Reagent Storage Module Operating Principles

Purpose

This document details the operating principles for the reagent storage module.

Module Function

The reagent storage module loads, stores, transfers, unloads, and disposes of reagent packs.

The reagent storage subsystem includes all components and assemblies that perform these reagent pack functions:

Loading
Identification
Transporting
Positioning
Storing
Chilling
Disposal

Location
Figure 1. Reagent storage module location (indicated in red)

Note: The reagent storage module is in the same location in the DxI 600 and DxI 800 instruments.

Operational Overview

Stage Description

1 Operator opens load tray cover and places up to four reagent packs into the DxI 800 load tray (two into
the DxI 600).

2 After the load tray cover is closed, the load tray automatically moves to the internal bar code reader.

3 Bar code reader scans the reagent packs so the reagent packs can be tracked.

4 Reagent packs are transferred to storage nests one at a time by the gripper. Because the gripper cannot
pass one pack over another, the gripper removes packs from the load tray from left to right.

5 When an assay is requested, the gripper moves to the desired reagent pack, grasps the pack, and moves it
to the pipetting nests for the reagent pipettors.

6 When the pipettors have completed the requested processes, the reagent packs are transferred back to an
open storage nest.

7 When a reagent pack is depleted, the gripper moves the empty pack to the waste chute for disposal into
the solid waste container. The gripper automatically discards expired packs, if configured to do so by the
operator.

8 If requested by the operator, any reagent pack in inventory can be returned to the operator. When
requested, the gripper moves to the storage nest that contains the reagent pack and then moves the pack
Stage Description

to the load tray. The load tray moves to the tray-out position and unlocks the load door cover. The
operator can remove the reagent pack.
Component Locations

Reagent Pack Locations

This section provides both the UI and trace file numbering sequences used in the reagent storage module.

When not in use, reagent packs are stored on nests oriented in rows and columns.
The pipetting nests are located at the top inside the module.
To transport reagent packs to and from the nests, clear pathways between the columns of nests allow a
two-axis gripper to move packs from location to location. Packs are moved to the pipetting nests when
needed for performing tests.
The reagent storage module has 50 storage nests. The number of pipetting and load tray nests varies by
model.
Each nest holds one pack. Unlike the reagent pipetting nests, the packs are not held in the storage nests
mechanically. Instead, the packs sit loosely in the nests.

Nest DxI 800 Locations DxI 600 Locations

Numbering
System

User Interface Pipetting Nests: Pipetting Nests:

begin with the number 1 at Position begin with the number 1 at Position
P1. P1.
 Nest DxI 800 Locations DxI 600 Locations
Numbering
System

are numbered left to right. are numbered left to right.

Reagent Load Tray Nests: Reagent Load Tray Nests:

are numbered left to right, Load Tray are numbered left to right, Load Tray
1, Load Tray 2, Load Tray 3, Load 1, Load Tray 2.
Tray 4.

Storage Nests: Storage Nests:

are numbered left to right and top to are numbered left to right and top to
bottom, beginning with S1 and ending bottom, beginning with S1 and ending
with S50. with S50

Trace Files Pipetting Nests: Pipetting Nests:

begin with the number 0 at Position
P1.
are numbered left to right.
Pipettor Nest 0 corresponds to
Pipettor 1.
Pipettor Nest 1 corresponds to
Pipettor 2.
Pipettor Nest 2 corresponds to
Pipettor 3.
Pipettor Nest 3 corresponds to
Pipettor 4.
begin with the number 1 at Position
P1.
are numbered left to right.
Pipettor Nest 1 corresponds to
Pipettor 1.
Pipettor Nest 2 corresponds to
Pipettor 2.

Reagent Load Tray Nests: Reagent Load Tray Nests:

are numbered left to right, positions are numbered left to right 4, 5.

4, 5, 6, 7.

Storage Nests: Storage Nests:

are numbered left to right and top to are numbered left to right and top to
bottom, beginning with 8 and ending bottom, beginning with 8 and ending
with 57. with 57.

Gripper: Gripper:

when the Gripper has a pack in its when the Gripper has a pack in its
grip, software numbers that as grip, software numbers that as
position 58. position 58.

