Company Information

© Copyright 2022. Epredia. All rights reserved. These instruments conform to the essential
requirements of:
Epredia makes every attempt to ensure that the information
contained in this supporting document is correct and clearly • In Vitro Diagnostic Directive 98/79/EC
stated but does not accept responsibility for any errors or
omissions. The development of Epredia products and services is
an ongoing process. Please ensure that any published information
Symbols
you use as a reference is up to date and relates to the condition
of the product. If necessary, check with your local Epredia The following symbols and conventions may be used
representative. throughout this document and on the instrument:
This document may not, in whole or in part, be copied,
This symbol is used on the equipment, or in a
photocopied, reproduced, translated, or converted to any
document, to indicate that instructions must
electronic or other form without prior written consent of Epredia.
be followed for safe and correct operation.
All information contained in this manual is proprietary and
confidential, and the exclusive property of Epredia and is This symbol is also used on the instrument, or
protected by copyright. in a document, to indicate that irritants or
potentially harmful chemicals are present.
Refer to the Material Safety Data Sheets for
the products, and always use Good
Laboratory Practice.

If this symbol appears on the instrument

Contact address always refer to the operator guide.

Shandon Diagnostics Limited, a subsidiary of Epredia This symbol is utilised on the instrument, or in
Tudor Road, Manor Park, Runcorn a document, to indicate that there are
Cheshire, WA7 1TA, UK potential biological risks associated with the
instrument and / or with instrument use.
Tel: +44 (0) 1928 534000 Always use Good Laboratory Practice.
Fax: +44 (0) 1928 534001
Web: www. epredia.com
Manufacturer
USA Distributor
Richard-Allan Scientific LLC, a subsidiary of Epredia
4481 Campus Drive A warning is given in the documentation if there is a
Kalamazoo, MI 49008, USA potential risk of injury, equipment failure or poor tissue
sample processing outcome.
Tel: 1-800-522-7270
Note
Fax: +1 269-372-2674
Web: www. epredia.com Notes give additional information about a job or
instruction, but do not form part of the instruction.
Contents
Company Information 3 Fit the Extraction Kit ....................................... 26

Symbols ........................................................... 3 Maintaining the Xylene Tray Level ................... 27

Contact address ............................................... 3 Fill the Mountant Bottle ................................... 28

USA Distributor ................................................. 3 Change the Purge Tray and Debris Tray ......... 29
Start up the ClearVue ..................................... 30
Contents 4 Fill the Dispense Head Cleaning Station ......... 30
EMC Statement ................................................ 6 Degas the Mountant Bottle ............................. 32

Safety Information 7 Flush the System ............................................ 32

Purge the System ........................................... 33
Introduction ...................................................... 7
Remove and Replace the Coverslip Hopper ... 34
General Safety .................................................. 7
Shutting Down the ClearVue .......................... 35
Disposal of Sealed Lead Acid Batteries ............ 8
Load a Basket ................................................ 36
Chemical Safety ................................................ 8
Unload a Basket ............................................. 37
Environment ..................................................... 9
Abort a Basket ............................................... 38
Warranty Statement .......................................... 9
Manually Abort a Basket................................. 38
Chapter 1 – Introduction to Remove Baskets from the Load & Unload Rail 39
ClearVue 10 Remove Slides during Coverslipping .............. 39
Introduction and Safety ................................... 11 Remove Baskets from Vertical Lift .................. 40
General Description ........................................ 12
Chapter 3 – Production Services
Basic Structure ............................................... 12
41
Electronics Assembly ...................................... 15
Introduction .................................................... 42
Design Purpose .............................................. 19
PARAM Tab ................................................... 43
Compatibility ................................................... 19
I/O Tab ........................................................... 43
Identification of Parts (front) ............................ 20
Inside ClearVue ............................................... 20 Chapter 4 – Functional Tests 61
Identification of Parts (rear) ............................. 20 Earth Continuity and Insulation Resistance Tests
Example of Varistain Gemini Basket ................ 21 ....................................................................... 62
System Interfacing .......................................... 21 Individual Motor Tests .................................... 62
System Specifications..................................... 21 Build Subassembly Tests ............................... 65
Coverslipping Method ..................................... 22 Instrument Verification Tests ........................... 74

Chapter 2 – Basic Operation 23 Chapter 5 – Settings 89

Daily Tasks ..................................................... 24 Adjust the Coverslip Position .......................... 90
Weekly Tasks ................................................. 24 Select the Coverslip Position .......................... 91
Level the ClearVue before Use ........................ 25 Change the Coverslip Transfer Head Position. 92
Change the Carbon Filter ................................ 25 Adjust the Screen Settings ............................. 94

ClearVue Service Manual Issue 08 4

 Adjust the Change the Time and Date Setting 94 Chapter 9 – Parts Replacement
Change the System Language........................ 95 177
Create the Engineers Log ............................... 95 Safety ........................................................... 177
Update the System Software .......................... 96 Tools Required ............................................. 177
Adjust the Mountant Dispense Volume ........... 97 Outer Case Removal .................................... 178
Slide Retainer Types ....................................... 97 Parts Replacement by Sub-Assembly .......... 182
Install the Offset Coverslip Transfer Head ....... 98 Software Update .......................................... 218
Alter the Slide Sensing Parameter ................. 100
Chapter 10 – Service Schedule
Chapter 6 – Maintenance 101 219
Cleaning and Maintenance Precautions ........ 101 Routine Maintenance Schedule .................... 221

Replacing Seals ............................................ 102 Chapter 11 – Spares List 226

Remove the Mountant Bottle ........................ 103
Prepare the ClearVue for Storage ................. 104
Chapter 12 – Technical Drawings
231
Chapter 7 – Cleaning 105 Electrical Drawings ....................................... 231
Cleaning the Mountant Bottle Cap ................ 106 Pneumatics Drawings ................................... 232
Cleaning the Mountant Bottle Seal ................ 107
Appendices 241
Cleaning the Xylene Tray Seal ....................... 108
Appendix A1 – Service Fault Codes ............. 241
Cleaning the Dispense Head Cleaning Station
..................................................................... 109 Appendix A2 – Cause Codes ....................... 242

Cleaning the Suction Cup ............................. 110 Appendix A3 – Parameters ........................... 245

Cleaning the Slip Dispense Carriage ............. 112 Appendix A4 – Accessories .......................... 247

Cleaning the Mountant Dispense Needle ...... 114 Appendix A5 – Spare Parts .......................... 248

Cleaning the Touch Screen........................... 115 Appendix B – Approved Reagents ............... 249

Cleaning the Slip Dispense Skirt ................... 115 Appendix C – Packing Instructions ............... 249

Cleaning the Gripper Return Plate................. 116 Appendix D1 – Main Menu ........................... 251

Cleaning the Slide Grippers .......................... 117 Appendix D2 – Mountant System Screens ... 252

Cleaning the Coverslip Transfer Head ........... 118 Appendix D3 – Options Screens................... 253

Cleaning the Camera .................................... 119 Appendix E – Understanding Log Files ......... 254

Chapter 8 – Troubleshooting 120 Index 261

Telephone Support ....................................... 121
Error Screens................................................ 121
Perform a Bead Test ..................................... 128
Identifying Problems with Slides.................... 129
Diagnosis Flowchart ..................................... 142
Troubleshooting Tables ................................ 143
Engineers' Log Extraction ............................. 176

ClearVue Service Manual Issue 08 5

EMC Statement
This IVD equipment complies with the emissions
and immunity requirements of IEC 61326-2-6.

This equipment has been designed and tested to

CISPR 11 Class A. In a domestic environment it may
cause radio interference, in which case it may be
necessary to take measures to mitigate the
interference.

The electromagnetic environment should be

evaluated prior to operation of the device.

Do not use this device in close proximity to sources

of strong electromagnetic radiation (eg: unshielded
intentional RF sources) as these may interfere with
the proper operation.

The ClearVue™ is referred to throughout this, and

other supporting documents, as the ClearVue.

The Varistain® Gemini (Inc. ES Variant) is referred

throughout this, and other supporting documents,
as the Varistain Gemini.

The Varistain® 24-4 is referred throughout this, and

other supporting documents, as the Varistain 24-4.

ClearVue Service Manual Issue 08 6

Safety Information
Introduction
Epredia instruments are designed for convenient • Do not use the instrument in close
and reliable service; however, improper use or proximity to strong electromagnetic
handling by a user may damage the instrument or radiation, as these may interfere with
cause a hazard to health. The instrument must not the proper operation. The
be used in a manner not specified by Epredia. electromagnetic environment should
Correct maintenance procedures are essential for be evaluated prior to operation of the
consistent performance. It is recommended that device.
users secure a maintenance contract with our
• Do not introduce any source of
service department.
ignition into, or near, the instrument
To remain compliant with regulatory requirements, once it has been loaded with
and to ensure that mandatory safety upgrades are reagents.
performed at the earliest opportunity, it is strongly • Do not remove any panels or access
recommended that all service activities are covers, unless specifically instructed
performed by Epredia-factory trained Engineers. to do so. The instrument does not
Warranty may be voided if service is performed by have any user serviceable parts.
non-factory trained Engineers. Potentially lethal voltages are present
Maintenance or repairs that are not performed by inside the instrument.
Epredia trained Engineers with proven training may • The instrument must be properly
affect the safety, performance and compliance of connected to a good earth (ground)
the equipment. via the Mains input supply and
positioned such that it is possible to
Please consult your local sales or support teams for
interrupt the Mains supply at the
more information about service contracts.
source by removing the plug from the
All users must read and understand socket.
the following sections before using • Use only factory approved
the instrument. accessories or replacement parts
within the instrument.
The following sections contain
important information for the safe • Only use reagents recommended in
setup and use of the instrument, and the operator guide.
should be read and understood by • Position the instrument such that it is
the user before using the instrument. possible to interrupt the Mains supply
at the source by removing the plug
General Safety from the socket.
• If the equipment is used in a manner
This instrument, as supplied, conforms not specified by Epredia, the
to IEC 61010-1; however, the addition protection offered by the equipment
of chemicals introduces potential may be impaired.
hazards. Good Laboratory Practice
must be employed and consideration
must be given to the potential for hazard
when dealing with these chemicals.

ClearVue Service Manual Issue 08 7

Disposal of Sealed Lead Acid • All the chemicals recommended
by Epredia have auto-ignition
Batteries temperatures considerably above
The sealed lead acid batteries within this instrument any surface temperature that can
need to be replaced every three years. be reached during a single fault
failure on the instrument. Small
If the instrument has mainly been operated in very
quantities of paraffin wax present
low temperatures, or has been exposed to frequent
will not reach a temperature that
Mains failures, the batteries should be replaced
will produce flammable vapour.
every year.

The battery manufacturers advise their customers to • The instrument contains no source
comply with the relevant regulations within their of ignition in any areas of the
particular country regarding disposal of this type of instrument where chemicals are
battery. stored or likely to leak in a single
The battery used within this instrument is: fault condition.
• The operator is fully aware of the
• 12 V 12Ah, valve regulated, sealed, lead acid
contents of the specification
type, rechargeable battery.
documents detailing the properties
This battery is classified as "Class 8 & Group III of the chemicals they are using.
UN No 2800 Batteries, wet, non-spillable, • The operator has carried out any
electric storage, special provision A67", and legally required assessment of
meets all requirements of the International Air chemicals used and is using good
Transport Association (I.A.T.A) Dangerous laboratory practice.
Goods Regulations.
• Some chemicals which may be
Batteries cannot be accessed by the used during operation are
customer and must only be replaced flammable - do not use sources of
by trained service personnel. ignition in the vicinity of the
instrument when it is loaded with
reagents.
Chemical Safety • Harmful chemical vapours such as
The introduction of chemicals creates potential Xylene and Toluene may be
hazards. Epredia has adopted the following position emitted during the normal
with regard to the subject of volatile chemicals used operation of some instruments
in laboratories: and the operator should be aware
of suitable precautions and safety
• The introduction of chemicals measures. The short term
creates potential hazards and exposure limits for Xylene and
Epredia has adopted the following Toluene will be no greater
position with regard to the subject 100ppm.
of volatile chemicals used in
medical laboratories:
• Non-specified chemicals are used
in the instrument at the customer’s
own risk.

ClearVue Service Manual Issue 08 8

Environment Warranty Statement
This instrument is required to comply with the Epredia is proud of their quality, reliability and of our
European Union's Waste Electrical and Electronic after-sales service. We continuously strive to
Equipment (WEEE) Directive 2012/19/EU. It is improve our service to our customers.
marked with the following symbol:
Please ask your distributor or Epredia representative
about service contracts which can help maintain
your instrument in an optimal operating condition.

Warranty provisions necessarily vary to comply with

differences in national and regional legislation.
Specific details can be found in the delivery
documentation or from your dealer or
representative.
At the end of the product life it must be recycled in
Please note that your warranty may be invalidated if:
accordance with local regulations. It can be returned
to a Municipal Collection Facility or to the retailer • This instrument is modified in any way, or not
when a replacement is purchased. Where used as intended by Epredia.
applicable this facility will be offered by the Product • Accessories and reagents which have not been
dealer. approved by Epredia are used.
Further information on Pyramid Innovation’s • The instrument is not operated or maintained in
compliance with these Directives, the recyclers in accordance with instructions.
your country, and information on Pyramid • The installation of the instrument was not
Innovation products which may assist the detection conducted by a certified Epredia representative.
of substances subject to the RoHS Directive are
available from your distributor.

ClearVue Service Manual Issue 08 9

Chapter 1 – Introduction to ClearVue
The following section covers the following
information:

• Introduction and Safety

• General Description
• Basic Structure
• Design Purpose
• Compatibility
• Identification of parts (front)
• Inside ClearVue
• Identification of parts (rear)
• Example of Varistain Gemini basket
• System Interfacing
• System Specification
• Coverslipping Method

ClearVue Service Manual Issue 08 10

 into, or near, the instrument once it has been
Introduction and Safety loaded with chemicals.
Welcome to the ClearVue; a fully automated, • Refer to laboratory procedures and
enclosed coverslipper intended for use in pathology manufacturer’s data sheets when using
and histology laboratories by appropriately trained reagents. Only use reagents specified in
medical laboratory technicians. Appendix B of the ClearVue Operator Guide.

The purpose of this Service Manual is to enable a • Ensure you employ normal standards of safety
qualified Epredia engineer to maintain the ClearVue and good laboratory practice. Think about your
in good condition. actions - always use common sense and the
best known practice when operating the
Safety instrument.

The Safety and Warranty Booklet (A79910001) and • If the ClearVue has been used with materials
the ClearVue Operator Guide (A79210100) should which are toxic or contaminated with pathogenic
both have been read and understood before using micro-organisms; follow the cleaning
this instrument. instructions given in Appendix C of the ClearVue
Operator Guide, and complete the Product
In addition, the following statements must be read Return Safety Certificate (See Safety and
and understood before commencing any work on Warranty Booklet) before servicing the
the ClearVue. instrument or returning the instrument to
• Potentially lethal voltages above 110Vac are Epredia.
present inside this instrument. Do not remove • Use only factory approved accessories or
any access covers unless trained to do so. replacement parts with the ClearVue.
Disconnect the instrument from the mains power • This instrument should be serviced annually by a
and switch the Battery Isolator Switch to the off Epredia trained engineer in accordance with the
’O’ position before carrying out any work on an instructions in this Service Manual.
area enclosed within an access panel.
• The ClearVue must be properly connected to a
good earth (ground) via the mains input supply.
All earth (ground) straps and connections must
be replaced correctly after service and before
switching the instrument on.
• Wear earthing (grounding) wrist straps and earth
(ground) yourself before handling connectors or
electronic components, as static electricity can
damage sensitive electronic parts. Damage from
static electricity can take weeks or months to
develop.
• The ClearVue is heavy and requires at least 2
people to lift it.
• As supplied, the ClearVue conforms to
IEC61010-1 and IEC61010-2-101; however the
addition of chemicals introduces potential
hazards. Follow good laboratory practice when
dealing with these chemicals, and be aware that
chemicals used with the ClearVue may be
flammable. Do not introduce sources of ignition

ClearVue Service Manual Issue 08 11

General Description Basic Structure
• The ClearVue is a high-throughput, precision The ClearVue has a modular design and there are a
engineered, slide coverslipper. number of sub-assemblies each with a distinct
• The ClearVue has been designed for general function:
laboratory use, and can handle baskets from the
various stainers.
Input Rail
• The ClearVue allows operators to load multiple The input rail acts as a buffer for the 5 baskets that
baskets at once in a mix-and-match fashion. can be loaded on to the ClearVue at once. The input
rail will then push each of the baskets in turn onto
Special design features of the ClearVue the lift block. The ClearVue counts the numbers of
baskets on the load rail by measuring the position of
• Special slide baskets compatible with a variety of
the first latch in relation to the pop out pin as it stalls
stainers from Epredia and from other
against the baskets. A xylene trough sits below the
manufacturers.
input rail to prevent drying of slides while the
• Compatibility with a range of coverslip sizes and
baskets are waiting to be processed.
positions on the slide.
• Up to 5 baskets of slides can be loaded at any Vertical Lift and Lift Block
one time, with the capability of adding further
The basket is pushed onto the lift block and retained
baskets without interrupting coverslipping.
against 2 pins by a ball spring pushing on the basket
• A downdraft system removes unpleasant fumes flag; this is essential as it holds the basket in a
away from the operator’s face when the unload controlled position for slide processing. The vertical
door is opened. lift carries the basket up through the ClearVue so
• Windows in the doors and internal illumination that the slides can be processed. At the end of
allow the operator to see the coverslipping in processing the vertical lift then carries the basket
progress. past the unload rail so that a cam follower can push
• The instrument uses a touch screen with clear the slider close block forwards to partially close the
instructions and information. basket slider; this retains the slides during
unloading. After this the basket is moved level with
• There is battery back-up for enhanced specimen
the unload rail ready for the basket Eject to push it
security in the event of a power failure.
onto the unload rail.
• Baskets are available with black and white
sliders which can be used to select different Basket Open and Lower Slide Retention
mountant volumes for different specimen types.
The basket-open assembly opens the basket slider
• Pre-loaded coverslip hoppers for reduced glass
(basket slide retainer) after the basket is pushed
handling.
onto the lift block. After the basket is opened the
• Internal camera takes images of the baskets and slide retainer and slider pusher are used to retain the
slides for accurate determination of basket type, slide in the basket as it is moved upwards. The slider
slider colour and slide positions. pusher is spring loaded both to ensure the basket is
• Full error recovery instructions. opened correctly and to help fully open baskets that
are loaded when partially open.

ClearVue Service Manual Issue 08 12

Slide Guide Assembly Coverslip Transfer Head
The slide guides main function is to guide each slide The coverslip transfer head picks a coverslip up off
into a position where it can be both removed from the coverslip dispense carriage and places it onto
and replaced into the basket without touching the the slide.
basket. To do this the spring loaded slide guide
When the coverslip is placed correctly onto the
assembly locates on the end of the basket and
mountant bead on a properly cleared slide the
guides each slide using 2 small guide surfaces and
mountant flow should be even on either side of the
a leaf spring. The 2nd function of the slide guide is
coverslip. The flow should move quickly down 2/3
to retain the slides in the basket after they pass
of the slide and then should continue slowly to the
above the basket open assembly and until they are
end with a small pause before the transfer head
removed by the grippers.
moves away.
Slide Grippers The shape of the transfer head, the position of the
sprung pads and the suction cup are all designed to
The slide grippers remove the slides from the basket
hold the coverslip in a specific shape and position.
and move them into the coverslipping area. The V in
This coverslip shape, positional control of the
each gripper jaw lifts the slide to a fixed and
coverslip transfer motor, bead shape and vacuum
consistent position for a good coverslipped slide.
decay time are all critical to ensuring that the
The gripper return plate fitted to the short gripper
mountant flow is correct and that coverslip is placed
jaw is used to push the slide away from the jaw even
without trapping any air.
if the slide is tacky with drying mounting media. A
sensor is used to detect the position of the short jaw The transfer head can be positioned to suit
which gives the ClearVue the ability to both measure coverslips located at the end of the slide or 40
and automatically adjust for different slide widths. coverslips placed centrally on the slide. An optional
This same sensor also enables the ClearVue to Cytyc specific head is also available as an
detect if a slide has jammed when being placed accessory.
back into the basket.
Basket Eject and Upper Slide Retention
Coverslip Dispense The upper slide retention is mounted on the basket
The vacuum assisted coverslip dispense takes a eject bracket and has 2 stages. The first stage is
coverslip from the bottom of the hopper and fixed and just ensures that the slide has not moved
presents it ready to be picked up by the coverslip too far out of the basket during index from the
transfer assembly. The coverslip dispense includes coverslipping position. The second stage is spring
two reflective optical sensors that are used to detect loaded and pushes the slides against the basket so
the size of coverslip as well as checking the quality that the basket slider can be closed without
of the dispensed coverslip. The coverslip dispense breaking any slides. After the basket has been
can detect double dispenses, missing coverslips, closed by the vertical lift and returned to the unload
broken coverslips, skewed coverslips, chipped rail the eject bracket pushes it off the lift block and
coverslips, and coverslips that are too long or short. far enough along the unload rail so that it can be
A skirt is used on the coverslip dispense to sweep unloaded by the operator.
rejected coverslips and debris into the debris tray.
Output Rail
Mountant Dispense Head The output rail acts as a buffer for baskets after they
The mountant dispense head dispenses a bead of have been processed on the ClearVue, leaving the
mountant onto the slide with a precisely controlled basket for 15 minutes on the output rail after
shape. The shape of this bead is designed to flow in processing has finished will give much more stable
a certain way and allows a coverslip to be placed on coverslips that are less prone to moving.
the slide without trapping any air bubbles.

ClearVue Service Manual Issue 08 13

Mountant Pump Actuator and Syringe Camera
The mountant pump dispenses a precise amount of The ClearVue uses a digital camera to sense the
mountant onto the slide to form the bead. The position of the gripper jaws and basket; this enables
movement of the pump is synchronised with the the slides to be positioned accurately relative to the
dispense head to ensure the correct bead shape gripper jaws. When the ClearVue is powered on and
and mountant volume. The syringe holds 2.5ml of goes through its initialization routine it takes a
mountant in its fully charged position. picture of the long jaw and uses it to assess the
vertical & horizontal position of the jaw. During
Cleaning Station Assembly processing the ClearVue also moves each basket
The cleaning station dips the dispense head needle into two different positions where pictures can be
into solvent to clean it between baskets and to taken of the basket. Algorithms in the software then
prevent dried mountant blocking the needle when compare the calculated positions for basket &
the ClearVue is not in use. gripper jaw to calculate how far the basket has to
be moved to line each slide up with the gripper jaws.
Mountant Bottle
The mountant bottle is simply a reservoir for storing
the mounting media. The ClearVue has the facility to
pressurize the bottle during the syringe load cycle.
There is also a de-gas option which can be used to
remove air trapped in the mountant.

Pneumatic Circuit
The pneumatic circuit provides both positive
pressure and a vacuum. There are two pumps in the
circuit, both of which are capable of producing
either vacuum or pressure. The first pump connects
via the upper solenoid bank to the bottle and
provides either pressure for loading the syringe or
vacuum for the de-gas function. The second pump
is used for vacuum only and connects via the lower
solenoid bank to either the coverslip dispense
carriage or the coverslip transfer head. An extremely
sensitive exhaust is connected to the transfer head
solenoid; controlling the exhaust (decay) time is
critical to getting the correct mountant flow between
the coverslip and the slide.

Covers and Filter

The covers on the ClearVue are ergonomically
designed from a tough polymer material to act both
as safety covers and as a flameproof enclosure. The
windows are made from an aerospace grade
material which is the clearest available that is both
flameproof and resistant to ClearVue solvents. The
filter used is a standard carbon filter.

ClearVue Service Manual Issue 08 14

Electronics Assembly • During initialization the processor programmes
the FPGA on the main board.
Overview • Links - All links should be fitted.

• Most of the ClearVue electronics are contained • Link 6 is used to connect the on board battery to
within the electronics box. maintain the BIOS settings.
• This consists of the mains input power supply
Main Board
with 24VDC output; the main board connected
to the processor board via the interconnect The main board carries out several functions. The
board; the battery charger board and the power supply section generates the required
batteries (for battery backup in the event of a voltages from the 24V PSU input (or from the battery
mains failure). input). The processor board, which plugs into the
main board via the interconnect board, writes to and
• Some of the motors, solenoids and sensors
reads from the FPGA (field programmable gate
connect directly to the main board in the
array) which interfaces to the sensors and drives.
electronics box.
• In addition there are four other boards Power Supply
connected to the main board via ribbon cables.
The front interface board and back interface Conversion from the 24V input (from the power
board are used to connect to some motors, supply or battery backup) to:
sensors, etc.; the display interface board • 15V - used by the battery charger and by the fan
connects to the touch screen and some drive circuits.
sensors; the camera interface board had the
• 12V - used for the illumination LED’s on the
camera and illumination LED’s. camera board (switched on the main board).
Used by the display board for the screen
Mains inlet and power supply
backlight.
• The mains inlet in the side of the electronics box It also goes to the disk drive for drives requiring
has a double pole switch and two fuses (for the a 12V supply.
live and neutral lines). It also contains a mains
filter. • 5V for some of the logic and the sensors.

• The earth from the mains inlet connects directly • 3.3V for some of the logic.
to the primary earth stud in the electronics box. • 1.2V for the FPGA core power.
• The power supply has a wide AC input range. Note
The output is 24VDC. There is a power fail signal.
The 24V input from the power supply is fused (F1).
The power supply contains a cooling fan.
24V Switching
Processor Board
The 24V supply to the motors is switched on only
• The processor board runs the software to
when the processor is toggling the power watchdog
operate the instrument.
timer (via the I2C bus) and when the FPGA
• Flash memory on the board is used to store the
recognizes that the processor is active. This is used
software, parameters, logs, etc. for the motor drive circuits, the solenoid valves and
• The processor communicates directly with the the pumps.
FPGA on the main board.
• The processor uses an I2C serial Power Monitoring
communications protocol to communicate with I2C devices are used to monitor the power supplies.
various devices on the main board and on the These are read by the processor.
battery board.

ClearVue Service Manual Issue 08 15

Test points and LED’s FPGA to latch coverslip dispense motor positions.
This information is used by the processor to
On the edge of the board are a series of test points
determine coverslip sizes, skew, double slips, etc.
and LED’s - these can be used to check the
voltages. Motor Drives

LED Test Point Voltage • The FPGA controlled the signals to the motor
drive circuits under the control of the parameters
LED1 TP1 15V sent determined by the processor.
• The FPGA controls the DAC’s which provide the
LED2 TP2 24V – This is switched
reference signals to determine the current drives
on when the processor
and, where appropriate, micro stepping to the
and FPGA are OK
motors.
LED3 TP3 12V • The motor encoder signals are read by the FPGA
and used to derive the quad positions. These are
TP4 GND
used by the processor to monitor and control the
LED4 TP5 5V operation of the motors.

Note
LED5 TP6 3.3V
The cleaning station motor drive does not have
TP7 1.2V variable current capability or encoder feedback.
TP8 GND Camera Interface
The FPGA controls the data flow from the camera.
Note
It saves frames, parts of which are read by the
Take care if clipping probes to the test points. Avoid processor to determine gripper positions, slides in
applying stress. These are delicate surface mount baskets, etc.
test points and can easily be damaged (and may
LCD touch screen Interface
damage the board) if too much stress is applied.
More robust GND connections can be found on the The interface between the processor and the screen
motor drive IC heatsinks or on the ’D’ connector is on the main board.
screwlocks on the main board.
Links
Drives
• Directly below the LED’s on the edge of the PCB
The solenoid valves, air pumps, fan drives and
are the links. The 16- pin header takes 8
camera illumination LED drives are all from the main
removable links.
board. These are all switched by the FPGA under
• Links 1 to 6 are configuration links which are
the control of the processor.
read directly by the FPGA.
Opto and Door Switches
• Links 7 and 8 are used for configuring multiple
The slotted opto switches and the magnetically FPGA programming.
operated door switches are read directly by the • On ClearVue all 8 links must be fitted.
FPGA.
• In addition to the removable links there are 2
Coverslip Optos ’hard links’. These are fixed links on the PCB.
These are used to indicate specific board build
The reflective opto sensors used for the coverslip
standards.
detection feed into an ADC to be read by the FPGA.
They also feed the reference signals coming from a • The status of the removable links 1 to 6, and the
DAC, controlled by the FPGA, into comparators. two hard links, can be checked in the Production
The outputs from the comparators are used by the Services screens.

ClearVue Service Manual Issue 08 16

Test Headers Charge / Battery Backup Switching
The 10-pin JTAG, 10-pin PROG and 16-pin TEST • When the mains supply is present the batteries
headers positioned below the LINK header are for are in the charging state. When a mains power
factory use. fail is detected the relay RL3 is switched to
configure the batteries in series to provide a
Fuse
nominal 24V for battery backup operation.
There is a fuse for the 24V power input from the
• When the unit is off, relays RL1 and RL2
PSU. disconnect the batteries from the rest of the
Interconnect Board circuitry.

The interconnect board is a passive board which fits

Monitoring
between the processor board and the main board.
The USB connector at the top is not used in • As well as the charge state monitoring (see
ClearVue. above) and the links (see below), there is voltage
monitoring and temperature monitoring on the
Battery Board and Batteries board. The battery isolator switch state is also
Batteries monitored as is the WGO signal to monitor
power fail / battery backup state.
There are two 12V 1.2Ah sealed lead acid batteries
situated within the electronics box. These are used • These monitors are all read by the processor via
to provide power in the event of a mains power the serial I2C bus.
failure. The backup power is only intended to
Links
complete baskets of slides being coverslipped and
to ensure that the system stops in a state where • LK1 must be fitted in position ’B’. This selects
recovery of baskets of slides is simple with the the correct power fail to battery backup
minimum risk of damage to specimens. switching state for ClearVue.
• Links LK2, 3 and 4 should also be fitted.
Battery Chargers
• In addition there are two ’hard links’ which
• There are two independent multi-stage charging cannot be changed. These indicate the build
circuits, one for each battery. level of the board.
• The charge sequence is:
Fuses
State 1: Trickle charge followed by bulk charge.
The trickle charge ensures that cells within the Each battery has its own fuse on the battery board,
batteries are not shorted. The bulk charge is F1 and F2.
nominally at constant current and provides most
of the charging of the batteries. Electronics Box - Miscellaneous Items
State 2: Over charge. As the voltage reaches the • There is a speaker connected to the main board.
required level the constant current gradually This is driven from the processor board.
changes to a voltage limited charge (over charge • There is a fan within the electronics box. This is
voltage) with the current gradually decreasing. driven from the main board. This has a feedback
State 3: Float charge. Once the current has signal to check fan speed. This fan is always on.
dropped off to the required level the voltage • The disk drive connects to the main board but is
drops to the float charge level. driven from the processor board. This is used for
loading software updates and for saving
• On battery boards from revision 2, the charger
engineer logs.
states can be read by the processor and are
displayed in the production services screens.

ClearVue Service Manual Issue 08 17

Camera Board Motors
• All of the motors are stepper motors.
Camera
• With the exception of the cleaning station motor,
• The camera is mounted on the camera interface
all motors have encoders fitted.
board.
• With the exception of the cleaning station motor,
• This is used to capture images of the gripper,
all motors use the same 8-way connectors, 4
basket and slides in the basket.
connections for the motor windings and 4 wires
for the encoder.
Interface
• The cleaning station motor uses a 4-way
The camera interface board, under the control of the connector for the motor windings.
FPGA on the main board, passes the data to the
• The motors are driven with various currents (up
FPGA.
to 1.5A/phase) and with various drive types (from
full stepping to micro stepping).
Illumination LED’s
The illumination LED’s are mounted on the camera Sensors
interface board.
• Most of the sensors are slotted opto switches.
These are bright when switched fully on. • There are also reflective opto sensors (used for
coverslip detection), magnetically operated
Do not look directly at the LED’s when
proximity switches (for the doors), a Hall Effect
the system is capturing an image
micro-switch (for the filter) and vacuum/pressure
transducers (on the back interface board).
Links
All links should be fitted. Pumps (Air)
• These connect to the back interface board.
Auxiliary connectors
• They utilise brushless DC motors.
There are connectors for programming the camera
and for analogue video signals. These are for factory Solenoid valves
use.
• The DC solenoid valves control the air flow from
the pumps to/from the transfer head for
Front Interface Board
coverslip pick-up, the coverslip dispense
This is a passive board which provides the carriage and the mountant bottle.
interconnect between some of the motors, sensors, • In addition a solenoid valve is used to switch the
etc. and the main board. mountant pump syringe between the dispense
head and the mountant bottle.

