4500 Series

SERVICE MANUAL

2009 Awareness Technology Inc. Unauthorized duplication is strictly prohibited. Information given
in this manual is restricted for use by authorized personnel and is to be used for the sole purpose of
providing routine instrument maintenance and repair service. No part of this manual may be copied
or redistributed without the express consent of Awareness Technology Inc. There is no transfer of
technology, copyright, trade name, patent, trade secret, or other proprietary right given or implied.
04/2009 Rev. A

Table of Contents
1. INTRODUCTION ................................................................................... 1
1.1 Warning Markings Inscriptions dAvertissement ................................................................. 1
1.1.1 Safety Symbols Le Symboles de Sret ......................................................................... 1
1.1.2 Safety Terms Terminologie de Sret............................................................................ 2
1.2 Layout ................................................................................................................................... 3
2. PRINCIPLES OF OPERATION ............................................................... 6
2.1 Power Requirements ............................................................................................................. 6
2.2 Voltage Supply...................................................................................................................... 6
2.3 Photometer ............................................................................................................................ 6
2.4 Display and Printer ............................................................................................................... 7
2.5 Temperature Control............................................................................................................. 7
2.6 System Control...................................................................................................................... 7
3. TROUBLESHOOTING ........................................................................... 9
3.1 Power Supply ........................................................................................................................ 9
3.2 Photometer ............................................................................................................................ 9
3.3 Temperature Control........................................................................................................... 10
3.4 Main PCB............................................................................................................................ 10
3.5 Internal Printer .................................................................................................................... 11
3.6 Display and Touch screen................................................................................................... 11
3.7 USB Connections................................................................................................................ 11
3.8 Error Messages.................................................................................................................... 13
4. SERVICE PROCEDURES..................................................................... 14
4.1 Opening the Instrument....................................................................................................... 14
4.2 Lamp Replacement ............................................................................................................. 15
4.3 Filter Replacement .............................................................................................................. 17
4.4 Filter Label.......................................................................................................................... 19
4.5 Printer Jam .......................................................................................................................... 20
4.6 Printer Repairs .................................................................................................................... 20
4.7 Printer Interface PCB Replacement .................................................................................... 20
4.8 Main PCB and/or Photometer Replacement ....................................................................... 20
4.8.1 Photometer Replacement ............................................................................................. 20
4.8.2 Main PCB Replacement............................................................................................... 22
5. Calibration ......................................................................................... 23
5.1 Software .............................................................................................................................. 24
5.1.1 Software Calibration .................................................................................................... 24
5.1.2 Restore Calibration Data.............................................................................................. 25
5.1.3 Reset Calibration Data ................................................................................................. 26
5.1.4 Software Calibration Temperature............................................................................ 27
5.1.5 Software Calibration Absorbance ............................................................................. 28
6. Replacement Parts ............................................................................ 30
6.1 Consumable Items and Accessories.................................................................................... 30
6.2 Non-consumable Items ....................................................................................................... 30
7. Block Diagram and Schematics ........................................................ 31

1. INTRODUCTION
This manual describes service and troubleshooting procedures for 4500 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 operators manual specific to the instrument.
The 4500 Series instrument is a general purpose, microprocessor-controlled, bichromatic
photometer system. In the standard configuration, the instrument is equipped with six optical
filters and 37 deg C incubation.

Standard wavelengths: 340, 405, 505, 545, 580, and 630nm

Alternate filters are available from 340 to 700nm

Through the LCD touch screen display, the instrument prompts the operator to read the tubes in
the appropriate sequence. It then performs the necessary calculations and prints out test results.
It accepts standard 12mm round tubes, and includes an incubation block with 12 round tube
stations. Both the incubation block and the read well are temperature controlled to 37 deg C.
An internal thermal printer provides a printed record of all samples and test parameters. All
calibration data, test parameters, and other information is stored in battery-backed (non volatile)
RAM. An aspirating flowcell with control module is available as an accessory.

1.1 Warning Markings Inscriptions dAvertissement

1.1.1 Safety Symbols Le Symboles de Sret
Safety symbols which may appear on the product:
Les symboles de sret peuvent apparaitre sur le produit:

WARNING
AVERTISSEMENT

Protective Ground
La Terre Electrique

CAUTION
LATTENTION

BIOHAZARD
BIOHAZARD

Risk of Shock

(Earth) Terminal

Refer To Manual

Risk of Infection

Risque de Choc

Prise de Terre

Se Rapportent a Manuel Risque dinfection

FUSE: For continued protection against risk of fire, replace fuse only with one of the
specified type and current ratings. Disconnect equipment from supply before replacing
fuse.
FUSIBLE: Pour la protection continue contre le risque du feu, remplacez le fusible
seulement par une du type spcifique et des estimations courantes. Dmontez
lquipement de lalimentation dnergie avant de remplacer le fusible.