Key:

L = the Load Tray

 P = the Pipetting Nest
S = Storage Nest

Trace File Terms Definition

CheckandChangePacks Indicates next planned move by gripper. The move could be a Moving pack to
pipettor or Returning pack from pipettor. No move occurs with the line of text.

i.e. ReagentSupply:TL_CheckAndChangePacks id:563193, Moving pack to

pipettor 3 from 17 and ReagentSupply:TL_CheckAndChangePacks id:563195,
Returning pack from pipettor 0 to 17

Moving pack to pipettor X Gripper moves a reagent pack from slot XX to pipettor X. The gripper moves to the
from XX slot location first. The gripper has no pack in its grip until a Passenger exchange
occurs.

Passenger Transfer Confirms a successful hand-off of the pack from the gripper to a slot, or the slot to
the gripper.

i.e. Pack:1816 Passenger transfer, ReagentSupply:17 to ReagentSupply:58

and Pack:1816 Passenger transfer, ReagentSupply:58 to ReagentSupply:2

Returning pack from Gripper moves a reagent pack from pipettor X to slot XX. Gripper moves to the
pipettor X to XX pipettor location first. The gripper has no pack in its grip until a Passenger exchange
occurs.

ReagentSupply:M_Learn Reagent storage module is doing a remap.

Load Tray Components
Note:

The DxI 800 load tray has a capacity of four packs.

The DxI 600 load tray has a capacity of two packs.
Loading reagent packs into tray

Stage Description

1 The operator manually loads reagent packs into a covered load tray.
Note: The normal state of the loading tray is outside the chilled storage area with the door unlocked.

2 With the load tray out, the operator opens the load door, loads the reagent packs, and closes the door.

3 The instrument automatically locks the cover in the closed position and then begins to move the load tray
into the chilled storage area.

4 As the tray moves into the storage area, the bar code label on each reagent pack is read as the pack
passes under a bar code reader.

5 The load tray moves fully inward, forcing a sealing surface into place that keeps the cooler air in the chilled
storage area.

6 The gripper removes the reagent packs from the load tray one at a time, and places each pack into a
storage nest.

7 When the input tray is empty, the load tray moves outside of the chilled storage area forcing a sealing
surface into place that keeps the cooler air in the chilled storage area.

8 The door is unlocked and the operator can load more packs.
Stage Description

Note: The door remains locked whenever the reagent load tray is not at the tray-out location or whenever
the reagent storage is full.

Operator-selected pack retrieval

Stage Description

1 From the user interface, the operator selects the pack to be retrieved.

2 The gripper retrieves the requested pack and moves it to the tray.

3 When all of the requested packs are on the tray or the tray is full, the tray moves to the tray-out position
and the door is unlocked.

4 The operator opens the door and removes the pack. After one hour, if the door has not been opened to
remove the pack, the tray returns to the chilled storage area and the user interface notifies the operator of
the event.
Tray positioning

Stage Description

1 The tray drive motor is attached to the tray with a screw drive. As the shaft rotates, the load tray moves
into the chilled storage area or the tray-out position.

2 Two sensors are used for tray position detection. One sensor detects the tray-out location and the second
sensor detects the tray-in location. Each location is adjusted by a software offset alignment value.
Note:

When the device is homed, the reagent load tray moves to the tray-in position.
During initialization, the load tray moves into home and then moves to tray-out position to be
available for pack loading.
When the gripper homes, the reagent load tray also homes.

Pack Identification

Reagent pack identification is accomplished during loading using a bar code reader.

Software tracks:

Pack positions.
Shelf-life during storage for unpunctured packs.
Open pack expiration for punctured packs.

DxI instruments use the same assay reagent packs as the Access and Access 2 platforms.

The load tray cover interfaces with a micro-switch. When the switch is actuated by closing the door, the load tray
presents packs to the internal bar code reader.
The reagent storage module contains two bar code readers:

A permanently mounted bar code reader: It is used to scan reagent pack labels as packs are loaded into
the reagent storage module. This reader uses laser technology to scan the bar code labels and
incorporates a mirror to redirect the beam 90 degrees. A window heater reduces the risk of condensation
on the window. The interface PCB provides an RS422 interface and +5 V DC power for the scanner. This
bar code reader is always powered on.

Note: Bar code label numbers cannot be entered manually, even if the bar code reader fails. This is a
safety feature that prevents loading an incorrect pack or pack number.