Back Interface Board Miscellaneous Items

This provides the interconnect between some of the There is a fume extract fan housed in the top cover.
motors, pumps, sensors, etc. and the main board. This is driven from the main board. This has a
It also has the three vacuum/pressure transducers feedback signal to check fan speed. This fan can be
used to monitor the coverslip dispense carriage off (when no filter is fitted) or may run at low speed
suction, the coverslip pick-up suction and the or high speed depending on the fume extract
mountant bottle pressure. requirements.

ClearVue Service Manual Issue 08 18

Design Purpose
The ClearVue is a high-throughput, precision
engineered, slide coverslipper, capable of
coverslipping 250 slides every hour in a precise and
efficient manner.

Before operating this instrument the user should

have read and understood the Safety section of the
Safety and Warranty Booklet (A79910001).

The ClearVue has been designed for general

laboratory use, and can handle baskets from the
following stainers:

• Varistain Gemini (Inc. ES Variant)

• Varistain 24-4
• Leica Autostainer
• Sakura Tissue-TekR DRS 2000™ Series
The ClearVue is capable of having multiple baskets
loaded at once in any order from any of the above
stainers.
High quality, 75 x 25mm microscope slides must be
used with the baskets.

Compatibility
The ClearVue is compatible with the following sizes
of coverslips:

• No. 1.5 x 24 x 40mm

• No. 1.5 x 24 x 50mm
• No. 1.5 x 24 x 55mm
The following slide dimensional tolerances are
permissible:

• Length 74.5 - 76.0mm

• Width 24.5 - 26.0mm
• Thickness 0.8 - 1.2mm

ClearVue Service Manual Issue 08 19

 13 Basket Unload Bracket
Identification of Parts (front)
14 Serial Number Label
Front view of ClearVue
15 Coverslip Transfer Head

16 Dispense Head Cleaning Station

Identification of Parts (rear)

Rear of the ClearVue

1 Load Door 7 Debris Tray

2 Unload Rail 8 Debris Tray Door

3 Unload Door 9 Mountant Bottle

Downdraft
4 Access Door 10
Ventilation

Cleaning Battery 3.5” Floppy Disk

5 11 Load Rail 17 22
Brushes Isolation Switch Drive
6 Touch Screen 12 Xylene Tray Main Power
Service History
18 23 Switch, Fuses
Booklet
Inside ClearVue and Connector

Screwdriver and
View through the Access Door 19 Filter Cover 24
Allen Key

Mountant Vents for

20 Bottle Cap 25 Electronics
Removal Tool Enclosure

21 Rating Plate

ClearVue Service Manual Issue 08 20

Example of Varistain Gemini System Specifications
Basket Physical Specifications
Height 500 mm (19.7”)

Width 645 mm (25.4”)

Depth 575 mm (22.6”)

Weight 48 kg (106 lbs)

Electrical Specifications
Voltage 100 - 240 V~

Frequency 50/ 60 Hz
System Interfacing
The Touch screen panel is the primary user interface Power (max) 300 VA
mode on the ClearVue. It is used to input data, Earth Leakage < 500 μA at 110-120 V~
operate the manual functions and inform the user of
instrument data. Fuses T 6.3 A, 250 V

In addition, the ClearVue will issue audible alerts Internal batteries Sealed Lead Acid type.
when appropriate. Not user replaceable.
General operation of the ClearVue is started by
~ denotes a.c.
opening and closing the Load door.

Stopping and restarting the ClearVue is controlled

Environmental Specifications
by the software to ensure safety, whilst at the same
time making sure that the samples are not Warning - For Indoor Use Only
compromised.
Temperature Temperature (operating
(operating limits) limits)

Temperature Temperature
(recommended (recommended
operation) operation)

Temperature Temperature (transport &

(transport & storage) storage)

Relative Humidity Relative Humidity

Opening any of the doors will not Altitude Altitude

necessarily cause the ClearVue to
Pollution Degree Pollution Degree
stop running; therefore care should
be taken when adding or removing Over Voltage
baskets. Over Voltage Category
Category

ClearVue Service Manual Issue 08 21

Coverslipping Method

The ClearVue has been specifically designed to

ensure consistent, high quality, coverslipping.
The following shows how the coverslip is laid.

This method of coverslipping has been proven,

through rigorous testing, to minimize bubbles and
ensure complete adhesion to the slide.

ClearVue Service Manual Issue 08 22

Chapter 2 – Basic Operation
The following section covers the following
information:

• Daily Tasks
• Weekly Tasks
• Level the ClearVue before use
• Change the Carbon Filter
• Fit the Extraction Kit
• Maintaining the Xylene Tray Level
• Fill the Mountant Bottle
• Change the Purge Tray and Debris Tray
• Start up the ClearVue
• Fill the Dispense Head Cleaning Station
• De-gas the Mountant Bottle
• Flushing the System
• Purging the System
• Remove and Replace the Coverslip Hopper
• Shutting Down the ClearVue
• Load a Basket
• Unload a Basket
• Abort a Basket
• Manually Abort a Basket
• Remove Baskets from the Load & Unload Rail
• Remove Slides during Coverslipping
• Remove Baskets from the Vertical Lift

ClearVue Service Manual Issue 08 23

Daily Tasks Weekly Tasks
The following tasks should be carried out at least The following tasks should be carried out at least
once a day: once a week:

At daily Start up, lift the Coverslip Empty, clean and refill the Dispense
Hopper before switching on head cleaning station

Top-up the Dispense head cleaning Remove any discarded coverslips from
station. Wipe the top with a xylene damp the Slip Dispense area and clean the Slip
cloth dispense carriage

Check the number of Coverslips in the Remove the Coverslip transfer head to
hopper and replace if necessary check that the Pads and the Suction cup
are clean and free of Mountant. Wipe the
Check the level of Mountant and top-up Pads with a xylene damp cloth to clean
if necessary
Check the level of xylene in the Xylene
Wipe the Suction cup with a xylene Tray
damp cloth to ensure it is clean and free
from debris. Replace if necessary.
Empty the Debris tray
Ensure the Suction cup is dry before use

Check the Purge tray and replace if

Clean the Gripper return plate
necessary

Purge the system 3 times. Lift the

Clean the Slip dispense skirt
coverslip hopper before purging

ClearVue Service Manual Issue 08 24

Level the ClearVue before Use Change the Carbon Filter
It is critical that the ClearVue is level Epredia recommends that the ClearVue be used
before use! with the Vent Adaptor Kit fitted.

If Carbon filters are being used it is important to

Levelling is carried out on the jackable feet of the
ensure that they are changed regularly, to comply
ClearVue to raise or lower any of the four corners of
with local legislation on vapour exposure limits.
the instrument.
To change the Carbon filter:
• Slide the Filter cover off to gain access to the
Carbon filter.

The following procedure should be carried out on all

required corners of the ClearVue:
• Use a 13mm wrench (spanner) to loosen the
Lock Nut of the Jackable foot.
• Lift the Carbon filter out of the chamber and
dispose of according to local regulations.
• Remove the cellophane wrapping from a new
Carbon filter and place into the chamber.

• Adjust the Jacking Nut with the wrench to raise

or lower the ClearVue as required.

• Tighten the Lock Nut to secure the Jackable foot

in position.
• Ensure the Airflow directional arrow is pointing
upwards.

Ensure the Lock Nuts are properly

tightened after adjustment

ClearVue Service Manual Issue 08 25

• Slide the Filter cover back into position making Fit the Extraction Kit
sure it is firmly clipped into place.
An optional Extraction Kit (A79210080) is available,
which allows fumes to be vented into a fume
cupboard, hood or the outside atmosphere.

The Extraction Kit should not be used to

extract fumes through the building
HVAC system or through a common site
extraction system

The Extraction Kit comprises the following parts:

• Filter Cover with Duct Adaptor

Write the installation date on the Carbon
filter using a permanent marker to • Jubilee Clip
ensure proper record keeping. • 2.5m Ducting Tube
To fit the Extraction Kit:

• Fit the Ducting tube and Jubilee Clip to the Duct

Adaptor.

• Replace the Filter Cover with the assembled

Extraction Kit.

Do not remove the Carbon Filter!

ClearVue Service Manual Issue 08 26

Maintaining the Xylene Tray • Slowly close the Xylene Tray completely to
ensure that the seal is properly engaged.
Level
The Xylene Tray is intended to provide a xylene rich
atmosphere to prevent slides on the Load Rail from
drying out. The Xylene Tray should be checked
every week and topped up or emptied as required.
To fill the Xylene Tray:

• Slide the Xylene Tray out about half way, taking

care not to spill any remaining xylene.

Alternatively, it is possible to open the Load door

and pour xylene into the Xylene Tray using a small
beaker. If this method is used and there are no
Baskets waiting on the Load Rail, the ClearVue will
perform a routine check after the Load Door has
been closed. If Baskets are loaded the ClearVue will
begin coverslipping when the Load Door is closed.

• Carefully pour xylene into the Xylene Tray or

remove using a pipette as required.

• The depth of the xylene should be approximately

half-way up the Anti-Surge Baffle.

ClearVue Service Manual Issue 08 27

Fill the Mountant Bottle Ensure no Mountant reaches the Air
Vent on the spout as this will cause
Most Mountants are harmful! the instrument to cease operation.

Notes
The Mountant Bottle supplies Mountant to the
After filling, de-gas the mountant bottle.
Dispense head. It is strongly advised not to allow the
Mountant bottle to run dry. If the Mountant Bottle has been allowed to run dry,
or the level has fallen below the bottom of the
To fill the Mountant bottle:
internal pipe, it will be necessary to:
• Remove the Mountant bottle cap.
1. Fill the Mountant Bottle.
2. De-gas the Mountant Bottle
3. Flush the system to remove any air from the
pipes

• Carefully pour Mountant into the open end of the

Mountant Bottle until the liquid reaches the
bottom of the collar. Ensure no Mountant is spilt
down the outside of the bottle.

• Replace the Mountant bottle cap and twist

clockwise by hand to tighten it.
Do not use the Cap Removal Tool,
or any mechanical means, to tighten
the Mountant Bottle Cap.

Do not overfill the Mountant Bottle.

ClearVue Service Manual Issue 08 28

Change the Purge Tray and Either:

Debris Tray • Unpack a new Coverslip Hopper; the end cap

doubles as a new Purge Tray, or
The Purge Tray is used as a receptacle for expelled
• Use one of the spare Purge Trays supplied with
Mountant and Xylene.
the instrument.
The volume of fluid in the Purge Tray should be
checked prior to carrying out either a Flush or Purge
function.

The Debris Tray contains any Coverslips which have

been discarded or broken during coverslipping.

To change the Purge Tray and empty the Debris

Tray:

• Open the Debris Tray Door.

• Place the new Purge Tray onto its shelf.

• Replace the Debris Tray.
• Close the Debris Tray Door.

• Remove the Debris Tray and dispose of the

contents according to local regulations.

• Reach into the instrument as shown and, using

the tab, carefully lift the Purge Tray down off its
shelf.

• Dispose of the used Purge Tray according to

local regulations.

ClearVue Service Manual Issue 08 29

Start up the ClearVue Fill the Dispense Head Cleaning
To start up the ClearVue: Station
• Open the Access door and lift up the Coverslip Take precautions when dealing with
Hopper. Xylene!

The Dispense head cleaning station ensures the

Dispense head does not get blocked with
Mountant. There should be a visible pool of Xylene
in the central well.

To fill the Dispense head cleaning station:

• Turn the Battery isolation switch to the On
• From the Main menu, press the Mountant key on
position ’I’.
the screen.

• When the Language select screen appears, use

the arrow keys on the Touch screen to highlight
the required language, and then press Select.

• Press the Access key.

• The Main menu now displays. The system will

carry out a series of automated checks and the
Status will show Initialising. When complete the
Status will show OK. The instrument is now • Press the Start key.
ready to use.

• Wait for activity within the ClearVue to stop, and

Access Ready to flash on the screen.
• Open the Access door.

ClearVue Service Manual Issue 08 30

• The Dispense head cleaning station is now be
accessible from above. It can either be removed,
by pulling slightly forwards and then lifting it
gently from its fitting, or left in the ClearVue.

• Use the end of the pipette to push the central

well down, to ensure that the Xylene levels are
consistent.
Note:
Ensure that the central well re-seats itself properly.
• If the Dispense head cleaning station has been
removed from the instrument, it can be filled
easier by removing the Dispense head cleaning
station lid and pouring xylene in up to the
required level.
• When finished, close the Access door and press
the Complete key.

ClearVue Service Manual Issue 08 31

Degas the Mountant Bottle
De-gassing the Mountant bottle will remove any air
bubbles from the Mountant.

To de-gas the Mountant bottle:

• From the Main menu, press the Mountant key on
the screen.

Flush the System

Flushing the system dispenses a large amount of
Mountant. This function should only be used if the
Mountant bottle has run dry or when cleaning the
system using Xylene.

To flush the system:

• Press the De-gas key.
• Ensure the Access door is closed.
• Lift up the Coverslip Hopper.
• From the Main menu, press the Mountant key on
the screen.

• Press the Start key.

• Press the Flush key on the screen.

• The ClearVue will now de-gas the Mountant

bottle.

• Ensure the Purge tray is empty and that there is

sufficient Mountant (or Xylene) in the Mountant
bottle (at least 80ml).
• Press the Start key.

• When the process has stopped press the Exit

key.

ClearVue Service Manual Issue 08 32

 • Ensure there is sufficient room in the Purge tray
before starting the Purge cycle.
• Press the Start key.

• Wait for the activity within the ClearVue to stop,

and then empty or discard the Purge tray.
• Press the Exit key. • Wait for this screen to appear and the activity
within the ClearVue to stop and then empty the
Purge tray.
• Press Repeat to restart the Purge process, or
Cancel to exit.

• Push the Coverslip Hopper down.

Purge the System

• Push the Coverslip Hopper down.
Purging the system is a routine procedure which
dispenses a small amount of Mountant to ensure
high-quality coverslipping.

To purge the system:

• Ensure the Access door is closed.

• Lift up the Coverslip Hopper.
• From the Main menu, press the Mountant key.

• Press the Purge key.

ClearVue Service Manual Issue 08 33

Remove and Replace the
Coverslip Hopper
To change the Coverslip hopper:
• Open the Access door.

Note
Ensure coverslips are the correct size. Ensure
Coverslip Hopper has not been dropped by
checking for broken coverslips.
• Remove the empty Coverslip hopper by pulling • Remove the end cap from the bottom of the
slightly forwards and then lifting it gently Coverslip Hopper and retain for use as a Purge
upwards. Tray.
• Load the new Coverslip Hopper ensuring that
the Dispense Directional Arrow is pointing
towards the back of the instrument.

Note
If the Coverslip Hopper is not empty, use the end of
the paintbrush provided to push the foam inside the
Hopper down until it secures the remaining
coverslips.
• Unpack a new Coverslip hopper and identify the • Ensure the Coverslip retention spring is located
Dispense directional arrow on the top. inside the slot in the Hopper mounting block.

ClearVue Service Manual Issue 08 34

 Shutting Down the ClearVue
To shut down the ClearVue:

1. Ensure there are no Baskets still in the

instrument.
2. Ensure the Dispense head is located in the
Dispense head cleaning station.
3. Switch the Mains power switch to the off O
position. Do not switch off the Battery isolation
switch.
• The Coverslip hopper should sit level and fully
down over the location pins. Notes
To conserve power and extend filter life, it is
recommended that the ClearVue is shutdown at
night.
If 24 hour operation is required, ensure that the
ClearVue is shutdown once per 24 hours to allow
Self-Test and Maintenance Logs to be stored.

• On the Main menu screen, press Clear count.

Note
Clear Count must always be selected after changing
the Coverslip size.

ClearVue Service Manual Issue 08 35

Load a Basket
To load Slides into Baskets:

• Move the Slide Retainer.

• The Basket is now ready to load onto a stainer

or directly into the ClearVue.

• Insert Slides, starting from the bottom shelf, with

the sample on the top.

To load Baskets of Slides:

• Open the Load Door.

• Ensure the Slides are placed in the Basket

correctly.

• Gently shake the Basket to remove excess

xylene and blot on absorbent paper.
• Place the Basket onto the Load Rail.
• When all the required Slides are in the Basket,
return the Slide Retainer to its original position to
secure the Slides in the Basket.

ClearVue Service Manual Issue 08 36

 • Remove the completed Basket from the Unload
rail.

Notes
Ensure Slide Retainer is closed before loading
basket.
Ensure Directional Arrow on basket is pointing
upwards.
If operating outside of the recommended
temperature range, ensure samples do not dry out Keep the Basket upright after
too quickly by loading no more than 2 Baskets at unloading - Basket Rack is supplied
any one time. for this purpose.

• Close the Load Door.

• The ClearVue will start automatically.

Unload a Basket
To unload a Basket:

• When a Basket of slides is completed, the

ClearVue emits an audible alert.
• Wait about 15 mins before removing a
completed Basket, to allow the Mountant to dry
• Close the Unload door.
enough to allow the Slides to be handled safely.
• Open the Unload door.

ClearVue Service Manual Issue 08 37

Abort a Basket Manually Abort a Basket
The Abort command can be used if a Basket being In the event of a power failure the ClearVue will
coverslipped needs to be returned to the Unload rail continue to process Baskets using its own internal
without finishing the coverslipping process. batteries.
To abort a basket: If there is insufficient charge in the batteries to
process the loaded Baskets, the ClearVue will
• From the Main menu press the Options key on
remove any remaining Baskets from the Load Rail
the screen.
and place them, unprocessed, onto the Unload Rail.

The ClearVue should be serviced

regularly, and the batteries checked,
or replaced, to ensure that they have
sufficient charge to perform the
automatic unload process in the
event of a power failure

However, in the unlikely event that the batteries are

• Press the Abort key. completely discharged and unable to automatically
unload the Baskets, the following procedures will
allow the Baskets to be unloaded manually:

• Remove Baskets from the Load rail

• Remove Baskets from the Unload rail
• Remove Slides which are in the process of being
coverslipped
• Remove Baskets from the Vertical lift

• From the Basket abort screen press the Abort Any Baskets which are unloaded
key. manually may contain slides which
have not been coverslipped, and
steps should be taken to preserve the
specimens.

If any Baskets are removed manually

due to a power failure or blockage,
the ClearVue must be switched Off
and On again to allow the mechanism
to re-calibrate.
• Remove the Basket from the Unload rail.

Note
The ClearVue will finish coverslipping the current
slide before it aborts the basket.

ClearVue Service Manual Issue 08 38

Remove Baskets from the Load
& Unload Rail
To remove Baskets from the Load rail:
• Open the Load Door.
• Remove any Baskets which are located directly
underneath the Load Door.
Note
If there are Baskets further along the Load Rail they • Remove any Baskets which are located directly
must be brought back underneath the Load Door underneath the Unload Door as normal.
before they can be removed.
• To move Baskets back underneath the Load Remove Slides during
Door insert the Screwdriver (supplied) into the
Coverslipping
hole at the side of the instrument, under the Load
Door. To remove Slides which are in the process of being
coverslipped:

• Open the Access Door.

• Turn the Screwdriver clockwise to bring the

Basket Pusher as far over to the left-hand side
of the instrument as possible.
• It should then be possible to reach through the • Remove the Coverslip Hopper.
Load Door and pull any remaining Baskets over
to where they can be removed.
Note
There is a ball-spring plunger half-way along the
Load Rail which the basket must be pulled over.
To remove Baskets from the Unload rail:

• Open the Unload Door.

• If the Dispense Head is over the Slide, reach

through the Access Door and manually pull it as
far towards the front of the instrument as
possible.

ClearVue Service Manual Issue 08 39

• Rotate the Coverslip Transfer Head until it is in • If there are any Baskets halfway onto the Lift
its top position to provide access to the Slide. Block, it may be necessary to lower the Lift Block
to remove them.
• Reach in through the Unload Door and push the
Basket Unload Bracket as far towards the right
of the instrument as possible.
• Reach in through the Load Door and pull the
long Gripper jaw as far towards the left as
possible.
• Insert the Screwdriver into the small hole in the
Main cover.

• Carefully remove the Slide from the Gripper jaws.

Notes
The right-hand Gripper jaw is spring loaded and can
be moved to the right to release the slide.
It is advisable to remove the Debris Tray and then
reach into the instrument through the Debris Tray
Door in order to support the Slide when removing it • The Screwdriver should slot into the Vertical Lift
from the Gripper jaws. lead-screw.
• Reach in through the Load Door and pull the • Turn the Screwdriver clockwise to raise the
long Gripper jaw as far towards the left of the Basket until it is level with the Unload Rail.
instrument as possible.
Note

Remove Baskets from Vertical Do not turn the Screwdriver anti-clockwise once the
Slides are above the Slide Guide as this could result
Lift in broken Slides.
To remove baskets from the vertical lift: • Close the Slide Retainer as soon as possible to
• Open the Unload Door. ensure that no Slides fall out of the Basket.
• Once the Basket is aligned with the Unload Rail,
pull the Basket onto the Unload Rail and remove
as normal.
If the Gripper jaws and Basket Unload
Bracket are not correctly located as
described above, any attempt to raise
the Basket may lead to damage to
the instrument, Basket or specimens

ClearVue Service Manual Issue 08 40

Chapter 3 – Production Services
• Introduction
• PARAM Tab
• I/O Tab
• MOTOR Tab
• ENG Tab

ClearVue Service Manual Issue 08 41

Introduction The available tabs are:

To access the Production Services screens use the Home

following method: The Production Services welcome screen also
displays the Software and FPGA Version Numbers.
• From the Main Menu press Options.
Note
Pressing the Home Tab from any screen where it is
visible will exit the Production Services area.
PARAM
This tab allows the Service Engineer to view and /
or change the Parameters.

I/O
• From the Option menu press Disc.
This tab shows Sensor Inputs, Switch System
Outputs (eg: pumps / solenoids) and information on
Voltages and Battery Backup Status.
MOTOR

This tab allows the Service Engineer to take control

of each of the individual motors.
ENG
• When in the Disc Options menu press the top-
right, bottom-left and top-right of the touch This tab allows the Service Engineer to perform
screen. various tests and checks.

• The Production Services screen should now be

visible.

Production Services consists of several Tabs, each

with its own function.

ClearVue Service Manual Issue 08 42

PARAM Tab I/O Tab
Pressing the PARAM tab takes you into the Pressing the I/O Tab will display the following
parameters page. screen.

Note
It is advisable to output the current parameter
settings to disk before attempting to adjust
parameters – refer to the Eng Tab – Page 3/7
section.

In this screen there are 5 buttons to choose from.

• I/O Tab – INPUTS

• I/O Tab – OUTPUTS
• I/O Tab - I2C
• I/O Tab – VOLTAGES
• The top line shows the parameter being edited.
• I/O Tab - LINKS
In this example its ”Camera Skew Correct”
• The line ”Parameter #0000” tells us which I/O Tab – INPUTS
parameter is being edited. In this case it is
Pressing the INPUTS button displays the following
parameter 0.
screen:
Note
Note
A full list of Parameters and Settings can be found
Use the arrow keys to scroll between the four
in Appendix A3 - Parameters.
’inputs’ screens.
• ”Value” indicates the current value the parameter
is set to.
• Pressing the ’I’ key gives a brief explanation of
the current parameter.
• There are also 8 buttons in the screen. 4 for
Adjust and 4 for Parameter.
• Under adjust, pressing the S+ or S- keys will
increment the parameter value by a large step.
Pressing the ++ or -- key will increment the • This screen shows the status of some of the
parameter value by 1. In both cases + means to slotted opto sensor inputs.
increase the value and - means to decrease the • ’0’ = opto open. ’1’ = opto closed (flag in opto).
value.
• The 4 parameter keys work in a similar manner.
Press the ++/-- for moving quickly through the
parameter list and press +/- to move in steps of
1.

ClearVue Service Manual Issue 08 43

• This screen shows the remainder of the slotted ON the air pump that is connected to the mountant
opto sensors. bottle. Pressing the ’0’ key will switch off the pump.
• It also shows the three pressure transducers. Press EXIT to return to the main I/O page.

Note
If the state of any pumps or solenoids are changed,
a full initialise must be carried out prior to using the
machine.
Refer to the Pneumatics Diagrams section for the
pneumatics diagram.

• This screen shows the door sensors and the filter • Mountant pump sol is the solenoid between the
syringe and the mountant bottle or dispense
switch.
needle.
• For the doors, a ’0’ indicates door open, a ’1’
• 0 = syringe to dispense needle. 1 = syringe to
indicates door closed.
mountant bottle
• For the filter switch, a ’0’ indicates filter present,
• Prep solenoid 1 is the coverslip dispense
a ’1’ indicates filter not present.
carriage solenoid.
• 1 = Vacuum to coverslip dispense carriage (Prep
sol 2 must be 0)
• Prep Solenoid 2 is the support arm suction cup.
• 1 = Vacuum to the suction cup (Prep sol 2 must
be 0)
• Bottle Solenoid 1 is the mountant bottle vacuum
solenoid. See table below for settings.
• This screen shows the speeds of the two fans. • Bottle Solenoid 2 is the mountant bottle pressure
• To exit the current screen and return to the I/O solenoid. See table below for settings.
screen, touch the 'Exit' key. • Bottle Pump is the vacuum pump for the
mountant bottle.
I/O Tab - OUTPUTS • Prep Pump is the vacuum pump for the coverslip
Pressing the OUTPUTS button displays the dispense carriage and suction cup.
following screen:
Prep Solenoid
Status
1 2

No vacuum on carriage or
suction cup (pump has
0 0
nowhere to pull air from; puts
strain on the system).

Vacuum to coverslip dispense

1 0
carriage.
In this screen its possible to change the condition of
various output functions on the ClearVue. For 0 1 Vacuum to suction cup.
example, press the ’-’ key to move the cursor down
1 1 Partial vacuum on both.
to the ’Bottle pump’ line and press ”1” - this will turn

ClearVue Service Manual Issue 08 44

 Bottle Solenoid Status • HL2, HL3, HL4: Fixed resistor ’hard links’ on the
battery board.
1 2 • B-SW: Battery isolator switch. ’0’ = switch off,
’1’ = switch on.
0 0 Vacuum to mountant bottle.
• WGO: Signal on the battery board indicating the
Mountant bottle sealed at automatic switching of the battery relays on
1 0
solenoids. power fail. ’0’ = normal state, ’1’ = power fail
state.
Pump circulates air around
0 1 Hard Links:
closed loop.
• For issue 1 battery board, all hard links are ’1’.
1 1 Pressure on mountant bottle.
• For issue 2 (and later), HL2 = ’0’.
On the pneumatics diagram all solenoids are shown
connected in their unpowered state i.e. 0 Battery Charger States

Note • Each of the two batteries (battery 1 and battery

2) is charged independently.
Setting both of the prep solenoids to 0 put strains
• For each charger there are two status signals OC
excessive on the pump and the vacuum regulator
and STL. These are read on the I2C bus as
and should therefore be avoided.
follows:
I/O Tab - I2C Charger State STL OC
Press the I2C key to display the following screen.
Bulk Charge 1 0

Over Charge 1 1

Float Charge 0 0

Note
These are only displayed correctly when the battery
board is issue 2 or above (HL2 = ’0’).

There are no features to edit or change in this page, • Press the screen in any location to return to the
this just shows the status of some of the I2C bus previous menu.
signals (mainly from the battery board).

• PFD: Power fail detection. 0 = OK, 1 = power fail

signal detected.
• PWR_WDT: Power watchdog. This should
normally be ’0’.
• pw state: The software power state. ’0100’ is the
normal state. ’0110’ is the state when first
running on batteries after a power fail.
• OC2, OC1, STL2, STL1: Battery charger states
- see below.
• LK2, LK3, LK4: Links on the battery board. ’0’ =
link present. ’1’ = link missing.

ClearVue Service Manual Issue 08 45

 I/O Tab – LINKS
I/O Tab – VOLTAGES
Press the Links key to display the following screen.
Press the VOLTAGES tab to display the following
screen.

Shown here are the hardware links and what their

status is.
• In this screen it’s possible to view all the
important voltages within the coverslipper. For the normal links ’0’=link present, ’1’=link not
• The right most column indicates the current present.
voltage seen, with one exception. The ’hard links’ are fixed resistors on the boards.
• The last value is the current temperature within
These are arranged in four columns as follows:
the electronics housing.

Note Column 1
When in power fail mode, Batt2 voltage will be both Identity on Location Comments
Batt1 + Batt2 values added together and shows the Screen
voltage available to the coverslipper when no mains
is present. MB Main Board, Link 1 Accesses via
FPGA

MB Main Board, Link 2 Accesses via

FPGA

MB Main Board, Link 3 Accesses via

FPGA

MB Main Board, Link 4 Accesses via

FPGA

MB Main Board, Link 5 Accesses via

FPGA

MB Main Board, Link 6 Accesses via

FPGA

MB Main Board, Hard Accesses via

Link 7 FPGA

MB Main Board, Hard Accesses via

Link 8 FPGA

ClearVue Service Manual Issue 08 46

Column 2 Column 4

Identity on Location Comments Identity on Location Comments

Screen Screen

Main Board, Accessed via Camera Board, Accessed via

MBhl0 CBlk1
Hard Link 0 I2C bus Link 1 FPGA

Main Board, Accessed via Camera Board, Accessed via

MBhl1 CBlk2
HardLink 1 I2C bus Link 2 FPGA

Main Board, Accessed via Camera Board, Accessed via

MBhl2 CBlk3
HardLink 2 I2C bus Link 3 FPGA

Main Board, Accessed via Camera Board, Accessed via

MBhl3 CBlk4
HardLink 3 I2C bus Link 4 FPGA

Main Board, Accessed via Camera Board, Accessed via

MBhl4 CBlk5
HardLink 4 I2C bus Link 5 FPGA

Display Board, Accessed via N/A Engineering Use Camera Type

DB1
Hard Link 1 touch panel
N/A Engineering Use Camera Ready
Display Board, Accessed via
DB2 Engineering Use Camera Digital
Hard Link 1 touch panel N/A
Mode
N/A Not Used
Note
Column 3 Camera Link data only valid from FPGA V1.04.

Identity on Location Comments

Screen

Battery Board, Accessed via

BBlk2
Link 2 I2C bus

Battery Board, Accessed via

BBlk3
Link 3 I2C bus

Battery Board, Accessed via

BBlk4
Link 4 I2C bus

Battery Board, Accessed via

BBhl4
Hard Link 4 I2C bus

Battery Board, Accessed via

BBhl3
Hard Link 3 I2C bus

Battery Board, Accessed via

BBhl2
Hard Link 2 I2C bus

N/A Not Used

N/A Not Used

ClearVue Service Manual Issue 08 47

MOTOR Tab Malfunction
Pressing the Motor tab will display the following This will be shown when a major system malfunction
screen. occurs.

Press the TAKE CONTROL button to access the

following page.

Pressing the TAKE CONTROL button

will immediately stop automatic Note
operation of ClearVue. Therefore it
Taking control of a coverslipper will force any
should never be pressed during
baskets loaded or processing to stop any further
normal operation and basket
action. The coverslipper will need to be initialized
processing
(when leaving production services via the HOME
In this screen, individual control over each motor is tab, if the status is UNKNOWN then a full initialise
possible. will start automatically).
The STATUS line indicates the current coverslipper • In this screen it is possible to take control of the
status and can be one of the following. current motor (displayed at the top of the page).

Unknown • For the example shown it’s the LOAD motor.