4500 Series Service Manual Rev. A

1.1.2 Safety Terms Terminologie de Sret

These terms may appear on the product:
Les marques sur le produit:
DANGER

indicates an injury immediately accessible as you read this

marking

DANGER Le de
marque:
DANGER
WARNING

indique le risque immdiat de dommages (assessible tandis que

vous lisez la marque)

AVERTISSEMENT!
Le de marque:
WARNING
CAUTION

indique quun risque de dommages qui nest pas immdiat alors

vous lisent cette marque

LATTENTION Le
de marque:
CAUTION

indique un risque a la proprit comprenant ce produit

indicates an injury hazard not immediately accessible as you

read this marking

indicates a hazard to property, including the product

These terms may appear in this manual:

Les marques dans loprateur manuel:

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 this
marking.

AVERTISSEMENT!
Le de marque:
WARNING
CAUTION

Ces rapports identifient les conditions ou les pratiques qui

pourraient avoir comme consquence les dommages ou les
pertes humaines.
CAUTION statements identify conditions or practices that
could result in damage to this product or other property.

LATTENTION Le
de marque:
CAUTION
BIOHAZARD

Ces rapports identifient les conditions ou les pratiques qui

pourraient avoir comme consquence les dommages a ce
produit ou a toute autre proprit.
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.

4500 Series Service Manual Rev. A

1.2 Layout
The instrument housing is comprised of a chassis (base and rear panel combined) and a formed
plastic cover. The cover is secured to the base by two #4 self-tapping screws.
An interactive 3.5 LCD touch screen color graphics display is mounted to the printer bracket
inside of the cover. A 20-column thermal printer and the printer PCB mount to a metal printer
bracket, which in turn mounts to the inside of the cover. The display and the printer assembly
both connect to the main PCB stack: LCD 54 conductor FFC connector; Printer 29 conductor
FFC connector; Touch Screen 4 conductor FFC connector.
USB Type A and Type B connections on rear panel to be used for mouse and PCB download
respectively. The USB Type A can also be used to upgrade firmware with a USB thumb drive.

Instrument Exterior:

Figure 1. Instrument Exterior

The photometer assembly connects to the main PCB via a 14-conductor ribbon cable and DIP
plug as well as a 10-conductor rainbow ribbon cable and double row header. The incubation
block connects to the main PCB via a 4-conductor cable and SIP header. The 12VDC cooling
fan is mounted to the chassis base and connects to the main PCB via a 2-conductor cable and
SIP header.

4500 Series Service Manual Rev. A

An external +19v laptop PC type power supply is used to supply power via a connector on the
rear panel.
Calibration may be performed in software
EPROM device is an internal 4mb flash memory
RAM device is an internal 8mb static RAM memory; internal 512kb EEPROM
memory
PCB revisionsinstalled components, locations, and jumpers. Refer to the
appropriate PCB layout in the PCB Layouts section of this manual.
Rear panel with power supply attached:
A) Power supply
connection
B) USB Type A
connector
C) USB Type B
connector

Figure 2. Rear Panel

4500 Series Service Manual Rev. A

Internal Chassis layout:

A) Incubation
block

B) Main PCB

C) Filter Wheel
Motor
D) Lamp

Board to
board
connection
(reference
Figure 7)

C
D E

E) Photometer
Figure 3. Chassis Layout

Chassis bottom:

Fan Outlet

Figure 4. Chassis Bottom

4500 Series Service Manual Rev. A

2. PRINCIPLES OF OPERATION
This section of the manual describes the operation and the interaction of the reader's main
systems. Most systems are controlled by the eZ80 on the main circuit board.

2.1 Power Requirements

The electrical rating of the unit is as follows:
Input voltage range: ...................................100 to 240 volts AC
Input current: .............................................4.7 Amps, 125V
Power consumption: ..................................90 Watts
Frequency:.................................................50-60 Hertz
For units used at 110-120 V inside the US: Use a UL listed cord set consisting of a minimum
18 AWG, Type SPT-1 two conductor cord, maximum 3 meters (10 feet) in length, rated 7 A,
125 V, with a polarized parallel blade type attachment plug.
For 220-240 V used inside the United States, use a UL listed cord as above, except rated
250 V.
For other locations, use the power cord certified for the country of use.