A handheld bar code reader: It is used to scan substrate bottle labels and is located at the top right end of
the SPU assembly. The interface PCB provides an RS232 to RS422 interface and +5 V DC power for the
bar code reader.

Pack Handling

Stage Description
Stage Description

1 Gripper transports reagent packs within the reagent storage module. The gripper assembly includes:

X and Z gear-belt-motor gantry.

Pneumatic gripper head with two moveable gripping surfaces:
o One with two prongs and one with a single prong.
o Two gripper sensors.

2 When a pack is requested for a test, the gripper is moved to the location of the required pack, grasps the
pack, and moves the pack to one of the spring-loaded pipetting nests for use by a pipettor.
Note: The gripper does not stay with the pack during pipetting. The gripper is free to service other areas
of the module while pipetting is occurring.

3 At the end of the pipetting cycle, the gripper returns to the pack and moves the pack to a storage nest or
to the waste chute. The pack is moved to the waste chute for automatic disposal if:

the last test in the pack has been used.

the pack is expired (if configured to do so).

4 The gripper moves between the storage nests using X- and -axis motions.

The Z-axis motion uses a drive motor coupled to a long spline shaft. As the shaft rotates, a torque
tube assembly coupled to a belt moves the gripper head in the Z-axis.
The X-axis motion uses a drive motor coupled to a belt that is attached to the gripper carriage.

5 The bottom of the assembly slides along the Z-axis drive shaft for directional support. The upper portion of
the assembly uses an upper guide rod and bushing for support.

Both the X- and Z-drive motors use encoders for positional location.
An inductive sensor located in the lower left corner of the module detects home for the gripper
carriage.

Pack Gripper Operation

Step Action

1 Air from the 32 to 35 psi pressure system pneumatically actuates the reagent pack gripper. A valve located
next to the reagent storage interface PCB switches air from either the gripper-open fitting or the gripper-
closed fitting.

2 Exhaust air from the gripper is released outside the module.

3 Three holes in the reagent pack allow the closed gripper to grasp, lift, move, and place packs in the desired
locations.

4 Two 24 V DC operated inductive sensors detect the gripper prong positions and are located on the gripper
head. The sensors have LEDs on the bottom that turn on when the sensor is actuated. These two sensors
detect four different gripper conditions:

Open - Gripper is open fully.

Bad Grip - Gripper is open more than what it would be if it contained a pack, but less than in open
condition.
Pack Present - Gripper prongs are in the holes in the reagent pack.
Closed - Gripper is closed fully (no pack).
Figure 2. Gripper assembly viewed from inside reagent storage module

Figure 3. Gripper sensors viewed from front of instrument

This series of drawings shows the flag location and sensor status as the gripper moves from fully open to fully
closed (viewed from the front of the reagent storage module):
 Left sensor is the gripper-open sensor
Right sensor is the gripper-closed sensor,

Note:

These graphics show original design parts. Sensor function remains the same regardless of shape.
Different revisions of the reagent storage gripper parts include:
o Round or square open or closed sensors.
o U-shaped flag or more complicated flag.
The sensors remain in these states for varying amounts of time as the gripper is moved from open to
closed. Some states exist longer than others.

Figure 4. Sensor output levels during operation

State Status Open Left Sensor Status Closed Right Sensor Status

1 Gripper open On Off

2 Jam On On

3 Pack present Off On

4 Gripper closed Off Off

Moving Packs

This diagram explains how the gripper assembly moves packs to location.

The Stage/Description table explains how the gripper assembly moves packs to location and how it returns to the
highway and home.

Note: DxI 800 shown. DxI 600 is the same except that it has only two pipetting and two load tray locations.

Stage Description

1 Software determines that a reagent pack is to be placed in:

Storage nest
Pipetting nest
Stage Description

Load tray

Note: Assume that there is a pack in the gripper.

2 Reagent pack gripper moves along the highway (left or right) until the gripper reaches the correct aisle.
The gripper stops momentarily to change from a horizontal movement to a vertical movement.

3 Gripper moves the pack vertically along the aisle until it is near the destination. Gripper stops momentarily
to change direction to left or right, depending on the destination.

4 Gripper moves horizontally, away from the aisle until the pack is positioned directly above the required
location. It stops momentarily to change direction downward.