• To change to a different motor, press the left and
If the coverslipper is yet to initialise or the TAKE
right arrow keys at the top of the page until the
CONTROL key has been used previously, the status
desired motor is selected.
will show UNKNOWN.
The following motors have control:
Idle
LOAD - Load rail motor
This will be shown on a fully initialised machine with
no baskets loaded. LIFT - Lift motor

Processing PREP-R - Coverslip transfer head

This will be shown when baskets are being BASK OPEN - Basket slider open
coverslipped. EJECT - Basket eject motor
Initialising SLIP DISP - Coverslip dispense motor
This will be shown when the coverslipper is GRIPPERS - Slide gripping motor
initialising.
M_PUMP - Mountant pump motor
Mountant
N_POT - Cleaning station motor
This will be shown when the user is in the mountant
• The box below this indicates the motors' current
menu pages.
Quadrature reading and expected position. In
most cases the position should match the quad.
A variation between these two values will
indicate a stalling motor or the axis has reached

ClearVue Service Manual Issue 08 48

 the end of its current travel. The quadrature value Basket This could collide with a basket on
is physically linked to the motor movement and slider open the lift block.
if the motor is not able to turn, the quad value will
remain mostly constant. Basket eject The eject bracket can clash with
• The SET key will set both the current quad and motor the support arm, the transfer head
position to 10,000. Press the STOP key to stop and the vertical lift block.
the current motor move.
Coverslip The coverslip dispense, support
• The four arrow keys below are to perform the dispense arm and dispense head needle
motor movements. As a rule, the arrow points in motor can clash with the transfer head,
the direction the motor assembly will travel. So the grippers, the eject bracket and
for example the load rail will move towards the the cleaning station pot (always
lift if the Right arrow key is pressed. Notice the move the cleaning station pot to
two arrow keys at the top are BOLD compared the bottom position before moving
to the lower arrow keys. The bold arrow keys the coverslip dispense motor).
perform small movements of 50 steps and the
lower keys produce movements of 800 steps. Slide The grippers can clash with a
• Also shown on this page are any sensors on the gripping basket on the lift (if loaded), the
motor transfer head and the dispense
motor axis. So the load page will show the
head.
HOME opto. A '1’ indicates the load opto is
being activated. Mountant Excess pressure can be
• Press the Release control button to return to the pump generated in the syringe if the
previous screen. motor dispense needle is blocked. Take
Note care, excessive quantities of
mountant may be dispensed into
Clashes between mechanisms can occur when the cleaning station pot or
moving motors from these screens. Take care when elsewhere in the machine.
moving any motors in this way as damage can
occur and can lead to errors when initialising. Cleaning Clashes can occur between the
station cleaning station pot and the
Load rail The load mechanism can clash motor dispense head.
motor with the lift block.

Lift motor Clashes can occur between the

vertical lift and the load rail, the
eject bracket, the grippers (if a
basket is loaded) and the basket
open mechanism (if a basket is
loaded).

Coverslip The transfer head can clash with

transfer the coverslip dispense, the
head support arm, the grippers and the
eject bracket. When rotated
clockwise the head position pin
(flag) can be damaged by hitting
the lower crank arm.

ClearVue Service Manual Issue 08 49

ENG Tab
Pressing the ENG Tab will display the Engineering
screens.

Use the arrow keys to scroll between screens.

Note
Some of the keys on these pages may change
depending on the latest version of the software.
• ENG Tab - Page 1/7
• ENG Tab - Page 2/7
• ENG Tab - Page 3/7
• ENG Tab - Page 4/7
• ENG Tab - Page 5/7
• ENG Tab - Page 6/7
• ENG Tab - Page 7/7

ClearVue Service Manual Issue 08 50

ENG Tab - Page 1/7 • "Prep" "0" (refer to the Eng Tab – Page 2/7
section)
• "5minmode" (refer to the Eng Tab – Page 6/7
section)
• Follow instructions on screen
• Load the basket of dry slides
• Ignore the first two and last slide in each basket
• Use the next key to move to the third slide in the
ProdTst1 basket
Production Test 1 - The Z casting • The grippers will move the slide out of the basket
and pause to capture an image from the camera.
This is a factory test. Do not run this test unless
specifically requested to do so by the factory or • After pressing next, the slide will pause before
unless directed to do so from within this manual. being put back in the basket. This is currently not
required, so press next to continue
If this menu is entered the load rail will need
• The image displayed on screen shows the
initializing as soon as the menu is exited. Baskets
gripper and the slide.
will not load if it is not initialized.
• There should be 2 to 3 pixels between the
ProdTst2 underside of the top part of the gripper and the
Production Test 2 - Back Interface Board slide top, as shown below:

This is a factory test. Do not run this test unless

specifically requested to do so by the factory or
unless directed to do so from within this manual.
ProdTst3

Production Test 3 - Horizontal Plate

This is a factory test. Do not run this test unless
specifically requested to do so by the factory or
unless directed to do so from within this manual.

ProdTst4 • To increase the number of pixels between the

slide and gripper, increase the number on the
Production Test 4 - Vertical Plate screen.
This is a factory test. Do not run this test unless
Note
specifically requested to do so by the factory or
unless directed to do so from within this manual. This will not alter the picture on screen, but will
change the relationship for the next slide selected.
ProdTst5
• If the number of pixels between the slide and
Production Test 5 - Parameter 92 Adjustment grippers is correct use the next key to confirm a
This is a factory test. Do not run this test unless minimum of 5 slides meet the requirement
specifically requested to do so by the factory or • Press accept and wait for the basket to
unless directed to do so from within this manual. complete.
To Run ProdTst5: • Press exit to return to production services.

• Prepare a basket of 20 dry slides and then select • Put "Prep" back to "1"
/ do the following:

ClearVue Service Manual Issue 08 51

Note Note
If using Leica or V24 baskets, load the baskets fully 1 increment = 0.04766 mm
but ignore the first 5 and the last 5 slides.
• This will not alter the current coverslip position,
Additional baskets of slides may be added if but will change the relationship for the next
necessary. coverslip dispensed.
Screen corruption may occur if keys are pressed as • Press next
the camera image is being drawn. • When both alignments have been set correctly
and accepted the test will continue to the end of
Switching off and restarting the instrument will clear
the basket to allow additional verification
this error.
• Press exit to return to production services.
ProdTst6
Note
Production Test 6 - Coverslip and slide alignment.
Additional baskets of slides may be added if
This is a factory test. Do not run this test unless
necessary.
specifically requested to do so by the factory or
unless directed to do so from within this manual. ProdTst7

To Run ProdTst6: Production Test 7 - Battery Test

• Prepare a basket of 20 dry slides, ensure a good This is a factory test. Do not run this test unless
hopper with adequate quantity and quality of specifically requested to do so by the factory or
coverslip is in place and then select / do the unless directed to do so from within this manual.
following:
Do not enter this menu unless you
• Load the basket of dry slides have been specifically instructed to do
• A coverslip will be dispensed and will pause by so. If you do enter by mistake with the
the coverslip transfer head wrong software version the machine
• The rear edge of the coverslip should be aligned will need to be switched off by the
with the rear edge of the coverslip transfer head battery which will lose any changes
made to setting and may corrupt the
• If the coverslip is correctly aligned press accept
machines files
• If it is not aligned use the up or down arrows to
move the next coverslip in the direction required Results

Note First asks for the serial number of the ClearVue then
copies the results to a floppy disk.
1 increment = 0.181 mm
• This will not alter the current coverslip position,
but will change the relationship for the next
coverslip dispensed.
• Press next
• The coverslip will be transferred to the slide and
pause
• The coverslip should be aligned centrally to the
slide (left to right)
• If the coverslip is correctly aligned press accept
• If it is not aligned use the left or right arrows to
move the next coverslip in the direction required

ClearVue Service Manual Issue 08 52

ENG Tab - Page 2/7

The following buttons are available:

Pnumat 1 SET VAC - Pulls a vacuum on the transfer head and
Pneumatics Test 1 - Bottle Pneumatics Test shows the current reading in PSI. Adjust the vacuum
regulator to the required value.
DECAY - Releases the vacuum on the transfer head
via the restrictor and times the decay.

EXIT - Return to previous menu.

Refer to the Vacuum System Test section for details.

Pnumat 3

Pneumatics Test 3 - Coverslip Carriage Vacuum

The following buttons are available:

MAX PRESS - Pressurizes the mountant bottle, up

to 10psi, and shows the maximum pressure
reached. This will be a PASS if 10psi is achieved
within 2 minutes, otherwise it will show a FAIL.
MIN PRESS - Pulls a vacuum on the mountant
bottle, down to -6psi, and records the lowest
vacuum reached. This will be a PASS if -6psi is
achieved within 2 minutes, otherwise it will show a Accessing this page will give information about the
FAIL. vacuum that is available on the coverslip carriage
during a coverslip dispense.
LEAK TEST - Pressurizes the mountant bottle, up
to 10psi, and holds the pressure to detect air leaks Press the RUN key to dispense a coverslip and
in bottles / fittings etc. This will be a PASS if the show the graph.
pressure is still greater than 7psi after 2 minutes,
Multiple runs will show multiple graphs overlaid.
otherwise it will show a FAIL.
Press CLR to clear the current graph or EXIT to
EXIT - Return to previous menu.
return to the previous menu.
Pnumat 2
The vac figure shown is the vacuum at the end.
Pneumatics Test 2 - Prep Pneumatic Tests
Remove the coverslip and ensure the vac level
drops to ambient level in less than 1 second.
Refer to the Coverslip Dispense System Test
section for details.

ClearVue Service Manual Issue 08 53

PREP Display values:

Prep key QUAD A/B/C/D - Latched quadrature positions of

slip dispense when the optos detected the slip on
• Toggles between '0' and '1'. The value shown
the carriage during a dispense. Note that on
on the key is its current state.
dispense of a good slip all values may appear the
• This switches the mountant dispense on and off. same in testslip. On a bad dispense, actual latched
• When set to '0', there is no coverslip dispense or values may be visible.
mountant dispensed. The slide will be taken out
Slip dispense direction:
of the basket and returned.
• When set to '1' it operates normally.
• This can only toggle when the machine is idle.
• This is reset to '1' during a full initialise.
• This function can be used for testing gripper
alignment, basket handling, slide handling etc,
without using mountant and coverslips.
Testslip

Test coverslip key.

Shows a screen for testing coverslip dispense. OPTIC 1 and OPTIC 2 - Current value being read
from the slip dispense optos (in realtime). Lower
readings indicate a slip (typically 200-600). Each
optic floats around the value 1300 to 1400 with no
slip.
LOGIC 1 and LOGIC 2 - Logic values of slip
detected during dispense, 0 = detected slip 1= no
slip.

Double - Double detect. 1 = not double, 0 = double.

The testslip page has two main functions. Latch -not used.

1. To check the coverslip dispense mechanism is QC Pass - 1 = good slip. 0 = slip properties failed
performing correctly. criteria.
2. To check the optic 1 and 2 coverslip sensors Q and P -Current slip dispense motor quad and
are working correctly. position values.
Buttons and actions:
Beads
SLIP OUT - Dispenses a coverslip from the hopper.
Beads key.
RETURN - Returns the carriage back to the
• Toggles between '0' and '1'. The value shown
coverslip pickup position.
on the key is its current state.
INIT - Performs an initialization on the coverslip • When set to '0', it operates normally.
dispense carriage.
• When set to '1' a bead of mountant is dispensed
HALF OUT - Dispenses a coverslip half way out so onto the slide but no coverslip is used.
that the glass is under the optos for opto calibration • This can only toggle when the machine is idle.
and adjustment.
• This is reset to '0' during a full initialise.
EXIT - Exit from the current screen.

ClearVue Service Manual Issue 08 54

• This function can be used to check the shape of Note
a bead of mountant without a coverslip being
These parameters are not saved until the machine
applied.
is shut down normally.
Dunks
profile
This is a factory test. Do not run this test unless
• Shows the current profile version, profile creation
specifically requested to do so by the factory or
date and checksums.
unless directed to do so from within this manual.
• The checksums should match.
• Toggles between '0' and '1'. The value shown
• The import key can be used to load a new profile
on the key is its current state.
from a floppy disk.
• When set to '0', it operates normally.
• When set to '1' the cleaning station is used to Note
clean the mountant dispense needle after every After importing a new profile a full initialise should be
slide. carried out before using the machine.
• This is reset to '0' during a full initialise. ProdTst8
EMC RUN
Production Test 8 - Doors / Fan / Real Decay times.
EMC test key
• This is a factory test. Do not run this test unless
• This activates a special continuous running specifically requested to do so by the factory or
programme used for factory test purposes only. unless directed to do so from within this manual.
This routine should not be used. Clashes may reset 7
occur between the dispense needle tip and the
gripper arms. This could cause damage to the • Full reset of every machine parameter, including
parts involved. the user settings.
• Also initiates a full initialise.

Note
ENG Tab - Page 3/7
ClearVue will not function correctly until Production
Tests 5 and 6, and Autoslip have been carried out
correctly.
exit2dos

• Switches off the ClearVue and drops to a DOS

prompt (regardless of whether processing or
not).
dump log • This function can be used to save changes to
• Copies the engineers log to floppy disk. parameter files when the ClearVue will not power
down correctly. Everything is saved as is for a
clearlog
normal shut down.
• Clears the engineer’s log. • This function is only useful to access the files on
params ->Mae.1992 the flash drive with a monitor and keyboard
attached.
• Saves parameter file to floppy disc.
• Also saves a '.csv' file of the parameters to the
floppy disk.
->params

• Imports parameter file from floppy disc.

ClearVue Service Manual Issue 08 55

ENG Tab - Page 4/7 i-prep

Initializes the transfer head motor.

Notes
The coverslip transfer head can clash with the slide
held in the grippers, the slip dispense carriage and
the dispense head. Ensure all assemblies are clear
before pressing 'init'.
Initializing the coverslip transfer head will also cause
Note the slip dispense to operate. Refer to 'i-slip' notes
before proceeding.
Do not carry out any initializations while ClearVue is
processing baskets. i-eject
fullinit Initializes the basket eject motor.
Performs a full initialize of the ClearVue Note
i-input The eject can clash with a basket held on the lift
block and the coverslip transfer head; ensure all
Initializes the load rail motor
assemblies are clear before pressing 'init'.
i-open

Initializes the basket open motor

i-lift

Initializes the basket lift motor

Notes
Do not perform an initialization while there is a
basket on the lift block.
The lift can clash with the load rail and eject bracket;
ensure all assemblies are clear before pressing 'init'.

i-npot

Initializes the cleaning station motor.

Note
The Dispense head cleaning station can clash with
the dispense head; ensure all assemblies are clear
before pressing 'init'.
i-slip

Initializes the coverslip dispense motor.

Note
The slip dispense and mountant dispense head can
clash with the dispense head cleaning station, slide
grippers and coverslip transfer head. Ensure all
assemblies are clear before pressing 'init'.

ClearVue Service Manual Issue 08 56

ENG Tab - Page 5/7

Notice the gripper is visible in the shot.

Note The crosshairs indicate the detected corner of the
Do not carry out any initializations while ClearVue is gripper at the last initialise.
processing baskets. Note
i-grip This is a negative image.
Initializes the gripper motor. This screen shows information regarding the
Note camera image analysis, including the last basket top
positions, the x and y positions of the gripper jaw,
Grippers can clash with a basket on the lift block,
etc.
the dispense head and coverslip transfer head.
Ensure all assemblies are clear before pressing 'init'.

i_pump

Initializes the mountant pump.

i_camera

Initializes the camera and finds the gripper position.

Note
Notes
This may give an incorrect gripper position if the
The 'cam focus clean’ value is an indication of any
grippers have been moved since last gripper
blurring of the image. A value of 5 or more may
initialization.
indicate that the lens needs cleaning.
TFT BLIT
'Cam status bits' are: Link 5, Camera type, Camera
This causes every image from the camera to be Ready, Digital mode. These are only valid after the
displayed on the screen. camera has been initialised and are for Engineering
Pressing the key again switches this function off. use only.

This is for factory use only. qds/pos

Snapshot This shows the quadrature feedback and drive

positions as well as the current speeds of the
Activates camera and shows current camera view various motors.
Example of screenshot from pressing the snapshot
key.

ClearVue Service Manual Issue 08 57

states • Purge

Shows every motor control state and status. • Volume

• De-gas
The information on this screen may be requested by
the factory during problem diagnosis. • Access
This allows use of all of the mountant systems
functions from within production services. A flush
can be carried out with the covers off the machine
to check for air in the system.
AutoSlip

The AutoSlip routine sets the optical thresholds for

the coverslip detection (including double coverslip
• The first column indicates the software state (5- detections). The thresholds are stored in the
digit number). When ClearVue is initialised, all of parameter file.
these should be '00100' except for 'Cam' which Before running this test ensure that a good coverslip
should be '00220'. hopper is installed and that coverslips can be
• The second column indicates the status (2-digit dispensed.
number).
Note
• For the mountant pump, 'dr' is the number of
dispenses remaining in the syringe based on the
High ambient lighting will invalidate the test. Where
current settings.
possible run with the covers on or ensure no direct
light is in the area.
• 'Baskets' is the number of baskets detected on
the load rail including any on the lift. The new values are only used when the next initialise
• 'lift loaded' indicates whether a basket is of the coverslip dispense occurs.
currently on the lift. The parameter file is saved when the machine is
• 'ST' is the overall machine status. powered off. If the machine cannot power down
correctly these values may be lost.

ENG Tab - Page 6/7

Beadopt

When 'beads' is set to '1' (ENG Tab, page 2) this

ms menu can be used to test the bead size and position.
Mountant System Menu. 'SIZE' switches the coverslip size between 40, 50
Note and 55.

The machine will initialise when this menu is exited 'OFFSET' switches the position between end and
to the home screen. middle.

This menu has keys for:

• Flush

ClearVue Service Manual Issue 08 58

 1. Double coverslip detected
2. No coverslip dispensed
3. Chipped corner detected
4. Half dispense (coverslip stuck under the opto's)
5. Length error
6. Coverslip in wrong position on carriage (too far
over hard stop or
jawalign
7. 'coverslip out adjust' set incorrectly)
This can be used to check the alignment of the 8. Skew detected
gripper jaws to the basket. This is for factory use
9. Good coverslip dispenses.
only.

5minmode

This function temporarily disables all the safety There is a risk of static shock when
interlocks on ClearVue and should only be used by performing this test - Ensure the
trained personnel. ClearVue should never be left debris tray is suitably earthed before
unattended whilst in '5Minmode'. commencing test.

slip QC dump scr

This can be used to check the quality of coverslip For factory development use only - do not use.
dispense.
Used to capture screen images.
CONTINUOUS operation can be switched on and
Activation of this feature may cause changes to
off (single dispense).
settings in the ClearVue. If this is accidentally run,
START initiates a single or continuous coverslip check all settings.
dispense.
ClearPST
INIT initialises the coverslip dispense system. This
Clears the production service test files generated in
also loads the coverslip opto parameters if they
ProdTst1, etc.
have been changed since the last initialise (such as
when using AutoSlip).

RETRY, when OFF the coverslip dispense will halt

as soon as an error is detected. When RETRY is ON
the coverslip dispense will attempt a number of
retrys (as set in the parameters).

CLEARCOUNTS clears the counters.

The box at the bottom of the screen is the

description of the last error detected.

The error codes on the right of the screen are:

ClearVue Service Manual Issue 08 59

ENG Tab - Page 7/7 Note
Always re-initialise the machine after changing the
hard stop before repeating this test.
X-spot
This screen allows the touch screen response to be
tested.

• A blank screen will appear.

LifeTest
• Touch the screen anywhere 10 times and a
This is for factory use and should only be used if cross will appear at that location.
directed to by the factory or this manual.
• On the 11th touch the screen will exit and the
Prep Rotate previous menu displays.
• This test can be used to check the coverslip UIFReset
transfer head hard stop setting. This option returns all user settings to their default
• Check the machine has initialised correctly and values (for example: coverslip position, screen
fully. angle, mountant dispense volume).
• Remove the covers from the machine, including Bmp Dump
the right hand side cover.
This is for factory use only.
• Put a magnet on the debris door only, hold in
place with tape as required (You can use the I/O
tab – INPUTS. Refer to the I/O Tab – Inputs
section to check the magnet is in the correct
place).
• Push the grippers into the prep area and place a
slide in the jaws.
• Remove the suction cup and use a bulldog clip
or crocodile clips to hold the sprung pads up out
of the way.
• Press 'Start'.
• The prep head will move over to the slide and
stop in the final position of prep (if it continues
on, the magnet on the prep door is not in the
correct place).
• The prep head should just touch the slide
without bending it. If it stops above it should be
less than 0.1mm above the slide.
• Repeat the test (press start again) to confirm that
it is not bending the slide.
• If the head bends the slide or stops more than
0.1mm above the slide, then reset the Coverslip
transfer head hard stop, refer to the Checking
and Adjusting the Coverslip Transfer Head Hard
Stop section.

ClearVue Service Manual Issue 08 60

Chapter 4 – Functional Tests
Earth Continuity and Insulation Tests

Individual Motor Tests

Build Subassembly Tests

Instrument Verification Tests

ClearVue Service Manual Issue 08 61

 Lift Block Motor Test
Earth Continuity and Insulation
• From the TAKE CONTROL screen scroll to the
Resistance Tests LIFT motor screen.
Check the following: • Press 'Set' and check that the QUAD and
POSITION values are set to 10000 and are not
• Earth continuity measures less than 1Ω
changing.
• Insulation resistance measures greater than
• Set the power to 64 (maximum).
999M Ω.
• Press one of the 'down arrow' keys - check that
the lift mechanism moves downwards and that
the QUAD and POSITION values increase.
Individual Motor Tests
• Press one of the 'up arrow' keys - check that the
The following motor tests use the 'TAKE CONTROL' lift mechanism moves upwards and that the
button located in the 'MOTOR' QUAD and POSITION values decrease.
Tab in Production Services (Refer to the MOTOR • Towards the top of the travel the basket slider
Tab section). closing mechanism is engaged. This can collide
with the basket eject mechanism. This should be
These tests should be carried out without any
avoided as damage can occur.
baskets loaded onto the instrument.
Take particular care that different mechanisms do Coverslip Transfer Head Motor Test
not clash and cause damage (Refer to the MOTOR
• From the TAKE CONTROL screen scroll to the
Tab section).
PREP-R motor screen.
• Input Rail Motor Test • Press 'Set' and check that the QUAD and
• Lift Block Motor Test POSITION values are set to 10000 and are not
• Coverslip Transfer Head Motor Test changing.
• Basket Open Motor Test • Set the power to 64 (maximum).

• Basket Eject Motor Test • Press one of the 'left arrow' keys - check that the
transfer head moves to the left (anti-clockwise)
• Coverslip Dispense Motor Test
and that the QUAD and POSITION values
• Gripper Motor Test
increase.
• Mountant Pump Motor Test • Press one of the 'right arrow' keys - check that
• Dispense Head Cleaning Station Motor Test the transfer head moves to the right (clockwise)
and that the QUAD and POSITION values
Input Rail Motor Test decrease.
• From the TAKE CONTROL screen scroll to the • Take care not to stall the motor by hitting the
LOAD motor screen. head position pin on the lower crank arm when
• Press 'Set' and check that the QUAD and rotating to the right (clockwise). The pin can be
POSITION values are set to 10000 and are not damaged.
changing. • When rotating left (anti-clockwise) ensure that
• Set the power to 64 (maximum). the mechanism does not hit the mountant
dispense arm or the grippers.
• Press one of the 'right arrow' keys - check that
the load rail mechanism moves to the right and
that the QUAD and POSITION values increase.
• Press one of the 'left arrow' keys - check that the
load rail mechanism moves to the left and that
the QUAD and POSITION values decrease.

ClearVue Service Manual Issue 08 62

 • Scroll back to the SLIP DISP motor screen.
Basket Open Motor Test
• Press 'Set' and check that the QUAD and
• From the TAKE CONTROL screen scroll to the
POSITION values are set to 10000 and are not
BASK OPEN motor screen.
changing.
• Press 'Set' and check that the QUAD and
• Set the power to 64 (maximum).
POSITION values are set to 10000 and are not
• Press one of the 'up arrow' keys - check that the
changing.
coverslip dispense mechanism moves towards
• Set the power to 64 (maximum). the rear of the machine and that the QUAD and
• Press one of the 'down arrow' keys - check that POSITION values increase.
the basket open mechanism moves towards the
• Press one of the 'down arrow' keys - check that
front of the machine and that the QUAD and the coverslip dispense mechanism moves
POSITION values increase. towards the front of the machine and that the
• Press one of the 'up arrow' keys - check that the QUAD and POSITION values decrease.
lift mechanism moves towards the rear of the • The coverslip dispense mechanism, support arm
machine and that the QUAD and POSITION
and dispense needle can clash with the prep
values decrease.
head, the basket eject mechanism, the gripper
arms and the cleaning station pot and cause
Basket Eject Motor Test
damage.
• From the TAKE CONTROL screen scroll to the • Ensure that these are in appropriate positions
EJECT motor screen. before moving this motor.
• Press 'Set' and check that the QUAD and • After the test has been carried out, the cleaning
POSITION values are set to 10000 and are not station (filled with xylene) should be moved back
changing. into position to prevent the mountant in the
• Set the power to 64 (maximum). dispense needle from drying out. This is most
• Press one of the 'down arrow' keys - check that easily carried out by going to the production
the basket eject mechanism moves to the left services ENG tab, page 4 (Refer to the ENG Tab
and that the QUAD and POSITION values – Page 4/7 section) and pressing the 'i-slip' key
increase. to initialise the coverslip dispense system
• Press one of the 'right arrow' keys - check that (including the cleaning station).
the basket eject mechanism moves to the right
Gripper Motor Test
and that the QUAD and POSITION values
decrease. • From the TAKE CONTROL screen scroll to the
• Care should be taken when moving the basket GRIPPERS motor screen.
eject motor. Damage may occur if the basket • Press 'Set' and check that the QUAD and
eject mechanism collides with the slider closing POSITION values are set to 10000 and are not
mechanism (when the lift block is towards the changing.
top of its travel), the prep head or the dispense • Set the power to 64 (maximum).
arm (particularly the mountant pipe).
• Press one of the 'right arrow' keys - check that
the grippers move to the right and that the QUAD
Coverslip Dispense Motor Test
and POSITION values increase.
• From the TAKE CONTROL screen scroll to the • Press one of the 'left arrow' keys - check that the
N_POT motor screen. grippers move to the left and that the QUAD and
• Press one of the 'down arrow' keys to move the POSITION values decrease.
cleaning station mechanism until it is clear of the • Take care that the gripper arms do not collide
mountant dispense needle. Failure to do so may with the prep head or the mountant dispense
result in damage to the needle. needle. Damage may occur.

ClearVue Service Manual Issue 08 63

Mountant Pump Motor Test Dispense Head Cleaning Station Motor
• From the TAKE CONTROL screen scroll to the
Test
M_PUMP motor screen. • From the TAKE CONTROL screen scroll to the
• Press 'Set' and check that the QUAD and N_POT motor screen.
POSITION values are set to 10000 and are not • Press 'Set' and check that the QUAD and
changing. POSITION values are set to 10000 and are not
• Set the power to 64 (maximum). changing.

• Press one of the 'down arrow' keys - check that • This motor runs at fixed power - changing the
mountant pump mechanism moves downwards power setting has no effect.
and that the QUAD and POSITION values • Press one of the 'up arrow' keys - check that
increase. cleaning station mechanism moves upwards
• Press one of the 'up arrow' keys - check that the and that the QUAD and POSITION values
mountant pump mechanism moves upwards increase.
and that the QUAD and POSITION values • Press one of the 'down arrow' keys - check that
decrease. the cleaning station mechanism moves
• The movement can only be seen if the covers are downwards and that the QUAD and POSITION
removed. values decrease.

• If the covers are fitted, the same test can be • When moving the cleaning station in an upwards
carried out to check that the QUAD and direction, ensure that it will not hit the mountant
POSITION counts change correctly, however to dispense needle - damage may occur.
verify that mountant is being dispensed, using • After the test has been carried out, the cleaning
the I/O tab, OUTPUTS (Refer to the I/O Tab – station (filled with xylene) should be moved back
Outputs section) set the 'Mountant pump sol' to into position to prevent the mountant in the
'1', next lower the cleaning station then move the dispense needle from drying out. This is most
coverslip dispense mechanism to place the easily carried out by going to the production
mountant dispense needle above the purge tray. services, (Refer to the ENG Tab – Page 4/7
Now, at the M_PUMP motor screen use one of section) and pressing the 'i-slip' key to initialise
the 'down arrow' keys and observe the the coverslip dispense system (including the
mountant being dispensed out of the needle. cleaning station).
• To refill the syringe set the 'Mountant pump sol'
to '0' and drive the dispense mechanism
upwards.
• Once finished, initialise the coverslip dispense
mechanism using 'i-slip' (Refer to the ENG Tab
– Page 4/7 section), to ensure that the needle is
left in the cleaning station to prevent the
mountant from drying out.

ClearVue Service Manual Issue 08 64

Build Subassembly Tests
• Electronics Sub-Assembly Tests
• Inspecting the Input Rail
• Inspecting the Vertical Lift and Lift Block
• Inspecting the Basket Open and Lower Slide
Retention
• Inspecting the Slide Guide Assembly
• Inspecting the Slide Grippers
• Inspecting the Coverslip Dispense
• Inspecting the Mountant Dispense Head and
Needle
• Inspecting the Coverslip Transfer Head
• Inspecting the Coverslip Transfer Drive
• Inspecting the Output Pusher and Upper Slide
Retention
• Inspecting the Output Rail
• Inspecting the Mountant Pump Actuator and
Syringe
• Inspecting the Cleaning Station Assembly
• Inspecting the Covers and Filter
• Inspecting the Mountant Bottle and Lines
• Inspecting the Pneumatic Circuit

ClearVue Service Manual Issue 08 65

Electronics Sub-Assembly Tests • Check that when the filter is removed, the filter
fan stops (0Hz).
To test the electronics subassembly the following
sequence should be used. • With the filter in place and the unload door
closed, the filter fan should show greater than
Stage 1 - Initialise 50Hz.

During this stage the speaker connection is • When the unload door is opened the speed
checked, all of the motors and opto switches are should increase to greater than 80Hz.
used and the camera illumination is also checked. • Go to the I/O Tab, I2C screen (Refer to the I/O
Tab – I2C section).
• With the prep door open, switch the machine on.
• Check that PFD shows '0', PWR_WDT shows
• The speaker should bleep and the internal
'0', pw state shows '0100' and WGO shows '0'.
illumination should be off.
• Check that B-SW shows '1' when the battery
• Close the prep door.
switch is on and that this is '0' when off.
• The speaker should stop bleeping and the
• Make sure that the battery switch is on.
internal illumination should come on.
• Switch the mains off.
• Allow initialise to finish.
• Check that PFD shows '1', PWR_WDT shows
• Check, on the main menu, that the 'Status' is
'0', pw state shows '0110' and WGO shows '1'.
'OK'.
Note
Stage 2 - Production Services
These signals must be checked immediately after
During this stage the doors and filter switch are switching the mains supply off.
checked, the fans are checked, the battery backup
The PFD and WGO signals are only valid for
system is checked, the voltage regulators are
approximately 5 seconds after which their states are
checked, the links on the PCB's are checked, the
indeterminate and either of them may show '1' or
slip dispense opto's are checked and the camera
'0'.
operation is checked.
• Switch the mains back on, check that the signals
• Go to the production services screens (Refer to
return to the correct state. It may take a few
the I/O Tab section).
seconds for 'pw state' to change from '0110'
• Go to the I/O Tab, INPUTS screen (Refer to the back to '0100'.
I/O Tab – Inputs section).
Signal Mains On Mains Off
• Scroll through to the screen with the doors.
• Check each door in turn. The screen should PFD 0 1*
show '0' for door open, '1' for door closed.
PWR_WDT 0 0
Note
pw state 0100 0110
When the load door is closed, the load rail system
should check for a basket. WGO 0 1*
• Check that when the filter is in place the screen
• Go to the I/O Tab, VOLTAGES screen (Refer to
shows '0'.
the I/O Tab – Voltages section).
• Check that when the filter is removed the screen
• Check that the voltages (and temperature) are in
shows '1'.
the following ranges:
• Scroll through to the screen with the fans.
• Check that the electronics fan feedback signal is
greater than 80Hz.