2.2 Voltage Supply

The circuit used should be substantially free of large voltage transients (Kilovolt amp loads)
such as large pumps, large centrifuges, refrigerators and freezers, air conditioners, large
autoclaves, ovens, and dryers. The instrument may fail to operate normally if the power
supply is interrupted. If this occurs, turn the instrument off for a moment. When you turn the
instrument back on, it will resume normal operation, but a standard curve which was not
stored in nonvolatile memory will be lost.

2.3 Photometer
The light from a tungsten-halogen lamp is passed horizontally though the tube or flowcell and
the sample it contains. The sealed box on the opposite side of the read well contains a
rotating filter wheel and photodiode. The filter wheel contains optical bandpass filters at
various wavelengths, and is speed controlled, via drivers U9A and U9B in parallel, to
approximately 4 rps under software control. As each filter passes in front of the photo
detector, an infrared optical switch generates a pulse (FCNT) at U13. C14 charges to the
peak voltage produced by the photo detector and amplifiers U16 and U14B.
The sampled voltage is buffered by U15A and then fed to comparator U15B which compares
the sampled voltage to the output of an exponential capacitor decay circuit built around Q3
and C16. The positive voltage at the comparator output enables a counter in the eZ80.
The photo detector output is proportional to the intensity of the light, whereas the width of the
positive phase of the comparator output is proportional to the absorbance. An oscilloscope
can be used to view the important signals at connector J36 while the instrument is in
operation. See Figure 6, Oscilloscope Waveforms.

4500 Series Service Manual Rev. A

2.4 Display and Printer

Interactive touch screen 3.5 LCD, color graphic display with thermal dot matrix printer with
graphic capability.

2.5 Temperature Control

The incubation block and read well are maintained at 37C. Thermistors (10k @25C)
mounted in the incubation block and in the read well measure the temperature. These
thermistors are multiplexed at a 0.5 second rate into the feedback path of oscillator U14A.
The waveform at pin 1 is a saw tooth of approximately 1.2 Vpp amplitude centered at +2.5 V.
Schmitt triggers U11 converts this to a square wave for current reversal and to drive the
CLK2 input of U4. The microprocessor heats the system to maintain the frequency of this
signal at 2.08 kHz, the 37C set point.
Power resistors located on the bottom of the incubation block are switched to 115VAC via an
optotriac which is driven by U9C. A green LED located on the main PCB illuminates when
cell heat is on. For the read well, driver U10 applies 12VDC (raw) across heater resistors
located on the cell heat PCB.

2.6 System Control

The instrument is based on the 8 bit 50MHz eZ80 microprocessor (U1). The software is
permanently stored in flash memory. In most instruments a battery-backed nonvolatile
EEPROM chip is used to store data such as calibration, test setups, samples, and also
maintains the date and time.

CAUTION: Do not make any hardware adjustments until you have

read the section entitled Calibration!

4500 Series Service Manual Rev. A

Figure 5. Troubleshooting

4500 Series Service Manual Rev. A

3. TROUBLESHOOTING
The flowchart in Figure 5 describes the logical steps to take if the instrument is malfunctioning. It
is only a guide to troubleshooting, and is intended to assist in determining problems which are
routine. It is not intended to take the place of an experienced technician, nor does it attempt to
cover all possible problems. Note, for example, that the temperature control system is not
covered.
In the following section, each subassembly or component group and possible problems and
solutions are outlined.

3.1 Power Supply

The internal power supply consists of a +15V, -15V, +5V switching power supplies and a
+3.3v linear supply all residing on the 4500-300 PCB. The 4500-200 PCB contains a local
+3.3V linear supply.

3.2 Photometer
The photometer assembly can be examined as several component systems:
Read well assembly and cell heat PCB
Lamp and brackets
Photometer PCB
Filter wheel and motor.
The read well assembly serves to hold the tube centered on the cell block, between a fixed
plate and a spring loaded plate. A micro switch mounted to the cell heat PCB operates when
a tube is inserted.
The lamp is tungsten-halogen, rated at 6V 10W. The lamp bracket holds the lamp and lens in
alignment with the rest of the assembly, that is, the filament is centered on the optical path.
The filter wheel turns on a shoulder screw shaft and is driven by the filter wheel motor via a
neoprene belt. The filter wheel itself requires no adjustments.
The rotation of the photometer filter wheel is under micro-processor control. The processor
turns the wheel on and off and maintains it rotating at a constant average speed. If the
processor fails to detect motion of the wheel within 7 seconds of the command to start, the
Filter Wheel Err message occurs.
Possible causes:
The belt has come off the wheel.
The motor does not respond to drive circuit.
The drive circuit and or connections are missing or defective.
The wheel detection circuit connections are missing or faulty.