5 Gripper moves the pack downward until it is five steps above the desired location, and then releases the
pack.

6 If the pack was delivered to a storage nest, then when the pack is released the gripper remains open and
is moved directly up or down over the storage nest until it reaches the highway. It does not return to the
aisle it used to arrive at this location because it will not hit any nests with the gripper open and it is quicker
to move directly to the highway.

If the pack was delivered to a pipetting nest or the load tray, then the gripper retraces its steps back to the
aisle and highway. Gripper cannot move directly downward from a pipetting nest or the load tray like it can
when leaving a storage nest.
Pipetting Nests

During reagent pipetting, a reagent pack is moved to one of the four (two for DxI 600) pipetting positions. Each
pipetting nest incorporates two spring-actuated pack hold-downs that prevent the pack from moving up when the
pipettor moves out of the pack. When the pipetting routine is complete, the gripper assembly can overcome the
force of the spring-loaded hold-downs and lift the reagent pack out of the pipetting nests. The pack is returned to a
storage nest after all pipetting is completed.

Pack Disposal

Disposal of expired or empty reagent packs is accomplished via a waste chute above or leading to the solid waste
container. The packs are dropped through a pneumatically operated door that is opened only during pack disposal.
A sensor on the air cylinder monitors that the door is closed. The door open condition is not monitored by a sensor
on the air cylinder. Many instruments were built with a magnet attached to the door, but that magnet was never
used for any specific purpose and was discontinued in late 2009.
Environmental Control
The internal storage temperature is maintained between 4 C and 10 C using forced air thermoelectric coolers
(Peltiers). The module uses three Peltier subassemblies to provide cooling for the reagent packs. Each of the
Peltiers is individually mounted to a duct assembly that removes the hot air created by the Peltiers. Each Peltiers
assembly includes a cold side sink, hot side sink, thermistor, and the Peltiers. The Peltiers are replaced as an
assembly and require the removal of the reagent storage module to access the Peltiers. Thermistors are used to
measure the temperature. A proportional integral derivative control loop in the software controls the output of the
Peltiers.

The Power Distribution PCB provides the 24 V DC power for the Peltiers drive.
The numbering pattern for the Peltiers is, from left to right, 1, 2, 3.
Peltier

An electrical device which generates cooling on one side and heat on the opposite side when DC voltage is applied.
The cooling side, when placed in contact with a metal surface, cools the metal to a temperature which is no greater
than 40 degrees less than ambient temperature. To effectively create the "cold" side, the heat generated on the
opposite side must be removed, this is accomplished by a heat sink and fan.

To maintain the desired temperature, the 3 Peltiers are controlled with a software PID control loop. As shown in the
diagram below, feedback from is monitored and feedback to the controller. This feedback constantly adjusts the
duty cycle somewhere between 0% and 100%. The greater the duty cycle the longer time the peltier device
receives power from the driver.

P = Proportional: The comparative relation of set point to error.

I = Integral: The accumulated average of errors over time.
D = Derivative: The rate of change of errors over time.

Air Infiltration is managed by having any openings in the module as close to the top as possible. Infiltration during
loading is minimized by sealing the tray mechanism against infiltration in both the open and closed positions. This
allows the load tray to be left in either an open or closed state while still keeping the air temperature inside the
reagent module within specification.

Any excessive fluid that collects because of condensation is removed as the waste chute door opens.

Interlock Switch
The two conditions for the cover interlock switch are:

Normal operation, switch closed: The cover interlock switch detects when the storage module cover is
opened. If the switch is actuated, software requires manual positioning of the gripper assembly to the
home location and then remapping (an identification process) of all onboard reagent packs.
 Power loss condition: During power loss, the state of the cover interlock switch is monitored (by a circuit
with a battery in it). Any time the reagent storage module interface PCB detects the switch has opened, a
status bit is set. This status requires that the gripper assembly be moved to the home position manually
and the instrument be remapped.

Printed Circuit Boards

The reagent storage module is controlled by the reagent storage module interface PCB. Refer to PCB, Interface,
Reagent Storage Module Operating Principles document for details.

Interactive Devices
The reagent storage module interacts with:

Reagent pipettors: Each of the reagent pipettors must be aligned to the reagent storage pipetting
positions.
Chassis DC fan: The DC fan assembly removes the warm air created by the hot side of the three Peltiers
assemblies.
Solid waste container: The solid waste container receives all reagent packs that exit the reagent storage
waste chute.

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