ClearVue Service Manual Issue 08 66

 Name Min. Displayed Voltage Max. Displayed Voltage Function

5V 4.50V 5.5V 5v Logic

3.3V 4.97V 3.63V 3.3V Logic

1.2V 1.08V 1.32V 12V FPGA Core

15V 13.50V 16.50V 15V Supply

12V 10.80V 13.20V 12V Supply

24V F 21.6V 26.4V 24V Fused

24V SW 21.6V 26.4V 24V Switched

24V PSU 21.6V 26.4V 24V from PSU

Batt 1 10.0V 15.0V Battery 1 Voltage

Batt 2 10.0V 15.0V Battery 2 Voltage

15V Supply (on Battery

15V Mon 13.50V 16.50V
Board)

Temp Ambient Ambient + 15 Temperature Sensor

Note
The battery voltages are dependant on the charge state.
• Batt2 voltage will show Batt1+Batt2 (nominal 24V) during mains power fail.
• With the battery switch in the on position, switch the mains off. Check that Batt2 changes to at least 20V.
• Switch the mains back on and check that Batt2 returns to a normal reading.
• Go to the I/O Tab, LINKS screen (Refer to the I/O Tab – Links section).
• Check that the links are as shown:

MB 0 MBhl0 0 BBlk2 0 CBlk1 0

MB 0 MBhl1 0 BBlk3 0 CBlk2 0

MB 0 MBhl2 0 BBlk4 0 CBlk3 0

MB 0 MBhl3 0 BBhl4 1 CBlk4 0

MB 0 MBhl4 1 BBhl3 1 CBlk5 0

MB 0 DB1 0 BBhl2 0* N/A 0

MB 1 DB2 0 N/A 0 N/A 0

MB 1 N/A 0 N/A 0 N/A 0

ClearVue Service Manual Issue 08 67

Note Inspecting the Input Rail
For issue 1 battery boards, the battery board hard • Ensure the unit is powered down.
link 2 will be '1'. • Check for any mountant build up and clean if
• Go to the ENG Tab, Page 2/7 (Refer to the ENG required.
Tab – Page 2/7 section). • Check for any glass or basket debris and clean
• Select 'testslip'. if required.

• Press INIT. • Check both latches travel freely in their mounts.

• Insert a hopper of coverslips. • Check that ball spring plunger moves freely.
• With no coverslip under the sensors, check that • Check the pop out pin moves freely.
the 'Optic 1' and 'Optic 2' readings are between • Check the drive nut is screwed fully into the latch
01200 and 01500 and that 'Logic 1' and 'Logic carrier.
2' are both '1'. • Ensure neither latch is loose on the latch carrier.
• Press HALF OUT. Check that a coverslip is • Ensure the motor and leadscrew turn freely
under the sensors. Check that the 'Optic 1' and without tight spots for the full travel.
'Optic 2' readings are between 200 and 1000
• Ensure there is no radial play in the bearings at
and that 'Logic 1' and 'Logic 2' are both '0'.
either end of the leadscrew.
• Press RETURN. Check that the slip is cleared.
• Check the belt tension; refer to the Input Motor
• Press SLIP OUT. Check that a 'Good slip' is Assembly section.
indicated.
• Power on the ClearVue and test the motor
• Go to the ENG Tab, Page 5/7 (Refer to the ENG function, refer to the Input Rail Motor Test
Tab – Page 5/7 section). section.
• Select 'snapshot'. • Go to screen 1 on the inputs page of production
• Check that the image is square and that the services, turn the motor manually and ensure
gripper jaw is positioned in the right hand side of that the 'load home' opto changes state as the
the screen. latch carrier passes through it.

Disk Drive Check Inspecting the Vertical Lift and Lift Block
During this stage the connections to the disk drive • Ensure that the unit is powered down.
are checked. • Check for any mountant build up and clean if
• Insert a floppy disk into the disk drive. required.
• Write an engineer’s log to the disk. • Check for any glass or basket debris and clean
if required.
• Move the disk to a PC. Check the files on the
disk have been written correctly. • Check none of the pins are bent.
• Open the log and check for corrupt characters, • Check that the spring plunger moves freely.
etc. in the engineer’s log. • Ensure the motor and leadscrew turn freely
without tight spots for the full travel. With the
Performance Test motor disconnected from the front I/F board the
During this stage the operation of all of the solenoids motor should travel from top to bottom with less
(including the mountant dispense) are checked and than 0.1Nm or torque.
the pressure sensors are checked. • Ensure there is no radial play in the bearings at
either end of the leadscrew.
Run performance test 1 (Refer to the Performance
Test 1 section). • Check the end float in the leadscrew is greater
than 0.05mm and less than 0.1mm.

ClearVue Service Manual Issue 08 68

• Check the belt tension; refer to the Lift Block • Check for signs of wear on the 2 small slide
section. positioning surfaces; if any aluminium is visible
• Power on the ClearVue and test the motor through the black anodizing the slide guide
function, refer to the Lift Block Motor Test should be replaced.
section.
Inspecting the Slide Grippers
• Go to screen 1 on the inputs page of production
services, turn the motor manually and ensure • Ensure that the unit is powered down.
that the 'lift align o/p' opto changes state as the • Check for any mountant build up and clean if
flag on the lift block passes through it. required, paying special attention to the surfaces
in the V of both grippers.
Inspecting the Basket Open and Lower
• Check for any glass or basket debris and clean
Slide Retention if required, paying special attention to the
• Ensure the unit is powered down. surfaces in the V of both grippers.
• Check for any mountant build up and clean if • Check for any signs of damage.
required. • Check for signs of wear across the gripper jaws,
• Check for any glass or basket debris and clean wear will manifest as a witness line across the v
if required. in the jaws and will progress until a groove is
• Ensure that the slider pusher travel freely and worn into the jaws. While a light witness line is
returns under its own spring force. acceptable any form of groove is not and the
jaw(s) should be replaced.
• Ensure that both slider pusher and slide retainer
are straight and undamaged. • Check the gripper return plate travels freely and
returns under its own spring.
• Check the linear actuator rotates freely with no
tight spots along the full length of travel. • Rotate the motor by hand and ensure that it
rotates freely and without any tight spots.
• Ensure that there is no excessive play in the
linear rail. • Move both grippers from left to right and check
for any areas of excessive play in the linear rail or
• Power on the ClearVue and test the motor
carriage.
function, refer to the Basket Open Motor Test
section. • If there is anything to suggest the grippers may
not be aligned correctly check the alignment,
• Go to screen 1 on the inputs page of production
refer to the Checking and Adjusting Gripper to
services, Move the slider pusher manually and
Gripper Alignment section.
ensure that the 'basket Open Home' changes
state as the flag on the lift block passes through • Power on the ClearVue and test the motor
it. function, refer to the Gripper Motor Test section.
• Go to screen 1 on the inputs page of production
Inspecting the Slide Guide Assembly services. Move the grippers manually and ensure
• Ensure that the unit is powered down. that both the 'Grippers home' and 'Grippers out'
opto’s changes state as the flag on the grippers
• Check for any mountant build up and clean if
passes through them.
required.
• Check for any glass or basket debris and clean
if required.
• Check that the slide guide moves freely and
travels back under the spring force.
• Check the condition of the leaf spring, ensuring
it is not bent or broken.

ClearVue Service Manual Issue 08 69

Inspecting the Coverslip Dispense • Check Parameter 59 and 60 are set correctly by
running Autoslip; refer to the Checking and
With the machine turned off:
Setting Coverslip Dispense Optical Sensors
• Remove the coverslip dispense skirt and clean section.
the rubber section. Check for damage and • Carry out motor check; refer to the Coverslip
replace if required. Dispense Motor Test section.
• Check the coverslip dispense skirt is free moving
• Check coverslip dispense optical switch by
in its slot. initialising and checking the dispense head
• Check the height of the end stop, refer to the needle is central in the cleaning station.
Coverslip Dispense End Stop Height section.
• Carry out Performance Test 3, refer to
• Inspect end stop for signs of wear and damage. Performance test 3 section.
Bottom edge should be sharp.
• Check carriage for mountant contamination or Inspecting the Mountant Dispense Head
build-up of dirt, clean if necessary. and Needle
• Ensure that all three of the vacuum ports in the • Remove the mountant dispense needle.
coverslip dispense carriage are clear from • Check for any mountant build up on the end of
debris. the needle and clean if required.
• Clean glass dust out of the coverslip dispense • Check for any mountant build up on mating
carriage and banjo fitting. surface between the dispense needle and arm
• Check the coverslip dispense carriage hard stop and clean if required.
for signs of wear or damage. All corners and • Check that the dispense needle end is still
edges should be sharp. circular and has not been damaged.
• Inspect the coverslip dispense system and • Check the mountant line is not damaged and
surrounding area for debris clean as necessary. that the nipple connector is tight and secure.
• Check the vacuum pipes and glass filter for
blockages and leaks. Inspecting the Coverslip Transfer Head
• Check the pulley on the coverslip dispense • Remove the coverslip transfer head.
motor is secured to the motor shaft. • Check for any mountant build up, splitting or
• Inspect the coverslip dispense timing belt for fraying of the suction cup.
damage and signs of wear. • Check for any mountant build up and for full free
• Check the optical sensor wires have not been travel of the sprung pads, by gently pushing at
snagged or damaged by either the coverslip either end and the centre of the pads - both pads
dispense cover or ribbon cable cover. should move freely and smoothly.
• Check the belt tension; refer to the Coverslip
Dispense Motor Assembly section.
With the machine turned on:

• Check the optical sensors have been set

correctly; refer to the Checking and Setting
Coverslip Dispense Optical Sensors section.
• Check the optical sensors are not contaminated
with glass dust, clean the sensing faces of each
with a long bristle brush reset them, refer to the
Carrying Out a Bead Test section and run
Autoslip.

ClearVue Service Manual Issue 08 70

• Check that the pneumatic line is not damaged • Check the motor drive pulley is correctly
and has a clean cut end. clamped to the motor shaft.
• Check the height of the suction cup and sprung • Power on the ClearVue and test motor function,
pads as shown. refer to the Coverslip Transfer Head Motor test
section.
• Go to screen 1 on the inputs page of production
services, turn the system manually and ensure
that the 'Prep Rotate' opto changes state.
• Go to screen 2 on the inputs page of production
services, ensure the 'Prep Rotate Head' opto
changes state when it is interrupted.
Inspecting the Output Pusher and Upper
Slide Retention
• Ensure that the unit is powered down.
• If the suction cup height is wrong, ensure it is
• Check for any mountant build up and clean if
pushed home fully or replace as necessary.
required.
• If the sprung pad heights are wrong, adjust the
• Check for any glass or basket debris and clean
locking nuts on top.
if required.
• If the sprung pads are catching or sticking clean
off any mountant and lubricate the pins with • Check that the eject bracket is straight by putting
a rule along it right hand side and making sure it
silicon lubricant or microtome oil.
is parallel down its full length.
Note
• Check that the sprung retainer is unbent, rotates
Keep all surfaces of the pads clear of lubricant. freely and travels back under its own spring
force.
The coverslip transfer head will be one of the
following colours: • Rotate the motor by hand and ensure that it
rotates freely and without any tight spots.
• Silver - Standard Head - Early builds with lower
• Move the unload bracket from left to right and
tolerances
ensure it travels along its full travel without tight
• Black - Standard Head - Current build with
spots or excessive play in either linear rail.
improved tolerances
• Power on the ClearVue and test the motor
• Blue - Offset coverslip transfer head.
function, refer to the Basket Eject Motor Test
After changing a coverslip transfer head, it is section.
important to check the position of the hard stop
• Go to screen 1 on the inputs page of production
(refer to Checking and Adjusting the Coverslip
services, Move the grippers manually and ensure
Transfer Head Hard Stop section). that the 'Eject home' opto changes state as the
flag on the unload passes through it.
Inspecting the Coverslip Transfer Drive
Inspecting the Output Rail
• Ensure that the unit is powered down.
• Rotate the transfer head and ensure the • Ensure that the unit is powered down.
mechanism moves freely. • Check for any mountant build up and clean if
• Check the condition of the drive belt, ensuring it required.
is not frayed or damaged. • Check for any glass or basket debris and clean
• Re-tension or replace as necessary, refer to the if required.
Coverslip Transfer Head Motor Assembly • Check the leaf spring is undamaged and moves
section. freely.

ClearVue Service Manual Issue 08 71

Inspecting the Mountant Pump Actuator • Power on the ClearVue and test the motor
and Syringe function, refer to the Dispense Head Cleaning
Station Motor Test section.
• Ensure that the unit is powered down.
• Go to screen 1 on the inputs page of production
• Remove the covers.
services.
• Check for any air in the lines or syringe.
• Move the dispense head cleaning station
• Check that the syringe is firmly screwed into the
manually and ensure that both the cleaning
mountant solenoid block – Do not use tools to station 'Down' and 'Up' opto’s changes state as
do this. Use the knurled part to turn the syringe. the cleaning station motor shaft passes through
• Tighten the retaining pin to 1.8Nm, refer to the them.
Mountant Syringe section.
• Ensure the M3 countersunk screws into the Inspecting the Covers and Filter
bracket are tight. If removing and replacing, use • Check for any mountant build up and clean if
Loctite 222 on the thread. required.
Note • Check for any glass or basket debris and clean
if required.
The length of these screws is critical to this
assembly. • Go to screen 3 on the inputs page of production
services.
• Check the Nyloc nut is secure, refer to the
• Open and close each door in turn and ensure
Mountant Pump Actuator Assembly section.
that the correct door sensor changes state as
• Check the machine is clear of glass and then
the door is opened and closed.
switch the machine on.
• Check the operation of the filter switch be
• Use 5minmode to allow the instrument to
removing and replacing the filter.
initialise without covers, refer to the ENG Tab –
• Check for any damage to the covers, Cosmetic
Page 6/7 section.
damage to the covers or windows is unimportant
• Perform an I-Pump, refer to the ENG Tab – Page
to the function of the ClearVue.
5/7 section.
Note
• Check the syringe plunger goes to the very
bottom of the syringe. Any damage that affects the opening / closing of the
• The stroke of the plunger should be 60mm. doors or that has created holes in the cover will
necessitate the replacement of the affected covers.
• Replace the covers.
• Run a bead test, refer to the Carrying Out a Bead • Clean out any debris stuck in the debris tray and
Test section. Xylene tray.

Inspecting the Cleaning Station Assembly Inspecting the Mountant Bottle and Lines
• Ensure that the unit is powered down. • Remove the covers.

• Check for any dried mountant build up and clean • Check for any air in the lines or syringe.
if required. • Remove the mountant dispense needle
• Check for any glass or basket debris and clean assembly from the support arm.
if required. • Place mountant dispense needle over a
• Check the condition of the pot seal and replace container to collect the mountant and Xylene
if required. waste (Gemini pots are a good size and shape
for this).
• Empty the pot and check inside for any dried
mountant. Do the following, looking for where any air enters the
system.
• Check that the pot locates easily onto stub shaft.

ClearVue Service Manual Issue 08 72

• Perform a couple of flush cycles, use 'ms menu', Mountant Bottle Pneumatics:
refer to the ENG Tab – Page 6/7 section.
• When looking at the back of the machine the
• Do a degas, use 'ms menu', refer to the ENG LEFT solenoid controls the Vacuum side of the
Tab – Page 6/7 section. circuit.
• Repeat the flush cycle. • The RIGHT solenoid controls the pressure side
The reason for doing this is in case any air was of the circuit.
brought into the pipes during the de-gas (very small • The LEFT solenoid connector is on the top.
leaks). Performing the flush afterwards will show
• The RIGHT solenoid connector is on the bottom.
where the small leak is, depending on when the air
• On this manifold both the central fittings are
is first seen in the syringe.
connected directly to the pump.
• Check all of the fittings are tight and that the
• Both the pressure and vacuum side of the pump
mountant lines are in good condition and the
are connected.
ends are cut perpendicular. Note that removal of
the lines is only required if checking for a leak. • This is the pump towards the rear of the
There is no need to check the ends of the pipes machine.
during normal servicing. Slip Pneumatics:
• Check the mountant bottle pneumatic lines for • When looking at the back of the machine the
any obstructions, particularly mountant. LEFT solenoid controls the Slip Placement.
• If there is any sign of mountant in the pneumatic • The RIGHT solenoid controls the vacuum on the
lines, replace the pipe work and check the slip dispense.
sensor is free of any mountant. • Both solenoid connectors are on the top.
Note • On this manifold both the central fittings go to
Ensure that the mountant line and fitting from the the slip dispense/ placement, via a filter and
solenoid to the dispense needle is pointing sensor.
upwards, refer to the Mountant Solenoid Assembly • Only the vacuum side of this pump is connected.
section. • The pressure side has a silencer to reduce noise.
• If the fitting is pointing downwards the line will be • The pump goes to the slip dispense solenoid
trapped and damaged and will have a directly and via the regulator to the slip
detrimental effect on the slip dispense and bead placement solenoid.
placement as the mountant line will be too short. • This pump is towards the front of the machine.
• Connected to the left hand side of the solenoid
Inspecting the Pneumatic Circuit
is a pipe that leads to the decay reservoir and
Run the following tests: then the variable restrictor, which controls the
speed at which the vacuum on the slip
• Mountant Bottle Pneumatic Test.
placement is released.
• Vacuum System Test.
• If issues arise, check for leaks and blockages in
• Coverslip Dispense System Test. the system before altering this setting.
• Remove the Solenoid Assemblies
• The Upper Solenoid Assembly controls the
mountant bottle pneumatics.
• The Lower Solenoid Assembly controls the slip
pneumatics.

ClearVue Service Manual Issue 08 73

Instrument Verification Tests
• Performance Test 1
• Performance Test 2
• Performance Test 3
• Mountant Bottle Pneumatic Test
• Vacuum System Test
• Coverslip Dispense System Test
• Checking and Adjusting the Coverslip Transfer Head Sprung Pads
• Checking and Adjusting Gripper-to-Gripper Alignment
• Checking and Adjusting the Needle Height
• Checking and Adjusting the Coverslip Transfer Head Hard Stop
• Coverslip Dispense End Stop Height
• Checking Software, FPGA and Pump Profile Version
• Checking and Adjusting Short Gripper Stop Cam
• Resetting Parameters
• Checking Door Sensors and Filter Switch
• Checking the Coverslip Transfer Head Position
• Checking and Setting Coverslip Dispense Optical Sensors
• Carrying Out a Bead Test

ClearVue Service Manual Issue 08 74

 • The coverslip should be positioned as shown.
Performance Test 1
• There will be some overspill at the top and
• Check that the time and date are correct on the
bottom ends of the coverslip.
instrument - change them if necessary.
• There should be little or no overspill on either side
• Load a basket with slides.
of the coverslip.
• Choose volume 13 from the mountant menu. • There should be no witness marks on the
• Run the basket through as normal, but remove it coverslip caused by the suction cup or transfer
as soon as it is finished. head sprung pads.
Note • There should not be a line of mountant on the
frosted portion of the slide.
Ensure the slides remain level as they may slip if they
are tilted. • There may be a small bubble towards the non-
frosted end of a few of the slides.
• Ensure there are no bubbles over 1mm in
• Lay the slides out flat as quickly as possible, diameter.
taking care not to disturb the coverslips.
• Ensure no single slide has multiple bubbles.
• Check the coverslip alignment against the
• Extract an Engineers Log and open it using either
following criteria:
the default Notepad Windows application, or as
• The coverslip should not overhang the slide at an Excel spreadsheet, using the ClearVue Macro
any point. to manipulate the data.
• The coverslip should be central from left to right
as shown.

ClearVue Service Manual Issue 08 75

Engineers Log as a Text File
• Locate the time and date that the basket was processed.
• The file format will be similar to the extract below:

11/20/2007 08:08:56 pos_0:030 pos_1:033 pos_2:084 @ quad:08715 Slide No: 00 1

Gripper detected slide ok, final pos adjust = :- 13 Quad 2

11/20/2007 08:08:57
1:56578 Quad 2:57219 Width of Jaws: 22.04 mm 3

DISPENSED SLIP PROPERTIES -> qa:10193 qb:10193 4

11/20/2007 08:08:59

qc:10469 qd:10469 er_no:00 5

11/20/2007 08:08:59 Good slip dispensed with latch optics at 00227, 00210 6

11/20/2007 08:09:01 End of dispense at quad:25513 position:25514 7

11/20/2007 08:09:02 End of suckback at quad:25458 position:25458 8

11/20/2007 08:09:07 Prep Decay Time - 03.21 9

Note
The shaded section at the end of each line has been added as a point of reference for this manual.
It will NOT be shown on an actual engineer’s log.

• The date is shown in the format MM/DD/YYYY and the time is in hh:mm:ss.
• When the correct time and date have been located, look for 'Slide No: 01' (see end of Line 1) which is the
first slide in a basket.
• Then locate the corresponding 'Prep Decay Time' (see Line 9) for the slide.
• The time should be between 2 and 4 seconds.
• Repeat this for all 20 slides (Slide No: 01 to Slide No: 20) and ensure they are all within the correct range.
Anything with a Prep Decay Time of < 1.5s will result in a large number of bubbles and unacceptable Prep
Quality!

ClearVue Service Manual Issue 08 76

Engineers Log Using the ClearVue Macro 8. Repeat steps 1-7 however this time the baskets
should be wetted with xylene, toluene or
• Select the tab at the bottom of the spreadsheet
Shandon xylene substitute.
labelled 'prep_decay'.
9. Go to the disk menu and write a log.
10. Switch off the ClearVue.
Interpreting Results
• Locate the date and time that the basket was • If the ClearVue is operating normally it should
processed. process all 5 baskets with no errors and no
• The date is shown in the format DD/MM/YYYY broken slides.
and the time is in hh:mm:ss.
Note
• There will be 20 prep decay times listed for the
basket. A small number of errors putting the slides back into
the basket are inevitable, therefore 1 user error 6
• All the prep decay times should be between 2
(engineering error 91) is acceptable during the 10
and 4 seconds.
baskets.
Anything with a Prep Decay Time of < 1.5s will result
in a large number of bubbles and unacceptable • Open the log file taken (refer to Appendix E –
Prep Quality! Understanding Log Files) and check for any
errors or warnings during the processing of the
Further details on analysing the Engineers Log baskets.
produced by the ClearVue Macro can be found in
• Check the log file (refer to Appendix E –
Appendix E – Understanding Log Files.
Understanding Log Files) for the consistency of
the 'auxiliary cam init' values, the values should
not vary by more than 1 pixel over the course of
Performance Test 2 the 10 baskets.
Performance Test 2 is designed to ensure that the • Check the log file (refer to Appendix E –
ClearVue can handle slides and baskets without any Understanding Log Files) for the consistency of
issues. the 'basket top1' values, the values should not
vary by more than 2 pixels over the course of the
The test should be carried out as follows:
10 baskets.
Method

1. Load 5 baskets with dry new slides in each.

2. Switch on the ClearVue and allow it to initialise
normally.
3. Go to production services page 2 and switch off
the prep.
4. Load 1 dry basket onto the load rail and close
the load door.
5. Observe the unit processing the basket until it
places the basket onto the unload rail.
6. Open the load door and load the remaining 4
dry baskets.
7. Observe the unit processing the baskets until it
placed all 4 baskets onto the unload rail.

ClearVue Service Manual Issue 08 77

Performance Test 3 • If more than two errors occur, investigate the
cause.
There is a risk of static shock when
• If two or less errors occurs select exit.
performing this test. Ensure the
debris tray is suitably earthed before
Mountant Bottle Pneumatic Test
commencing the test.
• The 'Pnumat 1' menu tests the pneumatics that
• Load a coverslip hopper into the hopper
pressurise the bottle to prevent cavitation during
supports.
loading of the syringe and pulls a vacuum to de-
• Go to page 2 of the Engineering tab in gas the mountant, pulling excess air out of the
Production Services and select 'test slip'. mountant.
• If the 'slip out' button is pressed one coverslip • Use 'Pnumat 1' test to check mountant bottle
will be dispensed and quality checked, the pneumatic system.
results of the quality test can be seen bottom left.
• Complete each test, Max Press, Min Press and
• If the 'return' button is pressed the carriage will Leak Test in order.
return.
• Details of Pass / Fail criteria are given in the ENG
• Repeatedly press the 'slip out' and 'return' Tab – Page 2/7 section.
buttons until 10 coverslips have been dispensed
• Repeat the Max Press test, but when the
and 'good slip' shown.
pressure reaches 5PSI, open the mountant
• Press 'Init' and exit menu. bottle lid to quickly release the pressure.
• Go to page 6 of the Engineering tab in • Check that the pressure on screen rapidly falls to
Production Services and select 'slip QC'. 0PSI (±1PSI).
• Turn continuous to on. • To check the bottle seals, remove the pneumatic
• Press start. line from the bottle and use a T piece to blank off
• Let it dispense 100 coverslips. If an error occurs the end.
it will need to be cleared and start will need to be • Repeat the Leak Test and compare the results
repressed. to the Leak Test with the bottle attached.
• For definition of error codes see the table below: • Each solenoid can be checked by using the I/O
Tab – OUTPUTS section to switch the solenoids
Error Description
on and off.
Double Dispense - 2 coverslips stuck • Refer to the I/O Tab – Outputs section for details
1
together for how to set each solenoid.
No Coverslip - Failed to dispense a • I/O Tab - INPUTS, can be used to monitor the
2
coverslip from the hopper vacuum.

Chipped - Dispensed coverslip has a

3
broken corner

Half Dispense - Coverslip has only come

4
out half-way or is broken in half

Length Error - The coverslip is not a

5
recognized standard size

Coverslip Past Hard Stop - Coverslip is

6
partially over the back of the carriage

Skewed - Coverslip has been dispensed

7
at an angle

ClearVue Service Manual Issue 08 78

Vacuum System Test • The decay should be 3 seconds, but the screen
will record a pass if the decay time is between 2
Checking the Vacuum Level and Decay Time
and 4 seconds.
• The 'Pnumat2' menu tests the vacuum level and
• To alter the vacuum decay time use a 2.5mm
decay time for the coverslip transfer head. allen key to adjust the exhaust restrictor, turn
• Use the 'Pnumat 2' test in ENG Tab – Page 2/7 clockwise to increase the decay time. Refer to
section. the Solenoid Assembly section for details on the
• Complete each test, Set Vac and Decay in order. exhaust restrictor.
• First, remove the pneumatic line from the • Return the pneumatic pipe to the coverslip
coverslip transfer head and place it in the blank transfer head and press exit to leave the test
fitting (bottom right of the vertical plate). menu.
• Each solenoid can be checked by using the I/O
Tab - OUTPUTS to switch the solenoids on and
off.
• Refer to the I/O Tab – Outputs section for details
for how to set each solenoid.
• I/O Tab - INPUTS, page 2 can be used to
monitor the vacuum.
• This can be completed either with the pneumatic
line connected to the blank fitting, or a coverslip
can be used on the suction cup.
Confirming the Decay Time

• Always check the decay time that is set here,

corresponds to the actual decay time when
processing baskets - This can be done by
analysing the Log file.
• Refer to the Performance Test 1 section for
details of how to analyse the Log file.
• Press the 'Pnumat 2' button. • If the decay set here is greater than the actual
• Press the 'Set Vac' button and leave the vacuum decay time in the log file, there may be a fault
to settle for 30 seconds. Check the maximum with the suction cup or the connection between
value and ensure that the recorded value is - the pneumatic line and the coverslip transfer
4.5psi, ± 0.5psi. Refer to the Vacuum Regulator head.
section for details on replacing the vacuum • Refer to the Inspecting the Coverslip Transfer
regulator. Head section for details on checking the
• To adjust the regulator, open the cap by pulling coverslip transfer head.
away from the mounting bracket. Checking the Coverslip Pick Up
• The cap can now be turned to adjust the vacuum
• Initialise the coverslip transfer head by choosing
level.
I-Prep.
• Push the cap closed after adjustment to prevent
• Watch as it initialises. You should see both
the settings from creeping.
sprung pads touch the coverslip dispense
• Press 'exit' to stop the test. carriage.
• Press the 'decay test' button to check the
vacuum decay time.

ClearVue Service Manual Issue 08 79

• If only one touches, the system is stalling too • If it is necessary to adjust the pads, do so using
high and hence the coverslip transfer head will the Nylock nuts on the shoulder above the pads.
not be able to come low enough to pick up the
Note
coverslip.
• Refer to the Inspecting the Coverslip Transfer Turning the nut through 1 revolution will raise or
Head section and Inspecting the Coverslip lower the sprung pad by 0.5 mm.
Transfer Drive section for details on checking the Turning the nut through 1 flat of the nut (60°) will
assembly. raise or lower the sprung pad by 0.083 mm.
• After any adjustment re-check the position and
Coverslip Dispense System Test
freedom of movement.
• Run Pnumat 3 test on ENG Tab - Page 2, refer
• Tool T61622 can also be used to set the sprung
to the ENG Tab – Page 2/7 section.
pad height. Insert the tool shown below then
• Confirm that the vacuum on the carriage when a tighten to 0.5Nm to set position then slacken by
coverslip is present is less than - 7psi (-10psi is 1 flat on each nut to allow removal of the tool.
a good, strong vacuum).
• Remove the coverslip and check that the
vacuum in the top right of the screen returns
quickly to 0psi, ± 0.5psi.
• Run Performance Test 3.

Checking and Adjusting the Coverslip

Transfer Head Sprung Pads

• Check that both pads are free to move to the

limits of their travel.
• Use feeler gauges to ensure that the gaps
between the main body of the transfer head and
the sprung pads are the same as those shown
above.

ClearVue Service Manual Issue 08 80

Checking and Adjusting Gripper-to-Gripper • Rest the DTI probe on the top of the gauge plate.
Alignment • Move the support arm so that the DTI probe
Checking and correction of angular alignment of moves from the near end of the gauge plate to
the gripper jaws the far end to determine the angular
misalignment (if any).
• Ensure the covers have been removed along
Ensure the DTI dial does not strike the vertical
with the camera cover.
plate when pushing it to the back of the
• Detach the dispense head from the support arm.
instrument.
• Remove the gripper return plate and the jam
Note
indicator finger from the short jaw arm.
• Assemble the DTI and bracket, and then screw Do not rest anything on the display screen or main
it to the support arm as shown. deck whilst checking the DTI reading as this can
affect the reading.
• If any adjustment is required loosen the angular
adjustment screw, make the necessary
adjustment and retighten the screw to 3Nm to
secure the gripper jaw.
• Remove the gauge plate from the short gripper
jaw and fix it to the long gripper jaw in the same
manner.
• Repeat the above testing and adjustment
method to ensure the long gripper jaw is
angularly aligned to the short gripper jaw.
The permissible run-out is shown below.

Note
Ensure the large hole in the bracket fits over the
boss on the support arm.
• Fix the gauge plate to the short gripper arm as
shown using the cap-head screw provided

Checking and correction of the height of the long

gripper jaws

• Remove the DTI and bracket from the support

arm and fix it to the lower linear rail as shown.

ClearVue Service Manual Issue 08 81

 • The fixing screws should be slackened off to
allow the adjustment and then tightened to 3Nm
when the adjustment is complete.
Note Note
The fixing screw from the linear rail must be When jacking the tail-end of the long gripper jaw, it
removed to allow the hole to be used for the is advisable to hold the tips of both jaws together to
bracket. ensure that the previously set tip does not move too
• Bring the jaws together so that they are end-to- much.
end. • After adjustment, re-check the tip-to-tip variation
• Manually raise or lower the end of the long to ensure it is still within tolerance.
gripper jaw until the tip is within 0.1mm of the
height of the tip of the short jaw.

Note
The tip of the long gripper jaw must be lower than
the tip of the short gripper jaw (to within tolerance).
• Position the DTI probe on the upper surface of
the long gripper jaw and manually move the jaw
to determine the run-out.
The tip-to-tail variation must be within 0.2mm.

• If the run-out is greater than 0.2mm the tail end

of the long gripper jaw can be raised or lowered
using the height jacking screw.