4500 Series Service Manual Rev. A

Analysis process:
Note: In general the wheel only rotates while the instrument is in a reading mode and the
lamp is on.

Remove the instrument cover per the cover removal procedure.

Check that the photometer cable J9 (blue) and the rainbow cable J15 are seated.
Turn the unit on. Measure 5-6 volts at the yellow wire of the filter wheel motor.
Ground the brown wire-the motor should rotate at a rapid rate.
Confirm that the filter count pulses appear at test points J8#2.
In a reading mode, check that pin# 1 of U9, ULN2003, is high (motor on) or pulsing.
Check that U9 pin #16 is low or pulsing.

The photometer PCB contains a photodiode, a very sensitive opamp circuit (U16) and
phototransistors Q7 and Q8. Because the photodetector and related circuitry is solid-state, it
should require no service. Avoid unnecessary handling of the photometer PCB or removal of
the optical cover.
The lamp is intended to be maintenance free for the life of the instrument, since the lamp is
turned off automatically after 30 minutes of instrument inactivity. Under heavy usage the
lamp remains on for longer periods and so may require replacement. Also, a physical shock
to the instrument could cause filament breakage. The lamp must be replaced if output
becomes low or the lamp fails completely. To check for low or no lamp output, insert a
borosilicate tube filled with plain water into the read well. Do not use a soda-lime glass tube,
since it does not transmit at 340 nm. Select test #186. The instrument prints the wavelength,
position, and the detected voltage for each filter. The voltages should be between 2 and 10
volts. If all of the voltages are below 2.0 volts, the lamp is the likely suspect. As a final check,
measure the voltage at the lamp terminals. If the lamp voltage is much lower than 4.5 VDC,
the regulator circuitry on the main PCB (Q1 and U9) may be the problem. Otherwise, replace
the lamp. Refer to the section Lamp Replacement.
If only one or two filters report low detected voltages, degraded filters or a misadjusted lamp
may be the cause. To check for misadjusted lamp, refer to Lamp Replacement section. The
optical interference filters contained in the wheel are of metal-deposition type construction
and are intended to be maintenance free for the life of the instrument. Some older
instruments incorporated emulsion-type filters whose transmittance can be reduced
dramatically if subjected to high humidity over very long periods. Refer to the section Filter
Replacement.

3.3 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
"Calibration". Be sure to read the entire section on calibration before attempting any
adjustments.

3.4 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 J36 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 6, Oscilloscope Waveforms.

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4500 Series Service Manual Rev. A

3.5 Internal Printer

The internal printer is a 384 dot graphics thermal printer. The eZ80 PCB manages the print
head motor and the head drivers. There are no adjustments, and service is limited to
replacement of the entire printer mechanism.

3.6 Display and Touch screen

The 320 x 240 pixel graphics TFT LCD display with integrated touch screen should be clearly
legible with no missing or dim pixels. There are no adjustments, and service is limited to
replacement.

3.7 USB Connections

USB Type A and Type B connections on rear panel to be used for mouse and PCB
download respectively. The USB Type A can also be used to upgrade firmware with a USB
thumb drive. There are no adjustments, and service is limited to replacement.

4500 Series Service Manual Rev. A

11

Figure 6. Oscilloscope Waveforms

12

4500 Series Service Manual Rev. A

3.8 Error Messages

Error messages are displayed to inform the user of a possible problem. They are intended to
help the operator locate the problem. If error messages appear frequently, the most likely
cause will be a hardware problem. Note: These messages may occur when doing software
upgrades due to different memory space locations for stored data.
The following error messages indicate possible interface or component problems.
Problem:

Solution:

FILTER WHEEL ERR

The instrument cannot detect pulses from

the filter wheel. Check for rotation of the
filter wheel as a dislodged or broken drive
belt will prevent the filter wheel from turning.
Check for signal at J8-2. Check the
photometer LED board and the
phototransistors Q7 and Q8 on the
photometer PCB. See the section
"Photometer" under "Troubleshooting".

LAMP FAILURE

The lamp does not appear to illuminated at

all. Low voltages were detected for all filter
positions. See the section "Photometer"
under "Troubleshooting".

The following error messages indicate possible failure of the NV RAM U3. U3 can be
checked by substitution.
Problem:

Solution:

DO ABS SET TEST 212!

The stored absorbance calibration values

were corrupted or not found. See the
section "Restore Calibration Data".

