronic calibration: 1. Shut off the instrument. Remove any tubes or cuvettes from the read well. Carefully lift up the instrument and locate the Calibration Data label on the underside of the unit. There are (2) values recorded there: Absorbance and Cell Temp. Write down these numbers. 2. Set the power switch to ON(1). 3. If the date and time have been reset or are incorrect, enter the correct date and time. See the section Set Date and Time in the Operators Manual. 4. Press TOOLS (F4). Press 4 and Enter. The Diagnostics Menu is shown. Choose 3 for Absorbance Calibration and Enter. Enter the Number. 5. Choose 4 for Temp Calibration and Enter. Enter the Number. 6. Press Run Test (F1), type in 213, and press ENTER to get a report of the calibration data. The cell temperature adjustment will be printed along with the absorbance adjustment. Make sure that these values are the same as those recorded on the calibration label.

5.3 Temperature Calibration


Materials and equipment necessary: 12 mm borosilicate tube Reference Thermistor probe YSI Inc. #44108 or equivalent. 30K @ 25C, 0.2 interchangeability Stat Fax 3300 Temperature Calibration Fixture Digital ohmmeter (DMM), 0.5% or better accuracy

Temperature calibration: 1. Ensure that the Flowcell is active. 2. Remove the Flowcell and install the Temperature Calibration Fixture into the read well. 3. Allow 15 minutes for equilibration. 4. Set the DMM to read 20K. Read the resistance of the Thermistor and the fixture. If the resistance is between 17724 and 18712 , no adjustments are needed. Otherwise, continue to the next step.

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Temperature calibration: (Continued)

5. Calculate the temperature offsets using the following formula: T = R - 18210 C Where: R is the measured resistance. C is equal to 750 if the measured resistance is greater than 18210. C is equal to 720 if the measured resistance is less than 18210. 6. The display shows: Cell adjust= Type the offset calculated for the cell and press ENTER. The maximum allowed adjustment is 3.0C . Entering values that exceed this net number will produce an out of range message. 7. Repeat steps 4 through 8 until the temperature is 37C 0.3. 8. Select test #213 to see the current net adjustments. Record the new values on the calibration label located on the bottom of the instrument.

5.4 Absorbance Calibration


Materials and equipment: 12 mm borosilicate tube Reference spectrophotometer Reference material which peaks at one of the instrument's wavelengths. Precise 1:2 serial dilution of the reference material.

1. Ensure that the Flowcell is active. 2. Place a 12 mm borosilicate test tube filled with 1 ml of water into the read well. 3. Select TOOLS, Diagnostics, FILTER VOLTAGES. Confirm that all of the filter voltages are between 2.00 and 10.00 volts. Refer to Section 4.2 Photometer Problems if voltages are not within this range. Never adjust trim pots on the Main PCB to achieve the proper voltages.

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4. Determine the absorbance of both the 1:1 reference material and the 1:2 dilution on a reference spectrophotometer. The 1:2 dilution should be in the range of .8 to 1.2 absorbance. The 1:1 material should be in the range of 1.6 to 2.4 absorbance. 5. Remove the tube and install the Flowcell in the instrument. Press Program to create an ABS test. Select the required wavelengths. Blank on the same diluent material used to prepare the concentrations. 6. Read the 1:2 dilution. Divide the absorbance as read on the reference spectrophotometer by the reported absorbance value. 7. Exit the absorbance mode by pressing QUIT to return to Main Menu. Press TOOLS, DIAGNOSTICS, Absorbance Calibration. At the prompt Absorbance factor= x.xxx?, enter the ratio calculated. When this factor is entered the instrument will display a net factor (the new calibration data). 8. Press QUIT and restart the absorbance mode. Blank as before on the diluent. The 1:2 dilution absorbance should now agree with the reference to within +/-.005 absorbance. 9. Read the 1:1 concentration. It should agree within +/-2 % of the reference. If necessary, carefully adjust trimpot TP3 to achieve this agreement. Re-blank and reconfirm the values. 10. Select test #213 to print the new calibration data. Enter these values on the calibration data label on the bottom of the instrument.

5.5 Restore Filter Labels


Like the calibration data, the wavelengths for the two optional filters are stored in nonvolatile memory. In the event this data is lost or corrupted, the following message will be displayed and printed. Filter Labels 7&8 Clrd! Filter labels need to be re-entered for two of the filters. Open the instrument and locate the filter label on the side of the photometer cover. Key 7 is xxx Key 8 is xxx Where xxx is a three-digit wavelength value. If there are no 7th or 8th filters, they will be listed as BLOCKED. Press RUN TEST (F1), type in 248, and press ENTER. The display prompts: Key 7 = ??? nm

Type in the wavelength for Key 7 that is printed on the label and press ENTER. Repeat for Key 8. use 000 for unused filter positions. Press QUIT to return to the main prompt. Note that, if values for Key 7 and Key 8 are entered when there are no filters present, the filters will be flagged as low when Self Check is run.

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6. CONTACT INFORMATION
If you continue to have problems after consulting your dealer, contact the factory. Phone: USA 772-283-6540 Fax: USA 772-283-8020 E-mail: support@awaretech.com Mailing Address: Awareness Technology, Inc.

P.O. Drawer 1679 Palm City, FL. 34991 USA When contacting us, please have serial number of the Stat Fax 3300 in question. Have a description of the problem with as much detail as possible. Save any relevant jobs or logs to disk and send or e-mail us the information.

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APPENDIX 1 SCHEMATICS

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Layout

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Layout (Continued)

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Layout (Continued)

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