ClearVue Service Manual Issue 08 82

Checking and Adjusting the Needle Height Adjusting the Needle Height

Checking the Height

• Push the long gripper jaw to the right and bring
both jaws into prep position.
• Place a slide between the grippers in the correct
position. Check that the slide is held securely
and does not wobble.
• Push the cleaning station down so that it clears
the dispense head needle.
• Push the dispense head towards the prep area
so that the needle is just behind the grippers
(See Figures 1 & 2).
• Using feeler gauges check the height of the
needle above the slide. The correct value should
be between 0.70 and 0.75mm at the gripped
end.
• With the needle locking screw still tight, use a
• Repeat the above test at the far end of the slide 10mm spanner (wrench) on the adjustment
and confirm it is in the range of 0.60 - 0.80mm. height screw to achieve the correct height. When
Note viewed from above, turning the needle clockwise
will reduce the needle height.
Be aware that the feeler gauge can bend the slide
• Loosen the needle locking screw and allow the
down especially at the far end of the slide and this
whole needle assembly to rotate to un-twist the
could give you a false reading.
mountant pipe.
• If the run out along the slide is greater than
• Re lock the needle in place, check it is secure
0.2mm then the gripper alignment must be reset,
and recheck the needle height at either end of
refer to the Checking and Adjusting Gripper to
the slide.
Gripper Alignment section.
• Ensure that all mating faces are free of mountant
or other debris and that the needle sits correctly
in the arm.

Note
Do not over tighten the needle locking screw as
customers need to be able to remove the needle
without tools.

ClearVue Service Manual Issue 08 83

Checking and Adjusting the Coverslip Note
Transfer Head Hard Stop Checking the The LifeTest button in the ENG Tab, page 7 (refer to
Position
the ENG Tab – Page 7/7 section) can be used as an
alternative method of checking the hard stop
setting.
Method for Adjusting the Hard Stop

• Slacken the single M6 retaining screw in the hard

stop until it is finger tight.
• Using a flat blade screwdriver rotate the hard
stop until a good fit is felt with the feeler gauges.
• Simultaneously tighten the retaining screw to a
torque of 5.5Nm whilst holding the hard stop in
position with the screwdriver.
• Always re-initialise and recheck the gap after
tightening the screw.

Coverslip Dispense End Stop Height

Checking the End Stop Height

• Remove the coverslip dispense skirt.

• Push down the cleaning station until it clears the
dispense head needle.
• Push the support arm backward until the
carriage hard stop is just in front of the end stop.
• Using feeler gauges check that gap between the
end stop and the coverslip location face is
0.2mm.
• Lift the transfer head sprung pads and retain in • Pull the dispense head forward until the back of
this position with crocodile clips or adhesive the coverslip location face is just under the end
tape. stop.
• Bring gripper jaws into prep position. • Re-check the gap between the end stop and
• Place a slide into the gripper jaws and check that coverslip location face.
it is held in place securely. • Ensure gap is 0.20mm at its narrowest point.
• Move slide forward into a position where it is
Note
under the transfer head but not the sucker.
• Move transfer head over until it is just touching Maximum permissible run-out is < 0.050mm.
the slide; being careful that head is just touching
and has not bent the slide or changed its position
in the jaws.
• Using feeler gauges check the gap between the
lower crank arm and the transfer head hard stop.
• Correct gap should be 0.5mm.

ClearVue Service Manual Issue 08 84

 Checking Software, FPGA and Pump
Profile Version
To view the Software, FPGA and Pump Profile
versions:

• From the Main Menu press Options.

• From the Options Menu press Disc.

Method for adjusting the height

• This will display the Disc Options screen.
• Remove the coverslip dispense cover.
• Slacken the end stop screw.
• Move the end stop up and down to achieve the
correct height ensuring that:
• The end stop is flush with its datum face on the
left hand side of the slot in the rear hopper
support.
• There will be a small amount of run out on the
carriage and the 0.2mm should be set at the • The Software and FPGA version numbers are
highest point of the coverslip location face. shown at the top of the screen.
• Ensure the end stop screw is fully tightened. • The Pump Profile version (Pr) is shown at the
• Replace the coverslip dispense skirt and hopper bottom-left of the screen.
and manually move the dispense head • If the version numbers are incorrect, refer to the
backwards and forwards to test the coverslip Software Update section.
dispense.
• If it dispenses correctly replace the coverslip
dispense cover and initialise the machine.
• Work through Performance Test 3.
Note
The run out in the carriage should be small enough
so that the maximum gap at any point is still less
than 0.25mm.

ClearVue Service Manual Issue 08 85

Checking and Adjusting Short Gripper Stop Resetting Parameters
Cam Note
To Check the Stop Cam Setting
Any user adjustment of parameter 72 (slide visibility
• Switch on the ClearVue and allow it to initialise threshold) will be lost after a reset 7. Make note of
normally. the value of parameter 72 before starting, and
• If the stop cam setting is correct the front edge change after reset 7 if required.
of the small gripper should be lined up with the • To reset the parameters choose reset 7, refer to
right hand side of the slide guide after the ENG Tab - Page 3/7 section.
initialization.
• Wait for the system to finish initialising.
• Then complete the following tests to reset the
parameters.
• Refer to the ENG Tab - Page 1/7section,
ProdTst5
• Refer to the ENG Tab - Page 1/7section,
ProdTst6
• These 2 tests will reset the relationship between
the slide to the gripper jaws and the coverslip
position on the slide. These settings are unique
to each instrument.
• Confirm the user settings are correct for the
customer as per the quick set up guide.

Checking Door Sensors and Filter Switch

• Using the door sensors screen in Production
Services - I/O Tab - INPUTS - open each door in
turn.
A '1' on the screen indicates that the door is
closed.

A '0' on the screen indicates that the door is

open.
• This screen also allows the filter switch to be
checked.
A '0' on the screen indicates that the filter is
To adjust the stop cam
fitted.
• Slacken the stop cam lock nut.
A '1' on the screen indicates that the filter is not
• Turn the stop cam until the edge of the short
fitted.
gripper lines up with the slide guide as shown;

Note
The large portion of the cam should be orientated
upwards as shown in the diagram below.
• Re-tighten the lock nut ensuring that the short
gripper does not move in the process.
• Check cam setting to ensure it is still correct.

ClearVue Service Manual Issue 08 86

Checking the Coverslip Transfer Head Checking and Setting Coverslip Dispense
Position Optical Sensors
• Confirm whether the user has selected the End To Check the Sensors
or Central position for the coverslip transfer head
• Enter production services.
in the user setting. Note that if using the Offset
Coverslip Transfer Head, either of these • Navigate to 'Test Slip'.
positions can be selected to the same effect. • Without a slip underneath the values shown for
• Confirm that it corresponds with the actual optic1 & 2 should both be >1100 & <1500. With
a hopper in place press ’r;Half Out’ and ensure
position of the coverslip transfer head.
the slip dispense pull a slip under the optical
• Follow the instructions below to check if the flag
sensors. Check that both optic readings are
on the coverslip transfer head is breaking the
below 950 with a slip in place.
sensor appropriately.
• Press 'Return' then 'Init'.
• Use the inputs screen, refer to the I/O Tab –
• Exit from 'Test Slip'.
Inputs section.
• With a hopper in place press 'Autoslip'.
• Exit from Autoslip when it is finished.
• Go to slip QC - change to continuous running
and ensure that a quantity of 20 can be
dispensed without errors.
If the Sensors Need Resetting

• Remove the main cover and then the 3 screws

securing the sensor cover.
• With a hopper in place press slip 'Half Out'
• Go to the second page and locate 'prep Rotate
Slacken the M3 screws securing the sensors to
Head'.
the hopper mount then move the sensor up and
• Rotate the head slowly anti-clockwise until the
down until the reading for that sensor is at its
crank arm stops against the coverslip transfer lowest. (must be below 950) then tighten the
head hard stop. screw, repeat for the other sensor.
• The 'Prep rotate head' sensor should change
• Press 'Return' then 'Init'.
from 0 to 1 as the head passes through the
• Exit from 'Test Slip'.
sensor if the prep head is set to the End position,
and should not change the sensor output if set • With a hopper in place press 'Autoslip' - exit from
to the Central position. If the Offset Coverslip Autoslip when it is finished.
Transfer Head is installed, it will be set to the End • Go to slip QC - change to continuous running
position. and ensure that a quantity of 20 can be
dispensed without errors.

ClearVue Service Manual Issue 08 87

Carrying Out a Bead Test • Open ENG Tab, refer to the ENG Tab – Page 2/7
section and press the Beads button. The value
There are two ways to complete a bead test: the
shown on the button should be '1'.
User Bead Test method and the Advanced Bead
Test method. • Open ENG Tab, refer to the ENG Tab – Page 6/7
section and use 'Beadopt' to select the slip size
User Bead Test and position of the bead.
This method either lays down the default bead • Load a basket of slides and begin processing.
(50mm coverslip, end position) or it will lay down the • Mountant will be dispensed onto the slide, but
bead suitable for the last coverslips that were put
no coverslip will be placed.
through. Note, if you have just switched the machine
• When the basket has finished processing the
on or cleared the coverslip count on the front screen
formation of the beads can be checked to allow
it will return to the default setting.
problems to be diagnosed.
To access the user bead test, do the following
• Refer to the Excessive Bubbles section for
starting from the Main Menu screen:
details on interpreting Bead Test results.
• Press 'Options'. Note
• Press 'Slip pos'.
Ensure processed slides are kept flat at all times to
• Open all 4 access doors.
avoid distorting the appearance of the beads.
• Place a basket of dry slides on the input load rail,
but do not close the load door yet.
• Touch the coverslip shown in the diagram on the
screen.

• The coverslip will disappear and you will hear an

ascending musical tone.
• Close all of the doors and let the machine
process the basket of slides.
• When finished, remove the basket and lay the
slides out flat.

Note
The mountant will run while it is still liquid, so ensure
the slides are kept flat at all times.
• Refer to the Excessive Bubbles section for
details on interpreting Bead Test results.
Advanced Bead Test

• This method gives the option to choose the bead

size and position.

ClearVue Service Manual Issue 08 88

Chapter 5 – Settings
The following section covers the following
information:

• Adjust the Coverslip Position

• Select the Coverslip Position
• Change the Coverslip Transfer Head
• Adjust the Screen Settings
• Change the Time and Date Setting
• Change the system language
• Create the engineers' log
• Update the system software
• Adjust the mountant dispense volume
• Slide retainer types
• Install the offset coverslip transfer head
• Alter the slide sensing parameter

ClearVue Service Manual Issue 08 89

Adjust the Coverslip Position Examples

The Coverslip position on the slide can be adjusted

by up to 1mm in any one direction in 0.25mm
increments.
To adjust the Coverslip position:

• From the Main menu press the Options key on

the Touch screen.
The positive number values indicate a movement in
the direction of the labelled arrows; hence the
Coverslip is positioned above and to the right hand
side of centre.

• Press the Slip Position key.

The negative number values indicate a movement in

the opposite direction to the labelled arrows; hence
the Coverslip is positioned below and to the left
hand side of centre.

• Use the Arrow Keys on the Slip Adjustment

screen to move the Coverslip to the required
position. The default position has a setting of 0.

• Press OK on the screen when the adjustment

has been made.
Note
Positive numbers indicate that the Coverslip has
moved in the direction of the corresponding arrow.
Negative numbers indicate that the Coverslip has
moved in the opposite direction to the arrow.

ClearVue Service Manual Issue 08 90

Select the Coverslip Position
The ClearVue is capable of using 3 different lengths
of Coverslip: 40mm, 50mm and 55mm.

The default setting for coverslip position is with a

2mm gap between the end of the slide and the end
of the coverslip.

• Select either End (default setting) or Centre then

press OK.

The 40mm Coverslips can be positioned centrally, • Move the Coverslip transfer head into the
and also offset by 5mm when using the Offset position specified.
coverslip transfer head. • Press OK on the Position Setup screen.

Note
When using the Offset coverslip transfer head with
40mm Coverslips, the ClearVue automatically
places the Coverslip on the slide in the correct
position, regardless of whether the End or Centre
position has been selected.

To select the position of the 40mm coverslip:

• From the Main menu press the Options key on

the Touch screen.

• Press the 40 Slips key.

ClearVue Service Manual Issue 08 91

Change the Coverslip Transfer A. Identify the coverslip transfer head and loosen the
thumbscrew by turning it anti-clockwise.
Head Position
Note
The coverslip transfer head has 2 possible positions
to allow the 40mm coverslips to be positioned either The example shown here is the procedure for
centrally or in the End (default) position. changing from the End (Default) position to the
Central position.
To change the coverslip transfer head position:

• From the Main Menu press the Options key.

• Press the 40 Slips key.

B. Pull the thumbscrew out to release the coverslip

transfer head.

• Select either End or Centre then press OK.

C. Note the position of the coverslip transfer head

and then remove it from the location pins.

• Open the Access Door.

• Remove the coverslip transfer head:

ClearVue Service Manual Issue 08 92

• Reposition the coverslip transfer head: The Offset coverslip transfer head can only be fitted
in the Default position.
• Press OK on the Position Setup screen.

• Close the Access Door.

A. Reposition the coverslip transfer head as

required.

B. Replace the coverslip transfer head onto the

location pins in either the default or central position.
Tighten the thumbscrew by turning it clockwise.

C. The reference mark on the top of the coverslip

transfer head indicates which position it is in.
Note
One or other of the Position Indicators will line up
with the Reference Mark to indicate the position.

ClearVue Service Manual Issue 08 93

Adjust the Screen Settings Adjust the Change the Time and
The Touch screen settings can be altered to adjust Date Setting
both the View angle and the screen Brightness.
To alter the time and date:
The View angle is the angle from which the screen
• From the Main menu press the Options key on
is best viewed - so a tall person would want a higher
the Touch screen.
View Angle than a shorter person.

The Brightness sets the amount of screen back-

lighting.

To adjust the Screen display:

• From the Main menu press the Options key on
the screen.

• Press the Set Time key.

• Press the Screen key.

• The Set Time display opens.

• This will open the Screen adjust display.

• Adjust the Time and the Date using the relevant

arrow keys.
• Adjust the Time Format: use the 24 hour key to
set the time to the 24-hour format. The 12 hour
key then displays to let you change the format to
12-hour.
• Adjust the Date Format: use the mm/dd key to
• Use the arrow keys to adjust the View Angle and
set the date to that format. The dd/mm key then
Brightness.
displays to let you change the format to dd/mm.
• When the Touch screen is configured, press OK
• When the settings are configured as required,
to return to the Options menu.
press Set to apply the settings.

ClearVue Service Manual Issue 08 94

Change the System Language Create the Engineers Log
After the initial start-up procedure it is possible to The Disc Options screen allows an Engineers’ Log
change the Language used on the touch screen to be taken. The Engineers’ log may be requested
display: by a Service Engineer to aid troubleshooting.
• From the Main menu, press the Options key on To create the Engineers’ log:
the touch screen.
• From the Main menu press the Options key on
the Touch screen.

• Press the Language key.

• Press the Disc key to open the Disc Options
display.

• The Language Select screen displays. Use the

arrow keys to highlight the required language
and press Select. • Insert a blank, formatted, floppy disc into the
Disc drive.
• Press the Write Engineers’ Log key.

• The ClearVue displays the Wait screen and

writes to the floppy disc.

ClearVue Service Manual Issue 08 95

 • Press the Software Update key.
• When the Wait screen has gone and the light on
the Disc drive has gone out, it is safe to remove
the floppy disc from the Disc drive.

Note
An Engineers’ log can only be written when the
ClearVue is idle (not processing baskets). An audible
warning sounds if you attempt to write an
Engineers’ log during processing. • The ClearVue will then automatically install the
updated software and reboot itself.
Update the System Software
Do not switch off or interrupt the
Do not perform a software update power during this process
unless instructed to do so by a
Epredia Service Engineer. • The new software will be active when the reboot
The Disc Options screen allows the ClearVue is complete.
software to be updated. A Software Update would
normally be performed by a Service Engineer;
however, it is possible for the user to perform an
update if supplied with a new version on a floppy
disc.

To perform a Software update:

• Insert the floppy disc, containing the updated

version of the software, into the Disc drive. From
the Main menu press the Options key on the
Touch screen.

• Press the Disc key to open the Disc Options

display.

ClearVue Service Manual Issue 08 96

Adjust the Mountant Dispense During processing, pressing the Mountant key from
the Main menu will automatically open the Mountant
Volume Volume screen.
The ClearVue will automatically adjust the amount of Adjusting the Volume during processing will have an
Mountant dispensed, depending on the colour of IMMEDIATE effect on the amount of Mountant
the Slide Retainer and the user-defined settings. dispensed.
To adjust the Mountant volume:

• From the Main menu, press the Mountant key on

Slide Retainer Types
the Touch screen. To allow for variations in the thickness of samples,
the ClearVue has a Basket Recognition feature. This
allows the ClearVue to determine the colour of the
Slide Retainer on the Baskets

• Press the Volume key.

The Baskets supplied with the ClearVue have a

Black slide retainer. Baskets with White slide
retainers are available as an Accessory (refer to
Appendix A1 – Damage Codes). The Black slide
retainer typically designates thicker samples; whilst
the White slide retainer designates thinner samples.
• Use the Arrow keys on the Mountant Volume
The ClearVue can detect the colour of the Slide
screen to adjust the dispensed volume for each
retainer and automatically adjust the amount of
Basket type. The recommended setting for
Mountant dispensed, based on the user defined
general use is 13.
settings, to ensure that the Coverslip adheres
properly to the slide.

Note
If there is very little variation in the thicknesses of
samples, the volume of Mountant dispensed for
Baskets with either a black or a white Slide Retainer
can be set to the same value.

• Press Exit when complete.

Note
Settings will automatically adjust to suit the
Coverslip length, so that the same Mountant Setting
dispenses a larger volume of Mountant for a 50mm
Coverslip than for a 40mm Coverslip.

ClearVue Service Manual Issue 08 97

Install the Offset Coverslip
Transfer Head
The Offset coverslip transfer head is used to position
40mm Coverslips 5mm from the end of the slide.
The Offset head is supplied with a pneumatic pipe
that must be connected between the Offset
coverslip transfer head and the Rotatable fitting on
the ClearVue.

Only use 40mm coverslips

otherwise the quality of output may
be poor! The ClearVue does NOT
display an error message if any
other size of coverslip is used.

To install the Offset coverslip transfer head:

• Open the Access door.

• Remove the Coverslip transfer head:

A. Identify the Coverslip transfer head and loosen

• Detach the Pneumatic pipe connecting the
the thumbscrew by turning it anti-clockwise.
current coverslip transfer head to the Shandon
ClearVue: hold down the blue portion of the
Pneumatic connector on the Rotatable Fitting
and pull out the Pneumatic pipe.

B. Pull the thumbscrew out to release the coverslip

transfer head.

ClearVue Service Manual Issue 08 98

 C. Hold the Offset head and push one end of the
C. Note the position of the Coverslip transfer head pneumatic pipe firmly into the pneumatic connector.
and then remove it from the Location pins. Do not push down on the connector.

• Fit the Offset coverslip transfer head: D. Insert the other end of the pipe into the connector
of the Rotatable fitting on the ClearVue.

• Pull firmly on the Pneumatic pipe to make sure it

is correctly fitted into the Pneumatic collars.

Incorrect fitting may result in poor

coverslipping performance

Note
When the Offset coverslip transfer head is fitted, the
ClearVue automatically places the 40mm coverslip
A. Fit the Offset head onto the Location pins.
on the slide in the correct position.

B. Align the Reference mark with the Default

position.

Tighten the Thumbscrew by turning it clockwise.

ClearVue Service Manual Issue 08 99

Alter the Slide Sensing • Press the shaded area of the slide for
approximately 3 seconds to display the Slide
Parameter sensing adjustment screen.
To improve throughput the ClearVue has an optical
system to sense the presence of Slides in a Basket.
The system is preset at the factory to provide the
optimal performance for the majority of users. In
some instances, the combination of Slide type,
Specimen type and Reagent might make it difficult
for the optical system to see Slides.

In the unlikely event that the ClearVue does not

coverslip all the Slides in a Basket and does not • Initially, the default value (95) is displayed on the
issue any errors or warnings, the sensitivity of the left side of the screen. Use the bottom arrow to
optical system can be increased by adjusting the reduce the value in steps of 5. If ClearVue is
Slide sensing parameter. missing slides when processing, initially reduce
To adjust the Slide sensing parameter: the value by 10.
• Press OK to exit the screen and return to the
• From the Main menu press the Options key on
Options menu.
the Touch screen:
• If the problem persists, further reduce the Slide
sensing value by 5 at a time. The lowest possible
value is 40.
Note
Adjusting the slide sensing will not affect the quality
of coverslipping but it might reduce the speed.

• Press the Slip position key.

• The Slip adjustment screen displays.

ClearVue Service Manual Issue 08 100

Chapter 6 – Maintenance
The following sections give details on how to carry Do not use abrasive compounds or
out basic maintenance procedures. metal components to clean the
If a problem occurs, which is not covered in these ClearVue or its accessories.
sections, contact the Epredia Service Department.

• Cleaning and maintenance cautions Always clean up spills immediately.

• Replacing seals
• Removing the mountant bottle In the event of a major spillage on or
around the ClearVue, immediately
• Preparing the ClearVue for storage
disconnect the instrument from the
Mains supply, and do not reconnect
until the instrument has been
Cleaning and Maintenance thoroughly dried and check by a
Precautions Epredia Service Engineer.

For Daily tasks refer to the Daily Tasks section. Potentially lethal voltages in excess of
110V a.c. are present within the
For Weekly tasks refer to the Weekly Tasks section.
ClearVue - Do not remove any access
If the ClearVue has been used with, or covers.
has come into contact with, hazardous
material, ensure that the appropriate Disconnect the ClearVue from the
decontamination procedures have Mains before cleaning.
been followed (See World Health
Inspect the instrument for obvious
Organization 'Laboratory Biosafety
damage or wear whenever it is being
Manual').
cleaned.
Cleaning or decontamination methods,
other than those recommended in this
document, should be checked with a
Epredia agent to ensure that they will
not damage the instrument.

Always wear suitable protective

coverings when carrying out cleaning
using chemicals.

Do not use chemicals which may

interact with the materials of
manufacture - If in doubt contact your
Epredia Representative.

Do not use hypochlorites in strong

solution.

ClearVue Service Manual Issue 08 101

Replacing Seals
There are two user-serviceable seals on the
ClearVue, located on the Mountant Bottle spout and
the Xylene Tray. If these seals become encrusted
with Mountant their ability to create a good seal is
impaired and they must be replaced.
To remove the O-Ring seal on the Mountant Bottle
spout:

Ensure that there are no Baskets currently being

processed within the ClearVue. A. Carefully stretch the O-Ring seal to fit over the
Retaining surface.
• Unscrew and remove the Mountant Bottle cap.

B. Once it is over the Retaining surface, roll it

towards the Recess.
• Identify the black O-Ring seal at the base of the
Mountant Bottle spout (shown here in yellow).

C. Allow the O-Ring seal to snap into place, then

ensure it is properly seated in the Recess.

To remove the O-Ring seal on the Xylene Tray:

• Use a pair of scissors or wire-cutters to carefully
cut the O-Ring seal, ensuring none of the
surfaces of the Mountant Bottle are damaged in Xylene is harmful
the process.
• Replace with a new seal: • Ensure that there are no Baskets currently being
processed within the ClearVue.
Note
• Taking care not to spill any remaining xylene,
The diagrams show the Mountant bottle spout seal remove the Xylene Tray and empty out any
replacement, but the technique is common to the xylene.
Xylene tray seal also.

ClearVue Service Manual Issue 08 102

 Remove the Mountant Bottle
Take precautions when dealing with
Xylene!

After Flushing the system with Xylene during the

initial set-up of the ClearVue, the Mountant Bottle
needs to be emptied of any remaining Xylene.

To remove the mountant bottle:

• Remove the mountant bottle cap by twisting it
anti-clockwise to loosen it.
• Identify the black O-Ring seal (shown here in
yellow).

• Use a pair of scissors or wire-cutters to carefully

cut the O-Ring seal, ensuring none of the
surfaces of the Xylene Tray are damaged in the
• Lift off the mountant bottle collar.
process.
• Replace with a new seal.
Refer to the Cleaning the Mountant Bottle Seal
section and the Cleaning the Xylene Tray Seal
section for information about cleaning the Mountant
bottle spout seal and the Xylene tray seal
respectively.

• Insert the Allen key (as provided) into the

Mountant Bottle fitting connector. Turn the Allen
key anti-clockwise to loosen the bottle and lift
the bottle out of the ClearVue.

ClearVue Service Manual Issue 08 103

 Prepare the ClearVue for
Storage
If the ClearVue is to be taken out of operation for a
long period of time, or put into storage, ensure the
following procedures have been followed:
• Empty the Mountant bottle and clean with
xylene.
• Flush the system with xylene.
• Cap the Mountant dispense needle.
• Empty the Dispense head cleaning station.
Do not disconnect the pipes! • Empty the Xylene tray.
• Ensure the instrument has been thoroughly
cleaned and decontaminated as necessary.
• Re-pack it into its original packing, refer to
• Carefully dispose of any remaining Xylene in the Appendix C – Packing Instructions.
Mountant Bottle. If the ClearVue has been used with, or
has come into contact with, hazardous
material, ensure that the appropriate
decontamination procedures have
been followed (See World Health
Organization 'Laboratory Biosafety
Manual').

If the ClearVue has been out of

operation for a month or longer, ensure
Do not attempt to stand the bottle up any Mountant is fully removed by
when detached from the instrument! performing a Flush cycle using xylene.

Reverse the above instructions to reassemble

ClearVue Service Manual Issue 08 104

Chapter 7 – Cleaning
The following sections give details on how to carry
out basic cleaning procedures.

If a problem occurs which is not covered in these

sections, contact the Epredia Service Department.

• Mountant Bottle Cap

• Mountant Bottle Seal
• Xylene Tray Seal
• Dispense Head Cleaning Station
• Suction Cup
• Slip Dispense Carriage
• Mountant Dispense Needle
• Touch Screen
• Slip Dispense Skirt
• Gripper Return Plate
• Slide Grippers
• Coverslip Transfer Head
• Camera

ClearVue Service Manual Issue 08 105

Cleaning the Mountant Bottle • Use a xylene soaked cloth to remove any dried
Mountant from the bottle spout. Pay particular
Cap attention to the threaded portion and its 3 cut-
outs.
Take precautions when dealing with
Xylene!

If the Mountant bottle cap becomes encrusted with

Mountant and difficult to open, the following
procedures should be followed to remove and clean
the bottle cap:

To remove the mountant bottle cap:

• Replace the Mountant bottle cap.

Hand tighten the Mountant bottle cap

only - do not use the cap removal tool!

• Place the Cap removal tool over the Mountant

bottle cap.

• Turn anti-clockwise by half a turn.

• Turn clockwise by a quarter of a turn. Repeat

steps 2 & 3 until cap is fully removed.
Once the Mountant bottle cap has been removed,
the following cleaning procedure should be
followed.

ClearVue Service Manual Issue 08 106

Cleaning the Mountant Bottle
Seal
Take precautions when dealing with
Xylene!

To remove the O-Ring seal:

• Ensure that there are no Baskets currently being

processed within the ClearVue. • Carefully prise the O-Ring seal from its seat,
• Unscrew and remove the Mountant bottle cap: ensuring none of the surfaces of the Mountant
bottle are damaged in the process.

Do not use a blade to remove the seal

as injury may occur.

• Manoeuvre the O-Ring seal over the large

diameter threaded portion of the Mountant bottle
spout.
• Roll the O-Ring seal up the spout until it comes
off.
To clean the seal:
A. Place the Cap removal tool over the Mountant
• Use a xylene-damp cloth to remove any
bottle cap.
encrusted Mountant from the seal.
• Check the seal for signs of tearing or splitting,
and replace if necessary.
• Refit the seal when fully dry.

B. Turn anti-clockwise by half a turn.

A. Carefully stretch the O-Ring seal to fit over the

Retaining surface.

C. Turn clockwise by a quarter of a turn. Repeat

steps B & C until cap is fully removed.
• Identify the black O-Ring seal at the base of the
Mountant bottle spout (shown here in yellow).

ClearVue Service Manual Issue 08 107

 • Identify the black O-Ring seal (shown here as
yellow).

B. Once it is over the Retaining surface, roll it

towards the Recess.
• Carefully prise the O-Ring seal from its seat,
ensuring none of the surfaces of the Xylene tray
are damaged in the process.

Do not use a sharp object to prise the

seal out.

• Manoeuvre the O-Ring seal onto the larger

adjacent portion of the Xylene tray.
C. Allow the O-Ring seal to snap into place, then
• Roll the O-Ring seal along the surface of this
ensure it is properly seated in the Recess.
portion until it comes off.
• Carefully guide the O-Ring seal over the rest of
Cleaning the Xylene Tray Seal
the Xylene tray until it is clear.
Take precautions when dealing with To clean the seal:
Xylene! • Use a xylene-damp cloth to remove any
encrusted Mountant from the seal.
To remove the O-Ring from the Xylene tray:
• Check the seal for signs of tearing or splitting,
• Ensure that there are no Baskets currently being and replace if necessary.
processed within the ClearVue.
• Refit the seal when fully dry.
• Taking care not to spill any remaining xylene,
remove the Xylene tray and empty out any
xylene.

ClearVue Service Manual Issue 08 108

Cleaning the Dispense Head
Cleaning Station
Take precautions when dealing with
Xylene!

To clean the dispense head cleaning station:

• From the Main menu, press the Mountant key on

the touch screen. • Open the Access door.
• The cleaning station is now accessible: carefully
pull it upwards to remove from its fixing.

• Press the Access key.

• Remove the lid and dispose of the contents

according to local regulations.

• Press the Start key.

• Wait for activity within the ClearVue to stop, and • Use a xylene damp cloth to clean all the surfaces
Access Ready to flash. of the cleaning station including the top of the
internal parts.
• Refill to about ¾ full with xylene.
• Reassemble the cleaning station and refit into
the ClearVue.

ClearVue Service Manual Issue 08 109

 Cleaning the Suction Cup
Take precautions when dealing with
Xylene!

Remove the suction cup

• Open the Access door.

Top up the cleaning station:

A. Drip Xylene into the dispense head cleaning

station until it is at a level where it can be
seen in the central well (approx. 18ml).
B. Use the end of the pipette to push the
• Remove the Coverslip transfer head:
central well down, to ensure that the xylene
levels are consistent.
C. Make sure that the central well re-seats
itself properly.
• When finished, close the Access door and press
the Complete key on the screen.

Identify the Coverslip transfer head and loosen the

thumbscrew by turning it anti-clockwise.

ClearVue Service Manual Issue 08 110

 • Ensure that all Mountant is cleared from the
inside of the suction cup, especially the bellows.
A cotton-bud (Q-tip) can be used to wipe the
internal surfaces.

Pull the thumbscrew out to release the coverslip

transfer head. • Remove the suction cup from the xylene and
allow to air-dry. Make sure the suction cup is fully
dry before refitting.
Refit the suction cup:

• Push it onto the suction cup fitting.

Note the position of the Coverslip transfer head and • Ensure the suction cup protrudes from the base
then remove it from the Location pins. of the coverslip transfer head.

• Remove the Suction cup by pushing down from

the top of the rubber

• Replace the Coverslip transfer head:

Clean the suction cup:

• When removed from the coverslip transfer head,
soak the suction cup in xylene.

ClearVue Service Manual Issue 08 111

Reposition the Coverslip transfer head as required. Cleaning the Slip Dispense
Carriage
To clean the Slip Dispense carriage:
• Open the Access door.

Replace the Coverslip transfer head onto the

Location pins in either the Default or Central • Remove the Coverslip hopper by pulling it
position. Tighten the Thumbscrew by turning it
towards the front of the ClearVue and then lifting
clockwise
it gently upwards.

• Without turning the Coverslip hopper upside

down, check the bottom of the Hopper for any
The Reference mark on the top of the Coverslip
broken Coverslips.
transfer head indicates which position it is in: either
the Default or End position.
Broken glass may be present!

Carefully remove any broken coverslips.

• Using the Brush provided, clear the top of the
Slip dispense carriage of any glass debris.

ClearVue Service Manual Issue 08 112

• Make sure the Groove and vacuum ports are
clear of glass dust. If the Vacuum ports are
blocked use an implement (less than 1mm
(0.039”) dia.) to push the blockage through.

• Remove the Slip Dispense skirt and clean in the

recess, refer to the Cleaning the Slip Dispense
Skirt section.
• Move the Slip Dispense Carriage forwards if
necessary by pressing the Access button on the
Mountant Screen and then following the steps
given in the Fill the Dispense Head Cleaning
Station section for access to the Dispense Head
Cleaning Station.