DO TEMP SET TEST 210!

The stored temperature calibration values

were corrupted or not found. See the
section "Restore Calibration Data".

MEMORY ERROR

The checksum failed when a stored test

was recalled. The test was deleted.

WATER VALUES RESET

The stored water absorbances were

corrupted or not found.

4500 Series Service Manual Rev. A

13

4. SERVICE PROCEDURES
4.1 Opening the Instrument
The cover must be removed to allow access to the inside of the instrument. Disconnect the
power cable and the serial cable (if connected) from the rear panel. Invert the instrument on
a soft nonabrasive padded surface such as a terrycloth towel, to prevent scratching. Refer to
Figure 4, Chassis Bottom. Locate and remove the (2) cover screws from the bottom of the
instrument. Do not remove or loosen any other screws. While holding the instrument cover in
place with both hands, return the instrument to the upright position.
Grasp the cover at the left side. Gently lift the cover upward and to the right, until the cabling
is visible. You can rest the cover on its side while you disconnect the cables. Refer to Figure
7, Cover Connections.
Remove the cover and set it aside.
To reinstall the cover, reverse the procedure. Position the cover on its side to the right of the
chassis base. Carefully fit the cover to the chassis base. Install the cover screws. Do not
over tighten the cover screws.

To main PCB
Reference
Figure 3,
Chassis layout

Figure 7. Cover Connections

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4500 Series Service Manual Rev. A

4.2 Lamp Replacement

The lamp should be replaced only if it fails to light, or several filter voltages are reported as
low.
Materials and equipment:
Replacement lamp
Phillips screw driver
Flat blade screw driver
Procedure:
1. If using the flowcell accessory, remove the flowcell and place the instrument in tube
mode.
2. Set the power switch to OFF (O). Open the instrument. Locate the photometer and the
lamp at the left side of the photometer. Refer to Figure 8, Lamp Replacement.

CAUTION: Lamp is HOT! Allow the lamp to cool before handling.

3. Loosen but do not remove the lamp terminal screws. Do not loosen or remove any other
screws. Remove the lamp by lifting it upward out of the connector.
4. Use a pair of pliers or tweezers to handle the new lamp. Do not handle with bare skin.
Insert the lamp leads into the connector until they bottom out. The lamp filament must be
centered on the lens and the lamp body must be parallel with the lamp bracket. While
holding the lamp in alignment, tighten the lamp terminal screws. You should be able to
visually confirm the lamp alignment by sighting through the lamp and lens to view the
aperture on the spring plate behind the lens. All three elements should be aligned. With
the newer lamp bracket (Figure 8a), you can adjust the height of the lamp using the
indicated screw to raise or lower the plate height.
5. Set the power switch to ON. Shield your eyes from the lamp beam and observe the
projection of the beam onto the aperture. Refer to Figure 9, Spot Alignment. The spot
should be small and centered on the aperture. The spot should be sufficiently large to
just encircle the aperture. If the spot is not centered, repeat step 4.
6. Insert a borosilicate tube filled with plain water into the read well. Do not use a soda-lime
glass tube, since it does not transmit at 340 nm. Select test #186. The instrument prints
the detected voltage for each filter position. All voltages should be between 2.00 volts
and 10.00 volts. If all the voltages report low, repeat step 5 until optimum lamp position is
obtained.

4500 Series Service Manual Rev. A

15

Figure 8. Lamp Replacement

Figure 8a. Lamp Alignment with Newer Lamp Bracket

Figure 9. Spot Alignment

16

4500 Series Service Manual Rev. A

4.3 Filter Replacement

Materials and equipment:

Replacement filter set

Phillips screw driver

Flat blade screw driver

Procedure:
1. Open the instrument. Refer to Figure 3. Locate the photometer. Unplug both photometer
cables from the main PCB.
2. Use a pencil to mark the front and side edges of the photometer on the chassis so that the
photometer can be installed in its original position.
3. Locate the (3) #6 screws holding the photometer assembly to the chassis. From the bottom
of the instrument, remove these screws and washers while noting the screw lengths and
locations from which they were removed.
4. Refer to Figure 10, Filter Replacement. Remove the four 6-32 screws retaining the
photometer cover. Set the photometer cover aside.

Figure 10. Filter Replacement

4500 Series Service Manual Rev. A

17

5. Remove the two 4-40 screws securing the photometer PCB. Gently move the PCB aside
without disconnecting any wires.
6. Remove the belt from the filter wheel and pulley. Loosen the shaft (shoulder screw).
Remove the shaft and filter wheel. Note the number of nylon washers and the order of
installation.