ClearVue Service Manual Issue 08 113

Cleaning the Mountant • Screw the needle assembly back in by hand.

Dispense Needle
Take precautions when dealing with
Xylene!

Remove the mountant dispense needle assembly:

• Open the Access door.

Take care not to screw the Mountant

dispense needle assembly in cross-
threaded as this will damage the
support arm.

Do not use a wrench.

After cleaning:
• Flush the system
• Unscrew the Mountant dispense needle
assembly and lift it out of the Support arm. Ensure the Dispense head cleaning
station is topped up

Do not disconnect the tubing!

Clean and replace the dispense needle:

• Place the needle assembly in a container of
xylene and allow to soak overnight.
• When the Needle is clean, replace the Mountant
dispense needle assembly in the Support arm.

ClearVue Service Manual Issue 08 114

Cleaning the Touch Screen Cleaning the Slip Dispense Skirt
Do not use solvents to clean the touch If the Slip dispense skirt becomes covered in glass
screen. Wiping the touch screen when dust it can be removed and cleaned.
the Cleaning screen is NOT displayed Clean the Slip Dispense skirt:
may cause unexpected results
• Open the Access door.
To clean the touch screen display:
• From the Main menu press the Options key on
the touch screen.

• Press the Clean key.

• Identify the slip dispense skirt.

• The Cleaning screen displays, in which it is

possible to touch the screen without any effect.
A countdown timer shows how long the cleaning
screen will continue to be displayed for.

• Lift the Slip Dispense Skirt out of the Mounting

slot.
• Wipe any glass dust off the Slip dispense skirt
with a dry paper towel.
• Replace the Slip Dispense Skirt into the
mounting slot and ensure that it is pushed fully
• To clean the touch screen, wipe with a soft, down so that it rests on the lower Location pin.
water-damp cloth. Thoroughly dry using a lint-
free cloth.

ClearVue Service Manual Issue 08 115

 Pay particular attention to the areas
Cleaning the Gripper Return where the plate contacts any other
surfaces.
Plate
Ensure that the Gripper return plate
Take precautions when dealing with can move freely from side to side.
Xylene!
If the Gripper return plate is heavily contaminated
To clean the Gripper return plate in-situ: with Mountant, remove it for a more thorough clean:
• Open the Access door. • Locate the Gripper return plate.
• Using the protruding handle, pull the Gripper
return plate to the right and then up. It should
now lift off its Location pins:

• Locate the Gripper return plate.

• Soak the Gripper return plate in xylene to remove
any Mountant. Use xylene to clean the Location
pins and other contact areas.
• Replace the Gripper return plate:

Ensure that the Gripper return plate

can move freely from side to side.

• Use a pipette to drip xylene onto the Gripper

return plate.

ClearVue Service Manual Issue 08 116

Cleaning the Slide Grippers
The Slide grippers remove the slides from the
Basket and hold them in place during coverslipping.
They are self-cleaning and should only require
manual cleaning during the annual service.

However, in certain situations it may be necessary

to perform additional cleaning; particularly in the
following cases:

• Excessive overspill of Mountant

• Mountant spraying due to failure to top up the
Mountant Bottle
• Debris stuck in the Gripper Jaw
Do not, under any circumstances, use
abrasive cleaners, abrasive materials
or unapproved solvents to clean the • Remove the Gripper return plate.
painted surface of the Long gripper. • Remove any debris from the 'V’ in each Gripper.

Damage to the painted surface of the

Do not use force to remove debris
Long gripper will impair the
performance of the ClearVue, and
may, in extreme cases cause the • If the debris is stuck with dried Mountant, use a
instrument to stop functioning or break pipette to apply xylene to soften the Mountant to
slides. allow removal.
• Use a xylene-damp cloth to wipe any dried
Take precautions when dealing with Mountant from the Slide grippers. Pay particular
Xylene! attention to both of the surfaces of the ’V’ on
both of the Gripper jaws.
To clean the Slide grippers:

• Switch off the ClearVue.

• Open the Access door.

• Identify the Slide grippers. To improve access to

the Slide grippers, push the Basket unload
bracket as far over to the left as it will go.

ClearVue Service Manual Issue 08 117

Cleaning the Coverslip Transfer
Head
Take precautions when dealing with
Xylene!

If the internal airway in the Coverslip transfer head

becomes blocked it can be cleaned as follows:

• Remove the Coverslip transfer head:

Note the position of the Coverslip Transfer Head

and then remove it from the Location pins.

• Detach the Pneumatic pipe from the top of the

Coverslip transfer head: hold down the blue
portion of the Pneumatic connector and pull out
the Pneumatic pipe.

Identify the Coverslip transfer head and loosen the

thumbscrew by turning it anticlockwise

• Ensure that the internal airway is free from

blockages such as glass debris or dried
Mountant. The Coverslip transfer head can be
soaked in xylene to aid removal of dried
Mountant.
Pull the thumbscrew out to release the coverslip • Once clean, remove the Coverslip transfer head
transfer head. from the xylene and allow to air-dry.

ClearVue Service Manual Issue 08 118

• Refit the Coverslip transfer head making sure Failure to ensure that the Pneumatic
that the Pneumatic pipe is fully inserted into the Pipe is properly connected may result
Pneumatic connector: in poor coverslipping performance
Reposition the Coverslip transfer head as required.

Cleaning the Camera

Never use solvents or water to clean
the camera. Never clean the camera
with the ClearVue switched on.

To clean the Camera:

• Switch off the ClearVue.

• Open the Access door.

Replace the Coverslip transfer head onto the

Location pins in either the Default or Central
position. Tighten the Thumbscrew by turning it
clockwise.

• Push the Basket-Open bracket to allow access

to the Camera.

The Reference mark on the top of the Coverslip

transfer head indicates which position it is in: either
the Default or End position.

• Carefully wipe the Camera lens using a lint-free

cloth.
• Close the Access door and restart the ClearVue.

Note
Note
Cleaning the camera is Not a routine maintenance
Pull firmly on the Pneumatic pipe to check that it is
task, and should only be done if advised by a
correctly fitted into the Pneumatic connectors.
Epredia Service Engineer.

ClearVue Service Manual Issue 08 119

Chapter 8 – Troubleshooting
• Telephone Support
• Error Screens
• Perform a Bead Test
• Identifying problems with Slides
• Troubleshooting Tables
• Machine Dead - No Power
• Dispense Needle Dirty/Blocked
• Slide Jams
• Coverslip Misdispense
• Coverslip Misdispense (cont'd)
• Breaking Coverslips
• Basket Jams
• Breaking Slides
• Mountant Overspill
• Skewed Coverslips
• Slides not Coverslipped
• Part Broken Coverslips
• Slides too Wet
• Diagnosis Flowchart

ClearVue Service Manual Issue 08 120

Telephone Support Error Screens
If you cannot resolve a problem using the If an error occurs an alert will be displayed on the
information contained within this Service Touch screen.

Manual, please call one of the following numbers.

Note
Please have a description of the fault, system
settings and symptoms to hand when calling.

Region Telephone

Main Epredia Support 1 800 253 7837

Number, United States Pressing the flashing Error message will display an
Error Screen which provides one or more of the
Main Epredia Support +44 (0) 1928 539 following options to rectify the error.
Number, International 000

The specific Error Screens explain the options

available.
If it is necessary to call the Epredia Service
Department they will ask for the Engineer’s Code
which is displayed in the top, right-hand corner of
the Error screen.

ClearVue Service Manual Issue 08 121

The following are screen-shots of the error screens
which may be encountered during the operation of
ClearVue.

ClearVue Service Manual Issue 08 122

ClearVue Service Manual Issue 08 123
ClearVue Service Manual Issue 08 124
Quick Reference to Errors
• When an error occurs, the flashing Error Number
shown on the Main Menu screen is the Operator
Code for the error.

• Pressing the flashing Error Number will display

the Error Screen relevant to the error
encountered.
• There will be a number in brackets in the top,
right-hand corner of the screen - this is the
Engineers Code for the error.

• The attached list cross-references each

Operator Code with the Engineers Code.
• The meaning of each Engineers Code is also
given.

ClearVue Service Manual Issue 08 125

Error Code Cross-Reference Table
Operator Engineers
Fault Description
Code Code

1 Failed to load basket onto the lift block

1 2 Failed to return to home sensor
3 Failed to initialise the input rail
60 Stall recovery failure
2 61 Failed to initialise
62 Failed to return within 5 quads from home
30 Stall moving to basket identity
31 Stalled moving to first slide position
32 Stalled moving to just closed a little
33 Stalled moving to fully closed
3 34 Stalled moving to aligned with output rail
35 Stalled returning home
36 Moving to align with input rail
37 Stalled moving to next slide position
38 General fail during initialisation or running
140 Stall moving to eject position
141 Stall returning to home after an eject
4
142 Stall moving to clear position for camera pictures
143 Failed to confirm basket eject at home position
5 90 Stalled removing slide from basket
6 91 Stalled returning slide to basket
7 111 Failed to obtain good slip
200 Failure to keep pressure during load cycle
8
204 During load cycle, pressure of bottle reached too quickly indicating blocked pipe/valve
201 During mountant load cycle, pump drift too large
9 202 Failure to initialise mountant pump
203 Failure to dispense the correct amount of mountant
160 No vac on prep head after picking up slip
10 165 No vacuum on prep head
169 Vac released too quickly on prep head
161 Failure to release vac on preparation
11
162 Bad vacuum levels seen on prep head
163 Prep rotation stalled
12
168 Failure to initialise prep head

ClearVue Service Manual Issue 08 126

Operator Engineers
Fault Description
Code Code

164 Head position wrong, tested on init and just before basket open
13
167 Head position wrong just before taking basket up lift

14 165 Request user to remove slide and continue

180 Failure to see optos in correct sequence

15 181 Failure to see optos in correct sequence

182 Failure to see optos in correct sequence

16 112 Bad vacuum seen on carriage > 3 times during processing

17 260 Battery switch in incorrect position

During power failure recovery, the input door is opened suggesting further baskets
18 20
are to be loaded

19 240 No filter found

248 Failure to load FPGA code

20 291 Touch Screen Error

205 Failed to load profile data information

21 247 Unprocessed basket warning

22 113 Stall moving to position

92 Stalled during initialisation

23 93 Failed to see home sensor when returning home

95 Failure to measure slide width

252 Failed to find gripper jaw in initialisation

24
39 Failure to calculate basket tops

25 253 Failed to locate gripper jaw

26 94 Slide too wide alarm. User will be alerted at the end of basket processing

ClearVue Service Manual Issue 08 127

Perform a Bead Test
The Bead Test is used to lay down lines of Mountant
on slides, which remain un-coverslipped to allow
inspection of the dispense quality.
Note
The Bead Test will typically lay down a line of
Mountant suitable for the last type of coverslips that
• The image of the coverslip will disappear and the
were used during processing.
ClearVue will emit an ascending tone.
If the instrument has just been switched On, or the • Close all the doors to begin processing the
Clear Count button on the Main Menu has been Basket.
pressed, the Bead Test will lay down a line of
• When processing is complete, remove the
Mountant in the default position (50mm coverslip,
Basket and lay the slides out on a flat surface.
end position).
Note
To perform a Bead Test:
The Mountant will run when it is still a liquid, so
• From the Main menu press the Options key on
ensure the slides are kept flat at all times.
the Touch screen.
Check the quality of the prepared slide, refer to the
Identifying Problems with Slides section.

• Press the Slip Position key.

• Open all 4 doors on the instrument.

• Place a Basket of dry slides on the Load rail. Do
not close the Load door.
• Touch the image of the coverslip.

ClearVue Service Manual Issue 08 128

Identifying Problems with Slides Note

The quality of prepared slides can be used to help

There may be a slight variation in the position of the
troubleshooting on the ClearVue. Any problems can
Coverslip depending on the quality of the Coverslips
then be solved either by the operator or by a Service used.
Engineer.

The two states which can be observed are:

• Quality of Mountant dispense (refer to the Carry

out a Bead Test section)
• Quality of coverslipped slide

Correct Mountant dispense appearance:

• Small initial drop

• Uniform middle strip of Mountant
• Larger drop at end, close to, but not
encroaching on the frosted area
The Diagnosis flowchart is intended to aid in the
diagnosis of problems relating to the quality of the
Mountant dispense, refer to the Diagnosis Flowchart
section.

Correct appearance of coverslipped slide:

• Minimal overspill of Mountant at the frosted end

of slide
• Coverslipped area free from bubbles
• Coverslipped area totally covered in Mountant
• Minimum Mountant overspill over the rest of the
coverslip perimeter
• Coverslip positioned correctly on slide

ClearVue Service Manual Issue 08 129

Excessive Bubbles
Select the image which most closely resembles the appearance of the coverslipped slide or mountant bead.

ClearVue Service Manual Issue 08 130

Prepared Slides – Troubleshooting

Description of Slide Possible Cause Solution

• Check decay setting (refer to the Vacuum

System Test section).
• Compare with the customers decay time found
in the Log file (Refer to the Engineer’s Log
Extraction section).
• Remove the suction cup and check that the
profile of the lip is flat, even and undamaged.
• Replace the suction cup if necessary (refer to the
Cleaning the Suction Cap section).

Do the following:
• Check that the coverslip transfer head hard-stop
Coverslip placement not
is clean.
controlled - coverslip is
dropped quickly into the • Coverslip transfer head should not have tight-
mountant and xylene. spots when rotated (refer to the Inspecting the
Coverslip Transfer Head section).
• Check, and adjust if necessary, the coverslip
Multiple bubbles visible at transfer head sprung pads (refer the Checking
non-frosted end of slide and Adjusting the Coverslip Transfer Head
Sprung Pads section).
• Check, and adjust if necessary, the coverslip
transfer head hard-stop (refer to the Checking
and Adjusting the Coverslip Transfer Head Hard
Stop section).
• Re-initialise the coverslip transfer head (refer to
the ENG Tab – Page 4/7 section) and watch the
preparation of a cleared slide.

Use 40mm coverslips or replace original transfer

head.
Using the offset coverslip
transfer head with the Check, and adjust if necessary, the coverslip
wrong size coverslips. transfer head hard-stop (refer to the Checking and
Adjusting the Coverslip Transfer Head Hard Stop
section).

Standard coverslip
transfer head and offset Check, and adjust if necessary, the coverslip
coverslip transfer head transfer head hardstop (refer to the Checking and
swapped without hard- Adjusting the Coverslip Transfer Head Hard Stop
stop being adjusted to section).
suit.

ClearVue Service Manual Issue 08 131

Description of Slide Possible Cause Solution

Remove Suction cup and clean using a xylene-

damp cloth.
Note
Suction cup Dry suction cup fully before refitting.
contaminated or broken
Replace Suction cup

Ensure pipe to Coverslip transfer head is properly

inserted

Offset coverslip transfer Use only 40mm coverslips, or replace the offset
head used with incorrect coverslip transfer head with original (black or silver
size coverslip coloured)

Offset coverslip transfer

head put onto early
Call Epredia Service department for advice.
production model (silver in
colour)

Carry out a bead test (refer to the Perform a Bead

Poor mountant bead.
Test section).

Coverslip placement not

Remove the coverslip transfer head and clean the
controlled – not releasing
sprung pads and suction cup.
the coverslip correctly.

• Remove the sprung pads.

• Clean the pins and holes.

Straight line of bubbles
down the length of slide • Lubricate the pins with silicon lubricant or
Sprung pads not
microtome oil.
moving freely
• Refit sprung pads and check (refer to the
Inspecting the Coverslip Transfer Head section
and the Checking and Adjusting the Coverslip
Transfer Head Sprung Pads section).

Remove Suction cup and clean using a xylene-

Suction cup damp cloth
contaminated with
Note
Mountant
Dry suction cup fully before refitting

Dispense Head too high Perform Bead test

Air in Pipes or Syringe Flush system to ensure bubbles have been expelled

ClearVue Service Manual Issue 08 132

Description of Slide Possible Cause Solution

• Ensure good laboratory practice.

• Check stainer for good liquid levels and cleanliness

Stainer reagent
(xylene > alcohol > water).
contamination.
• Check carryover, especially contamination droplets in
xylene or alcohol.

• Check the dispense head cleaning station - remove,

clean and refill with fresh xylene (refer to the Cleaning
Instrument
the Dispense Head Cleaning Station section).
contamination.
• Wipe the dispense head needle with xylene before
replacing the dispense head cleaning station.

• Flush the system with xylene twice.

Mountant contamination • Replace mountant with fresh from an unopened bottle.

• Flush through system.

Multiple non-uniform
bubbles Poor mountant bead Carry out a bead test (Carrying out a Bead Test section).

• Check decay setting (refer to the Vacuum System Test

section).

Coverslip placement not • Compare with the customers decay time found in the
• Often down one side controlled - coverslip is Log file (refer to the Engineer’s Log Extraction section).
of slide dropped quickly into the • Remove the suction cup and check that the profile of
• Various sizes of mountant and xylene. the lip is flat, even and undamaged.
bubbles
• Replace the suction cup if necessary (refer to the
Software Update section).

Uneven flow when

placing the coverslip, Place a spirit level on the output rail and adjust the feet to
due to uneven slide level the instrument (see Instrument Levelling Instructions).
drying.

Check quality and levels of staining reagents, and replace

Contaminated reagents
if necessary.

Ensure that all chemicals used are on the Approved

Incompatible chemicals Reagents list
used If problems persist contact your Epredia Scientific
Representative for advice.

Instrument not level Level instrument using the levelling feet.

ClearVue Service Manual Issue 08 133

Description of Slide Possible Cause Solution

Carry out a bead test (refer to the Carrying out a Bead

Poor mountant bead.
Test section).

• Check decay setting (refer to the Vacuum System

Test section).

• Compare with the customers decay time found in

the Log file (refer to the Engineer’s Log Extraction
section).

• Remove the suction cup and check that the profile

of the lip is flat, even and undamaged.

• Replace the suction cup if necessary (refer to the

Software Update section).

Do the following:

Coverslip placement not • Check that the coverslip transfer head hard-stop is
controlled - coverslip is clean.
dropped quickly into the • Coverslip transfer head should not have tight-spots
Single bubble at Non-
mountant and xylene. when rotated (refer to the Inspecting the Coverslip
frosted end of slide
Transfer Head section).

• Check, and adjust if necessary, the coverslip

transfer head sprung pads (refer to the Checking
and Adjusting the Coverslip Transfer Head Sprung
Pads section).
Often located underneath
the Suction cup • Check, and adjust if necessary, the coverslip
transfer head hard-stop (refer to the Checking and
Adjusting the Coverslip Transfer Head Hard Stop
section).

• Re-initialise the coverslip transfer head (refer to the

ENG Tab – Page 4/7 section) and watch the
preparation of a cleared slide.

Too much mountant in Blob

1 at non-frosted end of Check mountant volume setting (default is 13).
slide.

Mountant not flowing on Check mountant type against approved reagent list.
slide correctly (thick
mountant). Check temperature of lab is >17°C.

Dispense head needle

height intermittently Check slides are secure in gripper jaws (refer to the
changing due to slide Inspecting the Slide Grippers section).
moving in gripper jaws.

ClearVue Service Manual Issue 08 134

Description of Slide Possible Cause Solution

• Use 40mm coverslips or replace original transfer

head.
Using the offset coverslip
transfer head with the wrong
• Check, and adjust if necessary, the coverslip
size coverslips.
transfer head hard-stop (refer to the Checking and
Adjusting the Coverslip Transfer Head Hard Stop
section).

Standard Coverslip transfer

head and offset coverslip Check, and adjust if necessary, the coverslip transfer
transfer head swapped head hard stop (refer to the Checking and Adjusting the
without hardstop being Coverslip Transfer Head Hard Stop section).
adjusted to suit.

Dispense Head too high Check Dispense Head is fully screwed down

Contact Epredia Scientific Service department

Remove and clean Suction cup using a xylene-damp

cloth
Suction cup contaminated
with Mountant Note
Dry suction cup fully before refitting

Offset Coverslip Transfer Use only 40mm coverslips, or replace the Offset
Head used with incorrect Transfer Head with the original one (black or silver
size coverslip coloured)

Offset Coverslip Transfer

Head put onto early
Call Epredia Service Department for advice
production model (silver in
colour)

ClearVue Service Manual Issue 08 135

Description of Slide Possible Cause Solution

Carry out a bead test (refer to the Carrying Out a Bead

Poor mountant bead.
test section).

Coverslip contacting
Carry out Production Test 6 and check the position of
mountant too soon, while at
coverslip pick-up.
high speed.

Blob 2 at frosted end of slide

is too large, causing
coverslip to contact Check mountant volume setting (default is 13).
mountant too soon, while at
high speed.

Mountant not flowing on Check mountant type against approved reagent list.
slide correctly (thick
mountant). Check temperature of lab is >17°C.

Angle of coverslip is too

Check and adjust coverslip transfer head sprung pads
great, causing coverslip to
(refer to the Checking and Adjusting the Coverslip
contact mountant too soon,
Transfer Head Sprung Pads section).
while at high speed.

Single bubble at Frosted Coverslip contactings

end of slide mountant too soon because
slow speed position is too Check and adjust coverslip transfer head hard-stop
low relative to the slide, due position (refer to the Checking and Adjusting the
to incorrect fitting of Coverslip Transfer Head Hard Stop section).
coverslip transfer head
hard-stop

Check Dispense Head is fully screwed down

Dispense Head too high
Contact Epredia Service department

Remove and clean Suction cup using a xylene-damp

cloth
Suction cup contaminated
with Mountant Note
Dry suction cup fully before refitting

Offset Coverslip Transfer Use only 40mm coverslips, or replace the Offset
Head used with incorrect Transfer Head with the original one (black or silver
size coverslip coloured)

Offset Coverslip Transfer

Head put onto early
Call Epredia Service Department for advice
production model (silver in
colour)

ClearVue Service Manual Issue 08 136

Description of Slide Possible Cause Solution

Contamination from
Clean the instrument, ensuring all broken glass and dried
debris within the
mountant is removed.
instrument.

Thick or uneven
specimen causing
Check quality of specimen being coverslipped.
coverslip to lift off the
slide.

• Check for print quality on the slide - consider using

Thick or uneven printing slides with no printing in the section area.
causing coverslip to lift off
• Increase mountant volume setting.
the slide.
• Increase the decay time.

• Check for compatibility of all reagents and advise

customer if necessary.

• If unsure about contamination do the following:

Contamination / • Flush the system with xylene.
Distinct area with no incompatible reagents.
• Reload mountant.
mountant
• Clean and refill the dispense head cleaning station.

• Clean and refill transfer pots.

• Check mountant volume setting (default is 13).

Not enough mountant to
cover the slide. • Increase if necessary, but if customer is worried about
• Area of coverslip is not
overspill, refer to the Mountant Overspill section.
stuck to slide
• Ensure correct level of xylene in xylene tray.

Check the lab processes:

• Do they load multiple baskets onto the load rail?

Contamination or
excessive drying of slide. • Do the slides remain in air for an extended period of
time.

• What is the transfer medium.

• Are they cleaned thoroughly in clearing agent etc.

Debris under the Ensure coverslips are free from debris and dust
coverslip Ensure Slip Dispense Area is free of debris and dust

Ensure an appropriate amount of Mountant is being

Very low volume on dispensed
Mountant, AND slide is
Ensure Xylene Tray is Filled
very dry
Ensure slides are appropriately coated with xylene

ClearVue Service Manual Issue 08 137

Description of Slide Possible Cause Solution

Strip of no mountant

Poor quality (bowed)

Replace with better quality (non-bowed) coverslips
coverslips

• A distinct line of
coverslip is not stuck to
slide

Good bead. Ensure the None required

whole basket looks like
this. If in doubt, do more!

Inappropriate mountant Check mountant volume setting (default is 13).

volume dispensed onto
the slide.

Unapproved mountant Check mountant against Approved Reagent List.

with an extreme of
viscosity or characteristic
which is not compatible.

Mountant dispense Check slides are held securely in the gripper jaws (refer
needle height changes to the Inspecting the Slide Grippers section).
intermittently due to slide
moving in gripper jaws.

Mountant dispense Check, and adjust if necessary, the dispense needle

needle too high from height (refer to the Checking and Adjusting the Needle
slide, allowing mountant Height section).
to form a drop before
contacting the slide.

Excessive backlash in Inspect the mountant pump actuator and syringe

mountant system. assembly (refer to the Inspecting the Mountant Pump
Actuator and Syringe section).

Wrong version of profile Confirm that the pump profile version is correct (refer to
with incorrect suckback. the Checking Software, FPGA and Pump Profile Version
section).

ClearVue Service Manual Issue 08 138

Description of Slide Possible Cause Solution

Old mountant which has • Confirm the age and history of the mountant and the
been left for a long usage of the instrument.
period, or with no lid,
allowing the viscosity and • If in doubt, flush the system with xylene twice, then
characteristics to replace mountant with fresh from an unopened bottle
change. and flush through the system.

• Check if the customer has used the instrument with a

Air drawn into mountant very low volume of mountant (or none at all) in the
line from bottle. mountant bottle.
Compression of air • If so, ensure mountant levels are correct and flush
causes misdispense. system until all air has been expelled (refer to the
Inspecting the Mountant Bottle and Lines section).

Unapproved mountant
with an extreme of
Check mountant against Approved Reagent List.
viscosity or characteristic
which is not compatible.

• Check the dispense head cleaning station

• Remove, clean and refill dispense head cleaning

Contamination.
station with fresh xylene if necessary.

• Wipe the dispense head needle with xylene before

replacing the dispense head cleaning station.

Blocked dispense head

causing a build-up of Inspect the dispense head needle (refer to the Inspecting
pressure and the Mountant Dispense Head and Needle section).
misdispense.

ClearVue Service Manual Issue 08 139

Description of Slide Possible Cause Solution

Inappropriate mountant
volume dispensed onto Check mountant volume setting (default is 13).
the slide.

Unapproved mountant
with an extreme of
Check mountant against Approved Reagent List.
viscosity or characteristic
which is not compatible.

Mountant dispense
needle height changes Check slides are held securely in the gripper jaws (refer
intermittently due to slide to the Inspecting the Slide Grippers section).
moving in gripper jaws.

Mountant dispense
needle too high from Check, and adjust if necessary, the dispense needle
slide, allowing mountant height (refer to the Checking and Adjusting the Needle
to form a drop before Height section).
contacting the slide.

Inspect mountant bottle and line (refer to the Inspecting

Air in system.
the Mountant Bottle and Lines section).

ClearVue Service Manual Issue 08 140

Description of Slide Possible Cause Solution

• Dispose of the Mountant

• Flush the system with Xylene

Old Mountant
• Refill the Mountant bottle from a new, unopened
bottle of approved Mountant and Flush through
the system

• Dispose of the Mountant

Contaminated Mountant
• Flush the system with Xylene
(via thinning)
• Refill the Mountant bottle and Flush through the
system

Microbubbles • Dispose of the Mountant

Unapproved Mountant
with an extreme of • Flush the system with Xylene
viscosity
• Refill the Mountant bottle with an approved
Mountant and Flush through the system

• Ensure Xylene tray is topped up

• Carry the baskets to the ClearVue immersed in

Xylene and drain gently before loading onto the
input rail
Slides too dry
• Ensure errors are cleared promptly, or abort the
basket and store in Xylene while the error is
resolved

• Load one basket at a time

Replace the Stainer Reagents ensuring the water

Water/alcohol
level is lower than the alcohol (which is lower than
contamination from
the Xylene). Ensure the alcohol concentrations are
Stainer
correct.

ClearVue Service Manual Issue 08 141

Diagnosis Flowchart

ClearVue Service Manual Issue 08 142

Troubleshooting Tables
• Machine Dead – No Power
• Dispense Head Dirty
• Coverslip Position Wrong on Slide
• Mountant Overspill
• Mountant Dryback
• Dispense Needle Dirty/Blocked
• Slide Jams
• Coverslip Mis-Dispense
• Breaking Coverslips
• Basket Jams
• Breaking Slides
• Skewed Coverslips
• Slides not Coverslipped
• Part Broken Coverslips
• Slides too Wet

ClearVue Service Manual Issue 08 143

Machine Dead – No Power
Problem Possible Cause Remedy

Instrument is still
carrying out initial • Wait 30 seconds for the initial tests to finish.
tests.

• Connect the power lead.

No Mains power
supply. • Switch on the Mains power and instrument main power
switch.

• Check the fuse in the Mains lead and replace if necessary.

The Mains fuses have
The ClearVue
blown.
does not
respond when • Check the instrument fuses and replace if necessary.
the mains power
is switched on
• Remove the instrument rear panel and electronics box cover.
Internal fuse has
blown.
• Check internal fuses on the main board and replace if
necessary (refer to the Fuse Replacement section).

• Check that Mains power (a.c.) is reaching the input terminals.

• Check for power on the power supply output terminals

Power supply fault. (24VDC).

• Check the wiring from the power supply to the main board.

Check that the LEDs on the edge of the main board are on,
indicating that the following voltages are present (top to bottom):

• 15 V
• 24 V
• 12 V
• VCC (5 V)
Other power faults. • 3.3 V

Notes
The 24 V indicator LED will only be lit once the system has booted
and is running normally.
If the 15 V, 12 V, VCC or 3.3 Vindicator LEDs are not lit, replace
the main board (refer to the Main PCB, Interconnect PCB and
Processor PCB section).

ClearVue Service Manual Issue 08 144

Problem Possible Cause Remedy

If the 15 V, 12 V, VCC and 3.3 V indicator LEDs are lit, but the 24
V indicator LED fails to come on after approximately 30 seconds,
carry out the following sequence:

Processor fault. • Check that the interconnect board is correctly mated with the
processor board and with the main board.

• Re-program the processor board.

• Replace the processor board.

Instrument in
Standby mode; Touch the screen to switch instrument out of Standby mode.
screensaver ON.

If the 15 V, 12 V, VCC and 3.3 V indicator LEDs are lit, but the 24
V indicator LED fails to come on after approximately 30 seconds,
carry out the following sequence:
• Check that the interconnect board is correctly mated with the
Processor fault. processor board and with the main board.

• Re-program the processor board.

ClearVue is
• Replace the processor board.
powered ON but
the screen is If the 15 V, 12 V, VCC and 3.3 V indicator LEDs are lit, and the 24
blank. V indicator LED comes on after approximately 30 seconds, carry
out the following sequence:
• Check the ribbon cable from the main board to the display
board.

Display fault. • Remove the instrument covers and check the flex cable
between the display board and the display.

• Check the cables to the backlight inverter.

• Check the display board; inverter and display then replace as

necessary (refer to the Display PCB section, the Inverter PCB
section and the Touch Screen or Proximity Switch section).

ClearVue Service Manual Issue 08 145

Dispense Head Dirty
Problem Possible Cause Remedy

Dispense head Mountant build-up on Remove and clean the dispense head (refer to the Cleaning the
dirty. dispense head. Dispense Head Cleaning Station section).

Coverslip Position Wrong on Slide

Problem Possible Cause Remedy

Place a spirit level on the output rail and adjust the feet to level the
Instrument not level.
instrument (see Instrument Levelling Instructions).

Coverslip position left

Reset the coverslip position to 0 (refer to the Adjust the Coverslip
at an extreme (eg: -1,
Position section) and test the coverslip position again.
+1).

Gripper return plate is Remove and clean the gripper return plate (refer to the Cleaning
stuck the Gripper Return Plate section).

Check the required coverslip position with the customer and then
40mm coverslip ensure that the coverslip transfer head is correctly positioned
position set (refer to the Change the Coverslip Transfer Head Position section).
incorrectly. Ensure the software and transfer head position are consistent
(refer to the Select the Coverslip Position section).

Coverslip Wrong size of Ensure approved coverslips are used (refer to the Compatibility
position wrong coverslip or slide. section).
on slide.
Set coverslip position to 0 (refer to the Adjust the Coverslip
Machine settings
Position section).
have changed due to
new or refitted parts. Run Production Test 6 to set the coverslip position.

Replace and set the gripper jaws (refer to the Checking and
Worn gripper jaws.
Adjusting Gripper to Gripper Alignment section).

Check that coverslip transfer head is screwed in correctly (see

Excessive movement
Operator Guide Section 3-3).
of coverslip transfer
head. Check that the circlip is in place.