Warning!
WARNING: Retaining rings will pop out from filter wheel when its
spring tension is released during removal. Shield the opening with
hand and wear safety glasses.

7. Refer to Figure 11. Locate the filter to be removed. There are currently two means of
filter retention in field use; silicone glue or a Retaining Ring. Refer to Figure 10 and
determine if a Retaining Ring is used. 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 out of
the wheel using the eraser end of a pencil or other soft blunt object and the glue should
release. Remove any remaining filter components from that position in the wheel.
8. Locate the neutral density filters, dot screen, and transmittance filters that were included
with the replacement filter and drop them first into the cavity. Install the interference 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.
9. Install the filter wheel taking care not to pinch washers under the shaft. Reassemble the
shaft and washers as disassembled. Tighten the shaft securely. The filter wheel should
spin freely.
10. Install the filter wheel belt. Be sure that the belt is centered on the filter wheel and is not
twisted.
11. Install the photometer PCB taking care to center the board around the shaft.
12. Replace the photometer cover, taking care to position the cable in the slot of the cover.
Do not pinch the cable under the cover. Tighten cover screws only until snug. Do not
over tighten the photometer cover screws! Doing so will bend the photometer cover and
create light leakage.
13. Install the photometer subassembly to the chassis by replacing the (3) #6 self tap screws
through the chassis base in their original locations. Line up photometer with locating
marks made in step 2. Connect the (2) cables removed in step 1.

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4500 Series Service Manual Rev. A

14. Attach the power cord and connect the instrument to the mains supply. Set the power
switch to ON (1). Insert a borosilicate tube filled with plain water into the read well. Do
not use a soda-lime glass tube, since it does not transmit at 340 nm. Select test #186.
The instrument prints the detected voltage for each filters. All voltages should now be
between 2 and 10 volts. If not, 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.

4.4 Filter Label

The filter label located on the photometer cover describes the specific filter wheel
configuration for your particular instrument. Filter wheel position is the physical placement of
the filter on the wheel. The filter wheel position numbers are shown in Figure 11. Note the
position of the Index hole and the Home hole.
Each filter position can have several filter elements installed. The four-digit filter wheel
number identifies the filter wheel batch, including filter lot codes, dot screens, neutral density
filters, and assembly date for that particular manufacturing lot of filter wheels. Some earlier
filter label styles may include this individual information. If you require specific information for
a filter wheel number, contact the manufacturer.

Figure 11. Filter Wheel Positions

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19

4.5 Printer Jam

If the print head does not return to the home position, check for obstructions in the print head
path. Carefully remove any paper or debris with a pair of tweezers. Turn off the power
switch, wait 5 seconds, then turn on the power switch.

CAUTION: Do not apply force to the print head! Do not scratch the
platen or pry with sharp objects!

4.6 Printer Repairs

There are no adjustments, and service is limited to replacement of the entire printer
mechanism.

4.7 Printer Interface PCB Replacement

Pending

4.8 Main PCB and/or Photometer Replacement

The Photometer is connected to the main PCB by three (3) cables (reference Figure 17). The
key feature to look for on the Photometer is that the lamp socket is wired with yellow wires
(referred to as a 3-Cable Photometer). The replacement photometer will be a 3-Cable
photometer with the yellow wires.

4.8.1 Photometer Replacement

1. Open the instrument as described in Opening the instrument. Refer to Figure 3.
Locate the photometer. Note positioning of the cables leading from the photometer to
the main PCB and unplug the cables from the main PCB (reference Figure 17).
2. Mark the perimeter of the photometer on the chassis with a pencil so the
replacement photometer can be properly positioned.
3. Unplug the cables and then lift the photometer from the slots on the base of the
chassis and unplug the cables.
4. Install the replacement photometer subassembly to the chassis by aligning the
bracket slots over the raised pegs, placing the photometer into its original position.
Connect the cables removed in step 1.

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4500 Series Service Manual Rev. A

Main PCB to Photometer Cable Configuration

A Gray ribbon
cable with red
stripe,
B Multi-color
ribbon cable
C Yellow wires

Figure 17 Main PCB to Photometer Cable Configuration

4500 Series Service Manual Rev. A

21

4.8.2 Main PCB Replacement

1. Open the instrument as described in "Opening the instrument". Refer to Figure 3.
Locate the Main PCB. Unplug cables from the main PCB and disconnect the wires
from the transformer.
2. Refer to Figure 18. Remove the two screws securing the Main PCB. Secure the
replacement PCB in the same fashion as the removed PCB.
3. Reconnect transformer wires. See Block Diagram section of this manual for proper
wire connections. Plug in all remaining cables.