Worn nut causing

excessive end float Replace the gripper actuator (refer to the Gripper Actuator
on the gripper drive section).
motor.

ClearVue Service Manual Issue 08 146

Mountant Overspill
Problem Possible Cause Remedy

Mountant volume Check that mountant volume setting is between 10 and 15 (refer
set too high. to the Adjust the Mountant Dispense Volume section).

Baskets are too

Ensure baskets are drained at 45° and blotted on absorbent paper
'wet' when placed
before being loaded.
onto the load rail.

Coverslip position is
Ensure there is a 2mm gap between the coverslip and the end of
too close to the side
the slide, and that the coverslip sits centrally.
/ end of the slide.

Place a spirit level on the output rail and adjust the feet to level the
Mountant Instrument not level.
instrument (see Instrument Levelling Instructions).
overspill
Suction cup sitting
too low on the Ensure suction cup is fitted correctly (refer to the Cleaning the
coverslip transfer Suction Cup section).
head.

Check that slides are sitting correctly in the gripper jaws.

Coverslip transfer
head hard-stop
Check the hard-stop height and adjust if required (refer to the
height incorrect.
Checking and Adjusting the Coverslip Transfer Head Hard Stop
section).

ClearVue Service Manual Issue 08 147

Mountant Dryback
Problem Cause Solution

Insufficient volume Check that mountant volume setting is between 10 and 15 (refer
of mountant to the Adjust the Mountant Dispense Volume section).

Debris under the Clean the instrument of any debris.

coverslip.
Ensure the staining process is free from debris

Very thick specimen Increase the mountant volume (refer to the Adjust the Mountant
under the coverslip. Dispense Volume section).
Mountant dryback
Check that the stainer is set up correctly and allows sufficient
Poor clearing
clearing.

Incorrect clearing Ensure that the stainer is using the recommended clearing
agent used. agents.

Incorrect mountant
Only use recommended mountant.
used.

Excessive bubbles Refer to the Excessive Bubbles section.

Dispense Needle Dirty/Blocked

Problem Cause Solution

Low xylene level in Dispense head

Refill the Dispense head cleaning station fully
cleaning station

Mountant Use an approved Mountant

Quick drying Mountant has
dispense needle
formed a skin on the Needle
dirty/blocked Contact your Epredia Product Specialist for advice

Dispense head cleaning station

Call Epredia Service Team for support
not functioning correctly

ClearVue Service Manual Issue 08 148

Slide Jams
Problem Cause Solution

Incorrect size of slide used -

Use correct size of slide (refer to the Compatibility
slide jams or breaks in slide
section).
guide.

Skewed slide loaded in

Ensure all slides are loaded into baskets correctly.
basket.

Chipped or broken slide Ensure only undamaged slides are loaded onto the
loaded into basket. instrument.

Basket slider is not fully

Ensure the slider is fully closed prior to loading basket.
closed.

Gripper return plate stuck or Remove and clean gripper return plate (refer to the
fitted incorrectly. Cleaning the Gripper Return Plate section).

Damaged, broken or worn

Replace basket.
basket.

Build-up of dried mountant

Clean or replace basket.
on basket.

Inspect and clean if necessary (refer to the Cleaning the

Dirty camera lens.
Camera section).
Slide Jams
Excessive build-up of
mountant on the gripper Inspect and clean if necessary.
jaws.

Paint on long gripper Replace long gripper jaw (refer to the Gripper Jaws
damaged. section).

Align gripper jaws (refer to the Checking and Adjusting

Gripper jaws misaligned.
Gripper to Gripper Alignment section).

Spring plunger of vertical lift

Clean or replace spring plunger.
block is stuck.

Basket not in correct position

Run Production Test 5 to set Parameter 92.
for removing slide.

• Check Log file to ensure basket open quads are

Basket open assembly not always >11005.
pulling basket slider fully clear
• Inspect basket open assembly for mountant build-up.
of slides.
• Check motor, encoder and sensor functions.

Worn slide guide not

Inspect slide guide and replace if necessary.
positioning slides correctly.

ClearVue Service Manual Issue 08 149

 Problem Cause Solution

Worn gripper arms. Inspect gripper arms and replace if necessary.

Bent basket unload bracket. Inspect unload bracket and replace if necessary.

Excessive end float causes

basket to be in wrong Check for end float on vertical lift lead screw. Reach in
position for 1st slide, gripper and try to move lift block up and down; any movement
hit basket and create error greater than 0.05mm is excessive. Refer to the Lift Block
5[90] 'general grippers stall Leadscrew section for setting end float.
moving to slide out position'.

Other error Call Epredia Service Team for support

Coverslip Mis-Dispense
Problem Cause Solution

Failure to remove hopper

during power-up, purge, Ensure hopper is removed during power-up, purge,
flush and access dispense flush and access dispense head functions.
head functions.

Hopper empty. Load new hopper.

Debris in bottom of hopper. Clear broken coverslips from bottom of hopper.

Inspect coverslips in hopper.

Coverslips stuck together in
Remove troublesome slips.
hopper.
Replace hopper if necessary.

Debris on coverslip dispense

Coverslip mis- Clean coverslip dispense carriage.
carriage.
dispense
Debris on deck below
Clean area under and around hopper.
hopper.

Build-up of dried mountant

on coverslip dispense Clean coverslip dispense carriage.
carriage.

Loss of vacuum on coverslip

Refer to the Coverslip Vacuum Faults section.
dispense carriage.

Replace suction cup (refer to the Cleaning the Suction

Faulty suction cup.
Cup section).

Mountant debris on suction

Clean suction cup.
cup.

ClearVue Service Manual Issue 08 150

Problem Cause Solution

Loss of vacuum on suction Clean suction cup and replace if necessary (refer to the
cup. Cleaning the Suction Cup section).

Load hopper correctly (refer to the Remove and Replace

Hopper not loaded correctly.
the Coverslip Hopper section).

Incorrect size of coverslip Use correct coverslip size for hopper.

Hopper end-stop set

Inspect and adjust if necessary.
incorrectly.

Carriage hard-stop worn Replace carriage.

Carriage vacuum ports Clean the vacuum ports (refer to the Cleaning the Slip
blocked. Dispense Carriage section).

Coverslip dispense skirt not

Refit coverslip dispense skirt.
fitted.

Coverslip dispense skirt Clean coverslip dispense skirt (refer to the Cleaning the
needs cleaning. Slip Dispense Skirt section).

Coverslip dispense skirt

Replace coverslip dispense skirt.
damaged.

• Clean coverslip dispense skirt and support plate.

Coverslip dispense skirt
unable to move freely in its
slot. • Check for screws protruding through plate or excess
thread lock on sliding faces.

Optical sensors need

Clean underside of sensor using the long bristled brush.
cleaning.

Optical sensors need Reset the optical sensors and run 'Autoslip' (refer to the
adjusting. ENG Tab – Page 6/7 section).

Carriage drive failure Repair and replace failed components.

Other error Call Epredia Service Team

ClearVue Service Manual Issue 08 151

Breaking Coverslips
Problem Cause Solution

Failure to remove hopper

during power-up, purge, Ensure hopper is removed during power-up, purge,
flush and access dispense flush and access dispense head functions.
head functions.

Coverslips in hopper broken. Replace hopper for non-damaged one.

Level instrument (refer to the Level the ClearVue before

Instrument not level.
use section).

Clean coverslip dispense skirt and carriage (refer to the

Rejected slips not being
Cleaning the Slip Dispense Skirt section and Cleaning
wiped off carriage.
the Slip Dispense Carriage section).

Debris in bottom of hopper. Clear broken coverslips from bottom of hopper.

Inspect coverslips in hopper.

Coverslips stuck together in
Remove troublesome slips.
hopper.
Replace hopper if necessary.

Debris on coverslip dispense

Clean coverslip dispense carriage.
carriage.
Breaking
coverslips Debris on deck below
Clean area under and around hopper.
hopper.

Build-up of dried mountant

on coverslip dispense Clean coverslip dispense carriage.
carriage.

Loss of vacuum on coverslip

Refer to the Coverslip Vacuum Faults section.
dispense carriage.

Replace suction cup (refer to the Cleaning the Suction

Faulty suction cup.
Cup section).

Coverslip transfer head

Fix pneumatics to coverslip transfer head (refer to the
vacuum not building fast
Coverslip Vacuum Faults section).
enough.

Mountant or debris on
Clean suction cup.
suction cup.

Loss of vacuum on suction Clean suction cup and replace if necessary (refer to the
cup. Cleaning the Suction Cup section).

Load hopper correctly (refer to the Remove and Replace

Hopper not loaded correctly.
the Coverslip Hopper section).

ClearVue Service Manual Issue 08 152

Problem Cause Solution

Incorrect size of coverslip. Use correct coverslip size for hopper.

Hopper end-stop set

Inspect and adjust if necessary.
incorrectly.

Carriage hard-stop worn. Replace carriage.

Carriage vacuum ports Clean the vacuum ports (refer to the Cleaning the Slip
blocked. Dispense Carriage section).

Coverslip dispense skirt not

Refit coverslip dispense skirt.
fitted.

Coverslip dispense skirt Clean coverslip dispense skirt (refer to the Cleaning the
needs cleaning. Slip Dispense Skirt section).

Coverslip dispense skirt

Replace coverslip dispense skirt.
damaged.

Coverslip dispense skirt • Clean coverslip dispense skirt and support plate.
unable to move freely in its
slot. • Check for screws protruding through plate or excess
threadlock on sliding faces.

Intermittent vacuum sensor

Clean pressure sensor or replace if necessary and clean
fault leading to placement of
glass filter (refer to the Coverslip Vacuum Faults section).
broken coverslips.

Other error Call Epredia Service Team for support

ClearVue Service Manual Issue 08 153

Basket Jams
Problem Cause Solution

Failure to load basket

Load basket (refer to the Load a Basket section).
correctly onto load rail.

Eject stall due to full unload

Ensure baskets are removed from the unload rail in a
rail (User Error 4, Eng. Error
timely fashion.
140).

Incorrect size of slide used -

Use correct size of slide (refer to the Compatibility
slide jams or breaks in slide
section).
guide.

Basket slider not fully closed. Ensure slider is fully closed prior to loading basket.

Build-up of dried mountant

Clean or replace basket.
on basket.

Damaged or broken basket. Replace basket.

Faulty load rail causing

phantom baskets, failure to Inspect input rail (refer to the Input Rail Motor Test
load baskets or lift stall during section and Inspecting the Input Rail section).
move to basket identify.

Faulty vertical lift leading to lift Inspect vertical lift (refer to the Lift Block Motor Test
stalls and failure to load section and Inspecting the Vertical Lift and Lift Block
Basket jams
baskets. section).

Inspect basket open assembly (refer to the Basket Open

Basket slider hits slide guide
Motor Test section and Inspecting the Basket Open and
due to incorrect opening.
Lower Slide Retention section).

Paint on long gripper Replace long gripper jaw (refer to the Gripper Jaws
damaged section).

Basket jams on slide guide Inspect slide guide (refer to the Inspecting the Slide
due to seized slide guide. Guide Assembly section).

Basket jams on slide grippers

Inspect grippers (refer to the Gripper Motor Test section
during index upwards,
and Inspecting the Slide Grippers section).
leading to general lift stall.

Inspect basket eject assembly (refer to the Basket Eject

Basket jams on eject bracket
Motor Test section and Inspecting the Output Pusher
leading to general stall.
and Upper Slide Retention section).

Basket slider jams on slides Inspect basket eject assembly and upper slide retention
leading to lift stall on move to (refer to the Inspecting the Output Pusher and Upper
fully closed. Slide Retention section).

Other error Call Epredia Service Team for support

ClearVue Service Manual Issue 08 154

Slides not Coverslipped
Problem Cause Solution

Use approved size of slide (refer to the Compatibility

Incorrect size of slide used.
section).

Gripper return plate is stuck

with mountant and prevents
Remove and clean the gripper return plate (refer to the
the gripper jaws closing fully
Cleaning the Gripper Return Plate section).
on the slide (User Error 28
Engineering Error 94).

Excessive mountant build up

or debris on gripper jaws,
Clean gripper jaws and inspect for damage.
causing the slide to be
rejected for being too wide.

Staining protocol is leaving a Reduce the camera slide threshold (parameter 72) by
residue on the slide, making it 10. Repeat as necessary.
harder for the camera to see
Note
the slide. Slides in positions
1, 2, 3 and 20 always Lowering will increase the likelihood that ClearVue will
coverslipped, whilst other attempt to remove slides that don't exist. This will slow
positions are always or down the instrument and will also lead to increased
randomly missed. wear.

Slides not Gripper linkage or cam worn Replace Gripper linkage and cam (refer to the Gripper
coverslipped excessively. Actuator section).

Align gripper jaws (refer to the Checking and Adjusting

Gripper jaws misaligned.
Gripper to Gripper Alignment section).

Slide too high in grippers and

is being picked up on the Run Production Test 5 to set correct value for
nose (User Error 28, Parameter 92.
Engineering Error 94).

Anomaly caused by liquid on

basket giving basket top
Reload basket as this is a one-off error.
calculation error (User Error
24, Engineering Error 39).

Basket not high enough on lift

and out of camera view
during basket top Check that end float on vertical lift leadscrew is less
calculations. Basket is than or equal to 0.05mm.
ejected without processing
slides and with error 24[39].

ClearVue Service Manual Issue 08 155

Problem Cause Solution

• Process 5 dry baskets containing slides.

Faulty camera failing to
detect slides. Basket ejected
with only slides in position 1,
2, 3 and 20 coverslipped. • If Log file shows evidence of slides not being seen,
replace the camera board (refer to the Camera
Board Replacement scction)

Faulty camera failing to • Process 5 dry baskets containing slides.

detect baskets. Basket
ejected with no slides • If Log file shows evidence of slides not being seen,
coverslipped (User Error 24, replace the camera board (refer to the Camera
Engineering Error 39). Board Replacement section).

• Check gripper out opto state changes in Production

Services - I/O Tab - Inputs (refer to the I/O Tab –
Slide not detected due to
Inputs section).
faulty gripper out opto.
• Replace if required

ClearVue is not seeing the

Adjust the Slide Sensing Parameter
slides (No User Error)

• Process a basket of measured slides and use the

Fault motor encoder leading
Log file data to confirm problem (refer to the
to incorrectly reported slide
Performance Test 1 section).
widths.
• Replace motor assembly if required.

Access or Debris Tray door Do not open the Access or

opened at the wrong time Debris Tray door unless the ClearVue has stopped

Other Error Call Epredia Service Team for support

ClearVue Service Manual Issue 08 156

Breaking Slides
Problem Cause Solution

Incorrect size of slide used -

Use correct size of slide (refer to the Compatibility
slide jams or breaks in slide
section).
guide.

Poor quality slides used

leading to breaking as Use good quality slides.
coverslip is placed.

Chipped or broken slide(s) Ensure only undamaged slides are loaded onto the
loaded into basket. instrument.

Remove and clean gripper return plate (refer to the

Gripper return plate stuck.
Cleaning the Gripper Return plate section).

Damaged or broken basket. Replace basket.

Ensure slider is fully closed prior to loading onto the

Basket slider not closed.
instrument.

Glass debris stuck to gripper

Clean gripper jaws.
jaws.

Slide not removed from jaws

after a slide jam (User Error 6, Refer to the Unload a Basket section.
Breaking slides
Eng. Error 91)

Ensure suction up is fitted correctly (refer to the

Suction cup fitted incorrectly.
Cleaning the Suction Cup section).

Paint on long gripper Replace long gripper jaw (refer to the Gripper Jaws
damaged. section).

Coverslip transfer head sprung

pads are jammed due to Clean the coverslip transfer head.
mountant buildup.

Parameter 92 set too high,

Check and adjust Parameter 92 setting using
leading to grippers removing 2
Production Test 5.
slides from the baskets.

Align gripper jaws (refer to the Checking and

Gripper jaws misaligned.
Adjusting Gripper to Gripper Alignment section).

Coverslip transfer head

Replace coverslip transfer head.
damaged.

Dispense head needle height Set dispense head needle height correctly (refer to the
set incorrectly. Checking and Adjusting the Needle Height section).

ClearVue Service Manual Issue 08 157

Problem Cause Solution

Check and adjust hard-stop (refer to the Checking

Hard-stop for coverslip transfer
and Adjusting the Coverslip Transfer Head Hard Stop
head set incorrectly.
section).

Inspect basket eject mechanism (refer to the Basket

Basket eject bracket bent. Eject Motor Test section and Inspecting the Output
Pusher and Upper Slide Retention section).

Excessive end float allows

basket movement relative to
motor and cause slides to be in Check for end float on vertical lift lead screw. Reach
wrong position. Note that it in and try to move lift block up and down; any
does not create error message movement greater than 0.05mm is excessive. Refer
but may coincide with error to the Lift Block Leadscrew section for setting end
5[90], error 6[91] and float.
excessive variation in logged lift
top opto position.

Basket open assembly not Inspect basket open assembly (refer to the Basket
pulling slider fully clear of Open Motor Test section and Inspecting the Basket
slides. Open and Lower Slide Retention section.

Short gripper jaw breaks slide Check short gripper jaw stop cam setting (refer to the
during vertical index. Inspecting the Cleaning Station Assembly section).

Camera fault leading to erratic Confirm using Log file data and replace if necessary
sensing of basket top and jaw (refer to the Engineer’s Log Extraction section and
'y' positions. Camera Board Replacement section).

Excessive play in long gripper

linear rail leading to incorrect Replace gripper linear rail.
sensing of jaw 'y' position.

Inspect slide guide and replace if necessary (refer to

Slide guide assembly seized.
the Inspecting the Slide Guide Assembly section).

ClearVue Service Manual Issue 08 158

Skewed Coverslips
Problem Cause Solution

Baskets not stored level when

Ensure Drying Rack is on a level surface
Slides are wet

Leave Baskets on the Unload Rail for a minimum of

Insufficient drying time allowed
15 minutes

Slip Dispense Skirt dirty or

Clean or replace Slip Dispense Skirt
worn.

Skewed coverslips Suction Cup dirty or worn Clean or replace Suction Cup

Gripper Return Plate is dirty or

Clean Gripper Return Plate
stuck

Slip Dispense Carriage vacuum

Clean Slip Dispense Carriage vacuum ports
ports clogged

Transfer Head Pads stuck Clean Transfer Head Pads

Other Error Call Epredia Service Team for support

Part Broken Coverslips

Problem Cause Solution

Poor quality coverslips Replace coverslips

Part broken Use new hopper

coverslip on slide Dirty or worn Suction Cup Clean or replace Suction Cup

Check adjacent slides for contamination

Slides too wet

Problem Cause Solution

Leave Baskets on the Unload Rail for a minimum of

Insufficient drying time allowed
15 minutes

Too much xylene carryover Shake Basket to remove excess xylene before
Slides are too wet
from staining loading
when removed

from the Unload rail Filter not fitted Fit Filter

Filter switch damaged Call Epredia Service Team for support

Other error Call Epredia Service Team for support

ClearVue Service Manual Issue 08 159

Excessive Drying of Slides
Problem Cause Solution

Ensure xylene tray is topped up (refer to the

Xylene tray not topped up.
Maintaining the Xylene Tray level section).

Ensure all door switches operate correctly (refer to

Instrument doors are not
the Checking Door Sensors and Filter Switch
closed.
section).

Check how the slides are transferred to the

Slides drying before reaching instrument. Slides should be transferred in a trough
the instrument. of xylene before being drained and placed on the load
rail.

Check the Log file for errors.

Excessive drying of • Are they being dealt with quickly?

slides. • Are there multiple errors.
Errors slowing the instrument
down. • Troubleshoot and fix errors accordingly.

• Advise customer on the consequences of not

dealing with errors promptly, and how to abort a
basket if necessary (refer to the Abort a Basket
section).

Check the Log file for decay time.

• Should be approximately 3 seconds.

Slow decay time.
• If greater than 5 seconds, reset decay time.

• Ensure the instrument give bubble-free preps

before leaving the instrument at the new setting.

ClearVue Service Manual Issue 08 160

Loss of Parameters and Settings
Problem Cause Solution

Always leave the battery switch 'On' except during

transport.

Check battery board fuses (refer to the Fuse

Replacement section).
The most common cause of
this problem is because the • Run ProdTst7 (battery test) to check the battery
instrument has been switched condition (refer to the ENG Tab – Page 1/7
off without the battery switch section).
being 'On'.
• Replace batteries if necessary (refer to the
Battery section).
Note If user settings have been lost, re-enter the following
Batteries not holding their from the main screen - Options Menu:
charge or blown battery fuses
• 40 slip position (end or centre).
can also cause this problem.
• Screen (view angle and rightness).

The parameters and user • Slip position adjust.

Loss of parameters settings files are saved during • Time and date.
and settings the shutdown sequence. In the
• Language.
event that the system does not
shut down correctly (for the From the main screen – Mountant Menu:
reasons above) changes to the
parameters and settings made • Volume (for black and white sliders).
during the current session will
Note
not be saved, and the
previously saved parameters Instructions for setting these are in the Operator
and settings will be used on the Guide.
next initialisation.
If the parameters have all been lost or corrupted:

• Reset all of the parameters (refer to the Resetting

In the unlikely event of file
Parameters section).
corruption, the default settings
will be used. • Adjust Parameter 92 using ProdTst5 (refer to the
ENG Tab – Page 1/7 section).

• Adjust the coverslip and slide position using

ProdTst6 (refer to the ENG Tab – Page 1/7
section).

ClearVue Service Manual Issue 08 161

Extraction System Faults
Problem Cause Solution

Fan does not run - fan / filter

Check that fan / filter connector is connected (refer
connector on main cover not
to the Outer Case Removal section).
connected.

• Check filter is fitted.

Fan does not run – filter switch
fault. • Check filter switch is working (refer to the I/O
Tabs – Inputs section).

• Check fan operation (refer to the I/O Tabs –

Inputs section).
Fan does not run – fan fault. • Remove outer cover (refer to the Outer Case
Removal section) and replace fan (refer to the
Remove the Fan Assembly section).

Fan continues to run when filter Check filter switch is working (refer to the I/O Tabs
is removed. – Inputs section).

• Check fan operation (refer to the I/O Tabs –

Inputs section).

• Fan should speed up when unload door is

opened.

Fan speed does not vary when • Check unload door switch operation (refer to the
unload door is opened. I/O Tabs – Inputs section).

Note
Fan will run at high speed with unload door closed,
for approximately 25 mins after a basket has been
processed.

ClearVue Service Manual Issue 08 162

Pneumatics for Mountant Bottle

Mountant bottle not pressurising or not reaching vacuum

Problem Cause Solution

• Remove lid and clean (refer to the Cleaning the

Mountant Bottle Cap section).

• Check quality of seals.

Mountant bottle lid not fully
closed. • Clean / replace as necessary (refer to the
Cleaning the Mountant Bottle Cap section).

• Replace lid and perform pressure test (refer to

the Eng Tab – Page 2/7 section).

• Check seal between bottle and spout.

Mountant bottle not sealing • Clean / replace as necessary (refer to the
with the spout. Cleaning the Mountant Bottle Seal section).

• Ensure spout is not cross-threaded on bottle.

• Check that the end of the pneumatic line is cut

Leak from pneumatic line into
square and is not damaged.
fitting.
• Ensure line is fully pushed home in fitting.
Mountant bottle not
pressurising or • Check fittings are not cross threaded and are
fully tightened.
not reaching
vacuum.
Note
Over-tightening of fittings may cause thread to strip.
Fittings leaking.

• If fittings are in correctly but are still leaking, use

PTFE tape on the thread as a temporary fix.

• The spout section should then be replaced as

soon as possible.

• Check solenoids are connected (refer to the

Inspecting the Pneumatic Circuit section).

• Take control of the solenoids and check that they

are switching (refer to the I/O Tab – Outputs
Solenoids not switching
section).

• Ensure the red manual switch is in the correct

orientation (refer to the Pneumatic Drawings
section).

ClearVue Service Manual Issue 08 163

Problem Cause Solution

Solenoids not piped in

refer to the Pneumatic Drawings section.
correctly.

Replace the whole assembly.

Note
Solenoid valves not sealed
correctly. Do not modify or disassemble the solenoid valve. If
the valve has been tampered with, replace the
whole assembly.

Pump not piped in correctly. refer to the Pneumatic Drawings section.

• Disconnect the pipes from the pump.

• Take control of the pump and check that it works

Pump not working correctly. (refer to the I/O Tab – Outputs section).

• Replace if necessary (refer to the Pump

Assembly section).

Pipe not sealed onto sensor. Replace the pipe between the sensor and the filter.

Filter leaking. Replace the filter between the sensor and the valve.

• If pressure increases instantly then pipe is

Pipe blocked by mountant. blocked with mountant.

• Replace the pipe from the bottle to the sensor.

ClearVue Service Manual Issue 08 164

Mountant bottle not holding pressure

Problem Cause Solution

• Remove lid and clean (refer to the Cleaning the

Mountant Bottle Cap section).

• Check quality of seals.

Mountant bottle lid not fully
closed. • Clean / replace as necessary (refer to the
Cleaning the Mountant Bottle Cap section).

• Replace lid and perform pressure test (refer to the

Eng Tab – Page 2/7 section).

• Check seal between bottle and spout.

Mountant bottle not sealing • Clean / replace as necessary (refer to the
with the spout Cleaning the Mountant Bottle Seal).

• Ensure spout is not cross-threaded on bottle.

• Check that the end of the pneumatic line is cut

Leak from pneumatic line into
square and is not damaged.
fitting.
• Ensure line is fully pushed home in fitting.

• Check fittings are not cross threaded and are fully

tightened.

Note
Mountant bottle not
holding pressure. Over-tightening of fittings may cause thread to strip.
Fittings leaking.
• If fittings are in correctly but are still leaking, use
PTFE tape on the thread as a temporary fix.

• The spout section should then be replaced as

soon as possible.

• Check solenoids are connected (refer to the

Inspecting the Pneumatic Circuit section).

• Take control of the solenoids and check that they

are switching (refer to the I/O Tab – Outputs
section).

• Ensure the red manual switch is in the correct

orientation as shown.
Solenoids not switching.

ClearVue Service Manual Issue 08 165

Problem Cause Solution

Solenoids not piped in

Refer to the Pneumatic Drawings section.
correctly.

Replace the whole assembly.

Note
Solenoid valves not sealed
correctly. Do not modify or disassemble the solenoid valve. If
the valve has been tampered with, replace the whole
assembly.

Pump not piped in correctly. Refer to the Pneumatic Drawings section.

• Disconnect the pipes from the pump.

• Take control of the pump and check that it works

Pump not working correctly (refer to the I/O Tab – Output section).

• Replace if necessary (refer to the Pump Assembly

section).

Pipe not sealed onto sensor. Replace the pipe between the sensor and the filter.

Filter leaking. Replace the filter between the sensor and the valve.

• If pressure increases instantly then pipe is

blocked with mountant.
Pipe blocked by mountant.

• Replace the pipe from the bottle to the sensor.

Tighten syringe so that it is finger-tight or replace as

Syringe not tight.
required (refer to the Mountant Syringe Section).

• Check that the end of the pneumatic line is cut

square and is not damaged.

Fittings into mountant pump • Ensure line is fully pushed home in fitting.
solenoid block leaking.
• Tighten fittings to 3Nm or replace.

• If fittings have been replaced, flush the system

twice.

Solenoid valves not switching

Replace the valve block assembly.
fully.

ClearVue Service Manual Issue 08 166

Coverslip Vacuum Faults
Problem Cause Solution

Vacuum ports on coverslip

Clean ports with a piece of stiff wire or a pin (refer to
surface of the coverslip
the Cleaning the Slip Dispense Carriage section).
dispense carriage blocked.

Coverslip dispense carriage

vacuum pipe not reconnected Reconnect pipe correctly.
after maintenance.

Coverslip dispense carriage /

Remove banjo fitting and clean or replace as
banjo fitting blocked with glass
necessary.
dust.

• Check all pipes and fittings.

Coverslip dispense carriage
vacuum line leaking.
• Replace as required.

Coverslip dispense carriage

vacuum line glass filter Replace vacuum line glass filter.
blocked.

Coverslip dispense carriage • Empty out any glass dust.

Coverslip vacuum
pressure sensor
faults
malfunctioning.
• Replace if necessary.

Coverslip lower solenoid 1 Check solenoid is switching and sealing (refer to the
fault. Vacuum System Test section).

Coverslip dispense carriage

Replace screws and use an appropriate thread
sealing screws leaking or not
sealant.
fitted.

Coverslip pick up vacuum pipe

Reconnect pipe correctly.
left attached to test port.

• Check all pipes and fittings.

Coverslip pick-up vacuum line
leaking.
• Replace as required.

Debris on suction cup. Clean suction cup with a cloth or paper towel.

Clean suction cup with xylene and a cloth or paper

Mountant on suction cup.
towel.

ClearVue Service Manual Issue 08 167

Problem Cause Solution

Coverslip pick-up vacuum line

Replace filter.
glass filter blocked.

Coverslip pick-up pressure • Empty out any glass dust.

sensor malfunctioning.
• Replace if necessary.

Coverslip lower solenoid 2 Check solenoid is switching and sealing (refer to the
fault. Vacuum System Test section).

• Check sprung pads on coverslip transfer head

Coverslip pick-up head not are free to move and clean then re-initialise.
coming low enough. • Check parameter 62 is correct (refer to Appendix
A3 – Parameters).

Check the red solenoid manual over-ride switches

Solenoids not switching.
are in the correct position, as shown.

ClearVue Service Manual Issue 08 168

Mountant Pump and Syringe Faults

Syringe not loading with mountant

Problem Cause Solution

Mountant bottle not Refer to the Pneumatics for Mountant Bottle

pressurising. section.

• Check all screws are secure on the syringe,

linear rail and motor.

Bracket between motor and • Flush system.

syringe loose. • Perform a bead test (refer to the Performing a
Bead Test section).

• Carry out Performance Test 1.

Syringe not loading • Remove bracket from motor.

with mountant. • Take control of the motor and drive it up and
Faulty motor. down.

• Ensure the home flag at the bottom is cut.

• Replace motor or opto board as required.

• Release bracket from the linear rail.

• Take control of the motor and drive it up and

Faulty linear rail. down.

• Move the rail manually.

• Clean and oil the rail or replace as necessary.

ClearVue Service Manual Issue 08 169

Air in syringe

Problem Cause Solution

• Finger tighten the syringe.

• Flush system twice.

Syringe loose. • Perform a bead test (refer to the Performing a
Bead Test section).

• Carry out Performance Test 1.

• Replace syringe (refer to the Mountant Syringe

section).

• Flush system twice.

Syringe damaged.
• Perform a bead test (refer to the Performing a
Bead Test section).

• Carry out Performance Test 1.

• Replace seal or syringe as necessary.

• Flush system twice.

Syringe seal damaged • Perform a bead test (refer to the Performing a
Bead Test section).
Air in syringe.
• Carry out Performance Test 1.

• Replace the whole valve assembly.

Note
Do not tamper with the valve settings.
Leak on mountant pump valve.
• Flush system twice.

• Perform a bead test (refer to the Performing a

Bead Test section).

• Carry out Performance Test 1.

• Check all pipes have square ends and are

pushed fully into the fittings.

• Re-cut pipe as necessary or replace.

Leak from fittings. • Flush system twice.

• Perform a bead test (refer to the Performing a

Bead Test section).

• Carry out Performance Test 1.

ClearVue Service Manual Issue 08 170

Mountant not dispensing

Problem Cause Solution

• Ensure mountant bottle is topped up.

• De-gas.

• Flush system twice

Mountant bottle empty.
• Perform a bead test (refer to the Performing a
Bead Test section).

• Carry out Performance Test 1.

Mountant bottle not Refer to the Pneumatics for Mountant Bottle

pressurising. section.

• Check all screws are secure on the syringe,

linear rail and motor.

Bracket between motor and • Flush system.

syringe loose. • Perform a bead test (refer to the Performing a
Bead Test section).

• Carry out Performance Test 1.

• Remove bracket from motor.

• Take control of the motor and drive it up and

Mountant not down.
dispensing. Faulty motor.
• Ensure the home flag at the bottom is cut.

• Replace motor or opto board as required.