Remove
the two
screws
securing
the Main
PCB.

Figure 18, Main PCB Installation View

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4500 Series Service Manual Rev. A

5. CALIBRATION
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 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 accuracy and linearity is
advised. Since most lab test results are based upon standards rather than upon absolute
absorbances, the linearity of the instrument, rather than the accuracy, is the more critical
indicator of instrument performance.

CAUTION: Recalibration of the instrument should not be

considered until all possible interfering factors have been ruled out!
This includes:

Chemistry error

Operator error

Lamp failure

Degraded filters

Standards and blanks should be closely checked for accuracy and

results should be compared with a reference instrument. Use of a
commercially available photometer check set to verify photometric
accuracy and linearity is strongly recommended.
Software validation should always be attempted before resorting to
hardware calibration.
In the event the software calibration data is lost or corrupted, the
absorbance factor is set to 1.000 and the temperature offset
adjustments for the block and cell are set to 0.0.

Standards and blanks should be closely checked for accuracy and results should be compared
with a reference instrument. Use of a commercially available photometer check set to verify
photometric accuracy and linearity is strongly recommended. If field recalibration is needed, it
should only be performed with the proper reference materials and instruments.

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5.1 Software
Calibration data is used by the instrument to compensate for variations in electronic
components. During factory calibration, any necessary hardware adjustments are made
using precision reference standards and specialized electronic equipment. The calibration
data are stored in the instrument memory and also recorded on a label located on the bottom
of the instrument. In the unlikely event the instrument must be field recalibrated to meet
specifications, new calibration data are derived using reference standards and these values
are entered via the keypad. This requires no hardware adjustments.

5.1.1 Software Calibration

Do ABS Set Test 212!
Do Temp Set Test 210!
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 the checksum failure
occurs and until calibration is performed. The instrument also annunciates this condition
with multiple beeps.
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 value
entered at the keypad is multiplied by the stored value to obtain a new scaling factor.
The temperature calibration data is stored as offsets which the instrument adds to the
sensed temperatures. The value entered at the keypad is added to the stored offset to
produce a net adjustment. Separate offsets are maintained for the incubation block and
the read well.
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, the stored calibration data:
the absorbance scaling factor, the net block temperature offset, and the net cell
temperature offset.
In the event of calibration data loss, the temperature offsets for both the incubation block
and the read well are 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 below.
To recalibrate the instrument, refer to the sections "Software Calibration Temperature"
and "Software Calibration Absorbance".

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5.1.2 Restore Calibration Data

This procedure restores the calibration data to the original factory settings recorded on
the calibration data label.
Procedure:
1. Select test #213 to print the calibration data. Verify that the data is as follows:
ABS FACTOR 1.000
BLOCK TEMP 0.0
CELL TEMP

0.0

2. If the data printed in step 1 did not match the example, stop. Complete the procedure
"Reset Calibration Data", then repeat this procedure. Otherwise, locate the
calibration data label on the underside of the instrument. Copy the data from the
label for reference in the following steps.
3. If the date and time are incorrect, set the date and time as described in the Owner's
Manual.
4. Select test #210. The display shows:
BLOCK=
Enter the value from the Block Temp line on the calibration label.
5. The display shows:
CELL=
Enter the data from the Cell Temp line of the calibration label.
6. Select test #212. The display shows:
ABS FACTOR=
Enter the number from the Abs Factor line of the calibration label.
7. Select test #213 to print the calibration data. The printed data should now match the
values shown on the calibration data label. If it does not, complete the procedure
"Reset Calibration Data", then repeat this procedure.

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5.1.3 Reset Calibration Data

This procedure resets the calibration data. The absorbance scaling factor is set to 1.000,
and the temperature offsets are set to 0.0.
Procedure:
1. Select test #213 to print the calibration data. Verify that the printed data is as follows:
ABS FACTOR 1.000
BLOCK TEMP 0.0
CELL TEMP

0.0

2. If the data printed in step 1 matches the example shown, stop. The calibration data is
already reset. If the data printed in step 1 matches the data shown on the calibration
data label on the bottom of the instrument, and you do not wish to alter the
calibration, stop. Otherwise, make a note of the values printed in step 1.
3. Select test #210. The display shows:
BLOCK=
Enter the negative of the value printed for BLOCK TEMP. This will reset the block
temperature offset to 0.0.
4. The display shows:
CELL=
Enter the negative of the value that was printed for CELL TEMP. This will reset the
cell temperature offset to 0.0.
5. Select test #212. The display shows:
ABS FACTOR=
Enter the inverse of the value printed for ABS FACTOR in step 1. That is, calculate
1
ABS FACTOR
and enter the value.
6. Select test #213 to print the calibration data. The printed data should now match the
example in step 1. If not, repeat this procedure.

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5.1.4 Software Calibration Temperature

The object of this procedure is to establish agreement between the actual temperature
and the displayed temperature by measuring the actual temperature, then entering the
difference between the actual and the reported temperatures.
Note that precision thermistor probes are used. Do not use a thermometer. A typical
mercury bulb or other glass thermometer adds a great deal of thermal mass to the
system, as well as provides a conduction path for heat, thereby frustrating the
instrument's heating capability.
Materials and equipment:
(2) 12 mm borosilicate tube (or other cuvette appropriate for the instrument)
(2) Reference thermistor probe
YSI Inc. #44108 or equivalent.
30K @ 25 C, 0.2 interchangeability
Digital ohmmeter (DMM), 0.5% or better accuracy.
Procedure:
1. Complete the procedure "Reset Calibration Data".
2. Place a tube or cuvette filled with 1 ml of water into the incubation block. Immerse
the thermistor probe in the approximate center of the tube. Place a similar
arrangement in the read well. Select test #188 to extend the lamp time.
3. Allow 15 minutes for equilibration.
4. If the DMM being used is not autoscaling, set it so that 20K is in range. Zero the
meter and then read the resistance of the thermistors. If the resistance is between
17994 and 18435 , no adjustments are needed. Otherwise, continue to the next
step.
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. Select test #210. The display shows:
BLOCK=
Type the offset calculated above for the block and press ENTER.

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7.

The display shows:

CELL=
Type the offset calculated for the cell and press ENTER.

8. Repeat steps 3 through 6 until the resistance is within the specified range and the
displayed temperature is 37C 0.3. Select test #213 each time to print the current
net adjustments. The net offset after the temperature is set should be 1.5C or
smaller.
9. When you are done, select test #213 to print the new calibration data. Enter these
values on the calibration data label on the bottom of the instrument.

5.1.5 Software Calibration Absorbance

Materials and equipment:
12 mm borosilicate tube (or other cuvette appropriate for the instrument)
Reference spectrophotometer
Reference material which peaks at one of the filter wavelengths.
Precise 1:2 serial dilution of the reference material.
1. Complete the procedure "Reset Calibration Data".
2. Place a borosilicate tube filled with plain water into the read well. Do not use a sodalime glass tube, since it does not transmit at 340 nm.
3. Select test #186 and confirm that all of the detected filter voltages are between 2.00
and 10.00 volts.
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. Select the absorbance mode (Press ABS). Select the required wavelengths. Select 0
for no differential filter. 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. Note the result of this
calculation for the next step.
7. Exit the absorbance mode and select test #212. The display shows
ABS FACTOR=
Enter the result of the calculation performed in the preceding step. When this factor
is entered the instrument will multiply by the old factor and display a net factor (the
new calibration data).

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8. Select the absorbance mode again. 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. Read the
section Hardware Calibration before making any adjustments. Re-blank and
reconfirm the values.
10. When you are done, select test #213 to print the new calibration data. Enter these
values on the calibration data label on the bottom of the instrument.

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6. REPLACEMENT PARTS
6.1 Consumable Items and Accessories
Lamp..........................................................112004
Fuses (set of 2)..........................................102006
Printer paper (5 rolls) .................................150005
Carrying case.............................................000390
Borosilicate tubes 12x75mm 250/box ........157300
Borosilicate tubes 12x75mm1000/case .....157302
Dust Cover.................................................001990

6.2 Non-consumable Items

Main PCB ..................................................995003
Battery RAM chip.......................................163061
Belt, filter wheel .........................................132059
Motor, filter wheel ......................................105126
Photometer assy........................................(specify model)
Reaction block assy...................................(specify model)
Cover assy.................................................(specify model)
Fan assembly ............................................104503
Internal 14-pin cable (specify length) .........104xxx
Printer mechanism.....................................105645
Printer Platen ...........................................105651
Print Head (includes printer platen) .........105652
Printer interface PCB .................................995006
Display, LCD assembly w/both PCAs .......991045
Display, LCD graphics
162550
Filter & Neutral replacement set ................(specify wavelength) 111XXX
NOTE: Specify the instrument serial number when ordering so that replacement part
compatibility issues can be addressed.

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7. BLOCK DIAGRAM AND SCHEMATICS

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