• Release bracket from the linear rail.

• Take control of the motor and drive it up and

down.
Faulty linear rail.
• Move the rail manually.

• Clean and oil the rail or replace as necessary.

• Finger tighten the syringe.

• Flush system twice.

Syringe loose. • Perform a bead test (refer to the Performing a
Bead Test section).

• Carry out Performance Test 1.

• Replace syringe (refer to the Mountant Syringe

Syringe damaged. section).

• Flush system twice.

ClearVue Service Manual Issue 08 171

Problem Cause Solution

• Perform a bead test (refer to the Performing a

Bead Test section).

• Carry out Performance Test 1.

• Replace seal or syringe as necessary.

• Flush system twice.

Syringe seal damaged. • Perform a bead test (refer to the Performing a

Bead Test section).

• Carry out Performance Test 1.

• Replace the whole valve assembly.

Note
Do not tamper with the valve settings.
Leak on mountant pump valve.
• Flush system twice.

• Perform a bead test (refer to the Performing a

Bead Test section).

• Carry out Performance Test 1.

• Check all pipes have square ends and are

pushed fully into the fittings.

• Re-cut pipe as necessary or replace.

Leak from fittings. • Flush system twice.

• Perform a bead test (refer to the Performing a

Bead Test section).

• Carry out Performance Test 1.

• Check profile number.

Corrupted profile. • Check that the check sums are the same (refer
to the Eng Tab – Page 3/7 section).

• Take control of the motor.

• Check encoder values are stable and move with

Faulty encoder.
the motor.

• Replace as required.

ClearVue Service Manual Issue 08 172

Dispensing too much mountant

Problem Cause Solution

Mountant bottle not Refer to the Pneumatics for Mountant Bottle

pressurising. section.

• Check all screws are secure on the syringe,

linear rail and motor.

Bracket between motor and • Flush system.

syringe loose.
• Perform a bead test (refer to the Performing a
Bead Test section).

• Carry out Performance Test 1.

• Remove bracket from motor.

• Take control of the motor and drive it up and

Faulty motor. down.

• Ensure the home flag at the bottom is cut.

• Replace motor or opto board as required.

• Release bracket from the linear rail.

• Take control of the motor and drive it up and

Dispensing too much Faulty linear rail. down.
mountant. • Move the rail manually.

• Clean and oil the rail or replace as necessary.

• Finger tighten the syringe.

• Flush system twice.

Syringe loose. • Perform a bead test (refer to the Performing a

Bead Test section).

• Carry out Performance Test 1.

• Replace syringe (refer to the Mountant Syringe

section).

• Flush system twice.

Syringe damaged. • Perform a bead test (refer to the Performing a
Bead Test section).

• Carry out Performance Test 1.

• Replace seal or syringe as necessary.

Syringe seal damaged
• Flush system twice.

ClearVue Service Manual Issue 08 173

Problem Cause Solution

• Perform a bead test (refer to the Performing a

Bead Test section).

• Carry out Performance Test 1.

• Replace the whole valve assembly.

Note
Do not tamper with the valve settings.
Leak on mountant pump valve.
• Flush system twice.

• Perform a bead test (refer to the Performing a

Bead Test section).

• Carry out Performance Test 1.

• Check all pipes have square ends and are

pushed fully into the fittings.

• Re-cut pipe as necessary or replace.

Leak from fittings. • Flush system twice.

• Perform a bead test (refer to the Performing a

Bead Test section).

• Carry out Performance Test 1.

• Check profile number

Corrupted profile.
• Check that the check sums are the same (refer
to the Eng Tab – Page 3/7 section).

• Take control of the motor.

• Check encoder values are stable and move with

Faulty encoder.
the motor.

• Replace as required.

• Check volume settings for black and white

sliders.

• Check the log file for which slider colour the

Incorrect volume settings. instrument is registering.

• Confirm that this is correct.

• Correct as required or replace camera (refer to

the Camera Board Replacement section).

ClearVue Service Manual Issue 08 174

Syringe loading part way through a basket

Problem Cause Solution

• If the volume setting is high, and especially on

large baskets, the syringe may need to load part
High volume setting.
way through a basket.

• No action required

Mountant bottle not Refer to the Pneumatics for Mountant Bottle

pressurising. section.

• Check all screws are secure on the syringe, linear

rail and motor.

Bracket between motor and • Flush system.

syringe loose. • Perform a bead test (refer to the Performing a
Syringe loading part Bead Test section).
way through a • Carry out Performance Test 1.
basket.
• Remove bracket from motor.

• Take control of the motor and drive it up and

Faulty motor. down.

• Ensure the home flag at the bottom is cut.

• Replace motor or opto board as required.

• Release bracket from the linear rail.

• Take control of the motor and drive it up and

Faulty linear rail. down.

• Move the rail manually.

• Clean and oil the rail or replace as necessary.

ClearVue Service Manual Issue 08 175

 • The Event Log is a '.txt' file which can be read
Engineers' Log Extraction using various basic packages.
The procedure for extracting an Event Log is as • It takes the form of a 6000 event list in the
follows: following format.

• From the Main Menu press Options.

• From the Options menu press Disc.

• This will display the Disc Options screen.

• Insert a blank, formatted disk into the disk drive.

• Press the 'Write Engineers Log' button.
• The following screen will be displayed whilst the
Log is being written to the disk.

ClearVue Service Manual Issue 08 176

Chapter 9 – Parts Replacement
• Safety • T61622 Transfer head sprung pad setting tool
(Optional)
• Tools Required
• The following thread locking compounds are
• Outer Case Removal
required to service the Epredia ClearVue:
• Parts Replacement By Sub-Assembly
• Loctite 222
• Software Update
• Loctite 242

Safety • Loctite 638

The Safety and Warranty information must have

been read and understood before any work is
carried out on this equipment.
Ensure that all Earth connections are correctly
replaced.

Follow good laboratory practice at all times.

Tools Required
The following tools are required to service the
Epredia ClearVue:
• Set of metric allen keys (must include 2.5mm)
• #1 Posidrive screwdriver
• #2 Posidrive screwdriver
• Set of feeler gauges
• Small flat-blade screwdriver
• Medium flat-blade screwdriver
• Set of metric spanners (wrenches)
• Small external circlip pliers
• Tube cutter
• Side cutter
• 4mm pneumatic 'T' coupling and pipe.
(AP14467 & 100mm of M03681)
• Adjustable torque driver (0.5-5.5Nm. with a
resolution of 0.1Nm or better)
• Spring balance (0-3kg with a resolution of 0.1kg
or better)
• Dial Test Indicator (DTI) Gauge (with a resolution
of 0.02mm or better)
• T61627 Cleaning station setting tool.
• T61645 Gripper setting DTI bracket & gauge
plate.

ClearVue Service Manual Issue 08 177

Outer Case Removal
Step1
• Disconnect the power lead and switch the
battery isolator switch off
• Remove the filter cover by sliding it to the left and
then lifting it off
• Remove the charcoal filter

Step 3
• Unscrew the mountant bottle cap.
• Remove the collar by lifting it over the mountant
bottle spout.
• Replace bottle cap after collar is removed.

Step2
• Remove the 2 fixing screws as shown.
• Remove the back panel - the Earth connection
lead can be left attached.
• Disconnect the filter fan connector from the main
PCB.

ClearVue Service Manual Issue 08 178

Step 4
• Open the debris tray access door and remove
the debris tray.
• Unscrew the 2 fixing screws shown.

Step 6
• Remove the 2 fixing screws shown.
• Remove the right hand cover.

Note
Step 5 When refitting the right-hand cover, take care to
• Open the access door and the unload door. ensure that the pipe to the slip carriage is retained
within the slot in the cover.
• Loosen the 2 fixing screws, labelled 'A', to
release the main cover from the bracket on the
vertical plate.
• Remove the 2 fixing screws, labelled 'B', which
secure the bracket to the vertical plate.
• Making sure the filter / fan connector has been
disconnected (Step 2.3), carefully lift the main
cover off the instrument.

Note
Take care not to trap fingers or bang head on doors
when lifting the cover off.

ClearVue Service Manual Issue 08 179

Step 7
• Remove the 3 fixing screws shown.
• Carefully lift the left-hand cover off.

Note
When replacing the LHS assembly, ensure the wires
indicated are not trapped between the front.
inner liner and the LHS assembly, and ensure the
rear cover earth strap is routed correctly.

Step 8
• Remove the dispense head cleaning station from
its mount.
• Unscrew the stub shaft.
• Carefully disconnect the pipes running to the
pump assembly (located underneath the debris
liner) and the silencer.

Note
Take note of the pipe routing to facilitate re-
assembly
• Remove the 6 screws which secure the debris
liner.
• Manoeuvre the debris liner out in the direction
shown.

ClearVue Service Manual Issue 08 180

Step 9 - Exploded View

Item Part Number Description

1 A79230150 Filter Cover

Main Cover
2 A79210038
Assembly

3 A79220037 Back Panel

4 A79210032 LHS Assembly

5 A79230142 RHS Cover

Mountant Bottle
6 A79230151
Cover

7 A79210045 Mountant Bottle

8 A79230197 Debris Liner

9 A79230198 Debris Tray

10 A79210039 Display Complete

Use the Production Services Inputs screen (refer to

I/O Tab – Inputs section) to check the operation of
all door sensors, the filter switch and the fans

ClearVue Service Manual Issue 08 181

Parts Replacement by Sub-
Assembly
The following sections describe how to remove
• Lift Block
specific sub-assemblies and components in order
to replace, repair or clean them. • Pump Assembly
• Basket Open Assembly
Unless specifically stated in the
• Mountant Solenoid
procedure, ensure that the
instrument is switched off, • Mountant Actuator Assembly
disconnected from the mains supply • Mountant Syringe
and has had the battery back-up • Solenoid Assembly
isolated.
• Vacuum Regulator
Failure to carry out the above • Dispense Head Motor Assembly
procedure can result in fatal electric
• Basket Push Motor Assembly
shocks and serious damage to the
• Electronics Box
instrument
• Coverslip Dispense Motor Assembly
• Gripper Actuator
• Front I/F PCB
• Rear I/F PCB
• Input Motor Assembly
• Input Rail Assembly
• Display PCB
• Inverter PCB
• Touch Screen or Proximity Switch
• Slide Guide
• Support Arm
• Camera Board Replacement
• Lift Motor
• Lift Block Leadscrew
• Miscellaneous Tests for Other Replacements
• Gripper Jaws

ClearVue Service Manual Issue 08 182

Lift Block Parts Replacement Procedure • Loosen the locking screw by at least 3 full turns.

To remove the lift block assembly: • The vertical lift plunger can now be removed.

• Turn the leadscrew using a flat-bladed

screwdriver in the slot at the top, to raise the lift
block to an accessible height.
Note
If the lift block is raised too far the front plate will
move over and cover the fixing screws.
• Remove the 3 fixing screws.
• Remove the lift block assembly. To remove the lift block plunger:
To refit the lift block assembly: • Screw the lift block plunger until the ball spring is
• Position the lift block assembly so that it is in line with the front face of the lift block.
butted-up to the datum face on the linear rail This is best done by pressing a flat surface such
adaptor plate. as a slide against the front of the lift block and
• Replace the fixing screws. screwing in the lift block plunger until it just
touches the flat surface.

• Tighten the locking screw.

• Pull the eject bracket back over to the right.
And then

• Initialise the instrument.

• Carry out Performance Test 2.
• Carry out Performance Test 1.

Item Part Number Qty. Description

1 A79210005 1 Lift Block

Assembly

Replacing the lift block plunger

Note
The plunger can be replaced with the lift block in-
situ.
To remove the lift block plunger:

• Use the screwdriver to align the lift block

approximately with the unload rail.
• Push the basket eject bracket to the left out of
the way.

ClearVue Service Manual Issue 08 183

 Basket Open & Dispense Head Cleaning
Pump Assembly Parts Replacement
Station Assembly Parts Replacement
To remove the pump assembly:
Slide Pusher
• Disconnect the electrical connectors from the
rear I/F PCB. To remove the slide pusher:
• Disconnect the pipes taking note of their routing • Undo the retaining screw until it is clear of the
for re-assembly later. slide pusher guide.
• Unscrew the pump assembly fixing screws and • Remove the slide pusher by pulling it carefully off
remove the pump assembly. the slide pusher guide.
To further remove a single pump wired unit:
Note
• Remove the pump wired fixing screws.
Be careful not to lose the 2 springs.
• Remove the pump wired unit.
To replace the slide pusher:
To re-assemble, follow the previous instructions in
reverse order. • Push the slide pusher onto the slide pusher
guide ensuring that the springs are located
correctly in both sets of blind holes.
• Push the slide pusher all the way onto the slide
pusher guide so that the springs are
compressed.
• Tighten the retaining screw so that it acts as a
stop for the slide pusher.

Item Part Number Qty. Description

1 A79220045 2 Pump Wired

And then.

• Carry out the Mountant Bottle Pneumatic Test. Item Part Number Qty. Description
• Carry out the Vacuum System Test.
1 A79230016 1 Slide Pusher

2 AP15176 2 Spring

3 AP15169 1 Linear Rail

ClearVue Service Manual Issue 08 184

Opto Switches
To remove the opto switches:
• Remove the 2 fixing screws to allow the
mounting bracket to be removed.
• Disconnect the electrical connectors from the
rear I/F PCB.
• Remove the push rivets (2 per opto).
• Remove and replace the opto switch.
• Set the bracket position if either opto is replaced.

Actuator Assembly
To remove the actuator assembly:

• Remove the 2 bracket fixing screws.

• Remove the 2 mounting plate fixing screws
located around the back of the vertical plate.
• Disconnect the electrical connectors from the
rear I/F PCB.
• Remove the actuator assembly and bracket from
the instrument as a single unit.
• Manually remove the bracket and leadscrew.
• Remove the 3 flange fixing screws to release the
flanged lead-nut.
Item Part Number Qty. Description
• Remove the 4 actuator fixing screws to release
1 A78320005 2 Opto Switch the actuator assembly.

To set the bracket position: To refit the actuator assembly follow steps 1 to 7 in
reverse order.
• Screw tool T61627 to the top of the dispense
head cleaning station actuator. Note

• Move the actuator up until the tool touches the It is advisable to wind the linear actuator nut off the
underside of the dispense arm. end of the shaft to gain access and tighten the 3
• Take control of the 'N_Pot' motor from flange fixing screws.
Production Services (refer to the Motor Tab Replace the nut and push it into contact with the
section). motor before tightening the bracket fixing screws.
• Move the opto assembly upwards until the 'UP'
opto is just activated, and then lock the opto
assembly in place.
• Check the setting by using the minor increment
arrows to move upwards – the opto should not
be seen - and downwards - the opto should be
seen.
• Replace the adaptor shaft and the dispense
head cleaning station.

ClearVue Service Manual Issue 08 185

 Item Part Number Qty. Description

1 A79220051 1 Actuator
Assembly
Item Part Number Qty. Description
Dispense Head Cleaning Station Actuator
1 A79220070 1 Cleaning
Assembly
Station
To remove the dispense head cleaning station Actuator
actuator assembly:
And then.
• Remove the dispense head cleaning station and
the adaptor shaft from the top of the actuator • Carry out Performance Test 2.
rod. • Carry out Performance Test 1.
• Remove the 2 mounting plate fixing screws
located around the back of the vertical plate.
• Disconnect the electrical connector from the rear
I/F PCB.
• Remove the actuator assembly and mounting
plate as a single unit.
• Remove the 4 actuator fixing screws to release
the actuator from the mounting plate.
To refit the actuator assembly:

• Follow steps 1 to 5 in reverse order.

• Set the optos as described above.

ClearVue Service Manual Issue 08 186

Mountant Solenoid Assembly Parts • Load mountant.
Replacement • De-gas the mountant bottle.
To remove the mountant solenoid assembly: • Flush the system with mountant.

• Disconnect the actuator electrical connectors • Perform a bead test (refer to the Perform a Bead
from the front I/F PCB. Test section).

• Remove the electrical connector from the

bottom of the solenoid body.
• Remove the Nyloc nut from the top of the
actuator and lift the bracket upwards to clear the
thread.
• Unscrew the syringe from the manifold using the
knurled section at the bottom.
• Remove the 2 manifold fixing screws.
• Remove the assembly.
• Unscrew the 4 screws securing the actuator to
the mountant solenoid assembly.
• Remove the elbow bracket.
To refit the mountant solenoid assembly follow
steps 1 to 8 in reverse order.

Note
Ensure all wires are secured away from the moving
parts and the syringe is fully screwed in to a firm
finger-tightness.

And then.

• Flush the system with xylene.

• Carry out mountant bottle pneumatic test (refer
to the Mountant Bottle Pneumatic Test).

ClearVue Service Manual Issue 08 187

Mountant Pump Actuator Assembly Parts Mountant Syringe Parts Replacement
Replacement To remove the syringe:
To remove the mountant actuator:
• Unscrew the retaining screw from the bracket.
• Disconnect the mountant actuator electrical • Unscrew the syringe from the manifold.
connector from the front I/F PCB.
To refit the syringe:
• Release the cable-ties.
• Follow steps 1 and 2 in reverse order.
• Remove the Nyloc nut to separate the actuator
• When refitting the syringe, ensure that it is fully
from the bracket.
screwed in to the manifold.
• Remove the 4 fixing screws to release the
actuator from the manifold. Note
To refit the actuator assembly follow steps 1 to 4 in Do not use tools to tighten the syringe, but ensure
reverse order. that it is firmly screwed in.
Note • When replacing the retaining screw torque it to
Ensure all wires are neatly cable-tied away from the 1.8Nm.
bracket.

Item Part Number Qty. Description

1 A79220054 1 Mountant Item Part Number Qty. Description

Actuator
1 AP15217 1 Syringe
And then.
And then.
• Flush the system with xylene.
• Flush the system with xylene.
• Carry out the Mountant Bottle Pneumatic Test.
• Load mountant. • Carry out the Mountant Bottle Pneumatic Test.
• Load mountant.
• De-gas the mountant bottle.
• De-gas the mountant bottle.
• Flush the system with mountant.
• Perform a Bead Test. • Flush the system with mountant.
• Perform a Bead Test.

ClearVue Service Manual Issue 08 188

Solenoid Assembly Parts Replacement Vacuum Regulator Parts Replacement
To remove the solenoid assemblies: To remove the vacuum regulator:
• Disconnect the pneumatic pipes, taking note of • Remove the rear panel, refer to the Outer Case
their routing to facilitate reassembly. Removal section (Step 2).
• Unscrew the 2 fixing screws shown for the • Disconnect the pipes from the regulator, taking
assembly required. note of the routing for reassembly.
• Remove the required assembly. • Undo the locking ring which holds the regulator
To refit, follow the above steps in reverse order. in its bracket.
• Remove the pipe couplings from the old
regulator and fit them to the new one.
• Fit the new regulator ensuring the word 'VAC',
which is printed on the unit, is on the top.
• Refit the pipes.

Item Part Number Qty. Description

1 A79210015 1 Solenoid Assy

(Upper) -
Pressure De-

Gas Complete

2 A79210016 1 Solenoid Assy

(Lower) -
Vacuum

System Item Part Number Qty. Description

Complete
1 AP15246 1 Vacuum
And then. Regulator

• Carry out the Mountant Bottle Pneumatic Test. And then.

• Load and process a basket of dry slides with • Carry out a Vacuum System Test.
'Prep' On.
• Carry out a Coverslip Dispense System Test.
• Load and process a basket of dry slides with
'Prep' On.
• Check the Engineers Log for decay times (refer
to the Engineers’ Log Extraction section).

ClearVue Service Manual Issue 08 189

 Step 2
Coverslip Transfer Head Motor Assembly
Parts Replacement • Loosen the belt tension pulley using the 2 fixing
screws on the back of the motor mounting plate.
Step 1 • Remove the vacuum regulator fixings.
To remove the transfer head motor, belt or pulley: • Remove the 3 Nyloc nuts which secure the
• Remove the electronics box; refer to the motor mounting plate to the studs.
Electronics Box section. Note
• Remove the coverslip transfer head; refer to the
Do not lose the tensioning spring.
Change the Coverslip Transfer Head Position
section. • Pull the motor assembly and mounting plate off
the studs.
• Loosen the screws securing the upper and lower
drive arms to the pulley shafts, and remove the • Replace the motor assembly, pulleys or belts as
arms. required.
• If refitting the motor assembly, ensure the wires
Note
are oriented as shown.
Do not remove the circlip; the main mounting block • If refitting a pulley, set the height from the
and lower drive arm are removed as one. mounting plate as shown, and tighten the clamp
Note screw to 1.2Nm as per current methods.

If the circlip is removed for any reason it must be • If refitting the bottom pulley, ensure the flag is
replaced with a new one - do not reuse the original! oriented as shown.

Tip
If the drive arms are held tightly to their shafts, insert
the screw in the opposite side of the arm and a thin
piece of metal between the jaws to create a jacking
surface. Tighten the screw to produce some
clearance.
• Remove the pin to allow the pulley shaft to pass
through the vertical plate.

Item Part Number Qty. Description

1 A79230044 2 Timing Pulley

2 AP15242 1 Timing Belt

3 A79220047 1 Motor
Assembly

ClearVue Service Manual Issue 08 190

Step 3
To set up the belt drive:
• Fit the timing belt over all the timing pulleys and
under the tensioning pulley.
• Replace the motor assembly and mounting plate
onto the studs and secure with the relevant
fixings.

Note
Do not tighten the pillar screws yet.
• Orient the bottom pulley as described in the
previous step to ensure the flag is correctly
positioned in relation to the opto switch.
• From the front, fit the upper drive arm - do not
tighten yet!
• Re-insert the pin in the lower pulley shaft, then fit
and secure the lower drive arm (inc. main
mounting block).
• Move the lower drive arm to its TDC position and
place a straightedge along the vertical side face.
• Align the upper and lower drive arms so that they
are parallel, using the straightedge as a guide.
• Tighten the upper drive arm.
• Using a square, as shown, ensure the main
mounting block is perpendicular to the vertical
plate, then tighten the pillar screws.
• Loosen the spring fixing nut to allow the
Step 4
tensioning spring to rotate.
• Carefully stretch the tensioning spring so that the
Note
loop on the free end can be hooked over the
If necessary, remove tension from the belt by loosened upper fixing screw.
loosening the 2 tensioning system fixing screws. • Rotate the dispense head mechanism to ensure
• Remove the lower fixing screw and take off the that any belt slack is evenly distributed.
spring washer - then replace the fixing screw and • With the tensioning spring in position, tighten the
tighten it. lower fixing screw.
• Remove the home opto to prevent damaging it. • Un-hook the tensioning spring from the upper
• Back of the lower fixing screw by ¼ of a turn to fixing screw and return it to its 'parked' position
allow the tensioning system to slide but still - tighten the Nyloc to fix it in place.
remain well located. • Tighten the upper fixing screw.
• Remove the lower fixing screw, replace the
spring washer and then replace and tighten the
screw.
• Re-check the drive arm alignment using a
straightedge.

ClearVue Service Manual Issue 08 191

• Replace the home opto.

Item Part Number Qty. Description

1 A79220051 1 Actuator
Assembly

And then.

And then. • Initialise the instrument.

• Initialise the instrument. • Turn 'Prep' to '0' (refer to the Eng Tab – Page
2/7 section).
• Carry out Performance Test 2.
• Load and process 5 empty baskets.
Basket Push Motor Assembly Parts • Remove the empty baskets from the unload rail.
Replacement • Turn 'Prep' to '1' (refer to the Eng Tab – Page
To remove the basket push actuator assembly: 2/7 section).
• Load and process a full basket.
• Disconnect the electrical connectors from the
main PCB. • Ensure all slides are coverslipped without any
problems.
• Remove the 2 bracket fixing screws from the
front of the vertical plate.
• Withdraw the actuator assembly from the lead-
nut by pulling in the direction shown.
• Remove the 3 flange fixing screws to release the
flanged lead nut.
• Remove the 4 actuator fixing screws.
To refit the basket push actuator assembly follow
steps 1 to 5 in reverse.

ClearVue Service Manual Issue 08 192

Electronics Box Parts Replacement

Identification of Parts

To refit the electronics box:

• Follow steps 1 to 4 in reverse order.
• Refer to the following diagrams for details of wire
routing and terminations.

Item Part Number Qty. Description

1 AP15186 1 Power Supply

Unit (PSU)

2 AP14133 1 Disc Drive

3 A79210122 1 Battery Kit

4 A79220063 1 Fan Assembly

5 A79210123 1 Battery PCB

Kit

6 A79210109 1 Main PCB Kit

7 A79210124 1 Interconnect
Item Part Number Qty. Description
PCB Kit
Solenoid Assy
8 A79210121 1 Processor
(Upper) –
PCB Kit 1a A79510015 1
Pressure De-
Gas Complete

To remove the electronics box:

Solenoid Assy
• Remove the back panel and main cover.
(Lower) –
• Disconnect all cableforms to the main
1b A79210016 1 Vacuum
interconnect board.
System
• Disconnect the pipe from the pneumatic valve. Complete
• Remove the 4 fixing screws shown to allow the
electronics box to be removed.

ClearVue Service Manual Issue 08 193

 Opto Assy Item Part Number Qty. Description
Cableform –
2 A78320005 1 Transfer Head Ribbon Cable –
1 N/A 1
Home Pos’n Rear I/F PCB
Opto Ribbon Cable –
2 N/A 1
Opto Assy Display PCB
Cableform –
Ribbon Cable –
3 A78320005 1 Transfer Head 3 N/A 1
Camera PCB
Pin Sensor
Opto Ribbon Cable –
4 N/A 1
Front I/F PCB
Opto Assy
Cableform – In the event of having replaced the entire electronics
4 A78320005 1
Basket Push box:
Opto
• Check that the latest software version is installed
Actuator Assy (refer to the Checking Software, FPGA and
5 A79220051 1 – Basket Push Pump Profile Version section).
Mechanism • Perform a 'Reset 7' (refer to the Eng Tab – Page
3/7 section).
Actuator Assy
6 A79220051 1 • Carry out ProdTst5, ProdTst6 and ProdTst7
– Gripper
(refer to the Eng tab – Page 1/7 section).
Opto Assy • Perform an 'Autoslip' (refer to the Eng tab – Page
Cableform – 6/7 section).
7 A78320005 1
Gripper Home • Perform the Setup procedure (see Setup
Opto Instructions).
Motor Assy – • Carry out Performance Test 2.
8 A79220047 1
Transfer Head • Carry out Performance Test 1.
• Ensure all settings are correct.
Opto Assy
Cableform – If stored data is still accessible:
9 A78320005 1
Gripper Index • Copy the parameters to disk.
Opto
• Record the user setup information.
• Carry out Performance Test 2.
• Carry out Performance Test 1.
• Carry out Vacuum System Test.
• Ensure all settings are correct.

ClearVue Service Manual Issue 08 194

Electronics Box Individual Component
Replacement
• Power Supply
• Disc Drive
• Battery
• Fan Assembly
• Battery PCB
• Main PCB, Interconnect PCB and Processor
PCB
• Speaker
• Fuse Replacement

Power Supply
To remove the PSU:
• Ensure the mains power and battery isolation
switches are in their 'Off' positions. Item Part Number Qty. Description

• Disconnect the mains power cable. 1 AP15186 1 Power Supply

• Remove all of the M4 SEMS which secure the Unit (PSU)
electronics box cover to the electronics box
And then.
case.
• Disconnect the earth lead from the cover. • Initialise the instrument.
• Disconnect the PSU and speaker connectors • Ensure the speaker tone is audible after
from the PCB. initialisation.
• Disconnect the 3 wires (L, N and E) from the • Check the VOLTAGES screen (refer to the I/O
PSU. Tab – Voltages section) to ensure that the
24V_PSU value shown is between 23.5V and
• Unscrew the 2 Nyloc nuts and lift the PSU
27.5V.
bracket out of the case.
• Carry out ProdTst7 (refer to the Eng Tab – Page
• Remove the fixing screws which secure the PSU
1/7 section).
to the bracket.
• Carry out Performance Test 1.
• Disconnect the remaining wires, taking note of
their routing for reassembly later.
To replace the PSU follow steps 1 to 9 in reverse.

ClearVue Service Manual Issue 08 195

Disk Drive Battery
To remove the disk drive: To replace the batteries:
• Remove the electronics box cover (refer to the • Remove the electronics box cover (refer to the
Electronics Box section). Electronics Box section).
• Disconnect the ribbon cable and the power • Disconnect the battery lead from the main PCB
cable from the back of the disk-drive. and from the battery PCB.
• Loosen the 2 Nyloc nuts on the base of the • Replace each battery separately to ensure the
electronics box and remove the M4 SEM on the wires do not get crossed.
side of the instrument. • Always replace the batteries as a pair.
• Slide the disk-drive assembly out in the direction
shown, to allow the keyhole slots to pass over
the Nyloc nuts, and then lift out.
• To remove the bracket, remove the 4 fixing
screws located under the disk-drive.
To refit the disk-drive follow steps 1 to 5 in reverse.

Item Part Number Qty. Description

1 AP14192 2 Battery

And then.

• Carry out ProdTst7 (refer to the Eng Tab – Page

1/7 section).

Fan Assembly
To remove the fan assembly:

• Disconnect the electrical connector from the

Item Part Number Qty. Description
main PCB.
1 AP14133 1 Disk Drive • Release the wires from the Velcro straps.
• Remove the push-fit rivets which hold the fan
And then.
assembly in the case.
• Write an Engineers Log to the a floppy disk (refer
To refit the fan assembly follow steps 1 to 3 in
to the Engineers’ Log Extraction section).
reverse.
• Check that the Log file is correct (no corrupt
characters, correct text order etc.) Note
Ensure the fan assembly is fitted with the cut-out
oriented as shown, and with the air-flow drawing air
into the box.

ClearVue Service Manual Issue 08 196

 Item Part Number Qty. Description
Item Part Number Qty. Description
1 A79220063 1 Fan Assembly
1 A79220023 1 Battery PCB
And then.
And then.
• From the INPUTS screen (refer to the I/O Tab –
Inputs section) check the operation of the fan. • Carry out ProdTst7 (refer to the Eng Tab = Page
1/7 section).
• The frequency displayed should be > 80Hz.

Battery PCB Main PCB, Interconnect PCB and Processor

PCB
To remove the battery PCB:
To replace the processor, main or interconnect
• Remove the electronics box cover and PSU PCB:
bracket (refer to the Electronics Box section).
• Remove the electronics box cover (refer to the
• Disconnect the battery lead from the PCB.
Electronics Box section).
• Pull the PCB off the mounting studs.
• Unplug all connectors from the main PCB.
To refit the battery PCB follow steps 1 to 3 in
• Remove all M4 SEMs to release the main PCB
reverse.
from the electronics case.
• Lift out all 3 PCBs together.
• Remove the fixing screws connecting the
processor PCB and spacer to the main PCB.
• The PCBs should now be able to be separated
from each other.
• Fit the replacement PCB and reassemble by
following steps 1 to 6 in reverse.

ClearVue Service Manual Issue 08 197

 • Write an Engineers Log to a floppy disk (refer to
the Engineer’s Log Extraction section).
• Ensure the Log file reads correctly and is not
corrupt.
• Carry out Performance Test 1.

Speaker
To remove the speaker assembly:
• Remove the electronics box cover and PSU
bracket (refer to the Electronics Box section).
• Remove the 4 push-fit rivets to release the
speaker assembly.
To replace the speaker assembly follow steps 1 and
2 in reverse.

Item Part Number Qty. Description

1 A79220021 1 Main PCB

2 A79220022 1 Interconnect
PCB

3 AP14741 1 Processor
PCB

If the processor PCB has been replaced:

• Check that the latest software version is installed

(refer to the Checking Software, FPGA and
Pump Profile Version section).
• Perform a 'Reset 7' (refer to the Eng tab – Page
3/7 section).
• Carry out ProdTst5, ProdTst6 and ProdTst7
(refer to the Eng Tab – Page 1/7 section). Item Part Number Qty. Description
• Perform an 'Autoslip' (refer to the Eng tab – Page
6/7 section). 1 A78420081 1 Speaker
Assembly
• Perform the Setup procedure (see Setup
Instructions). And then.
• Carry out Performance Test 2.
• Switch the instrument off.
• Carry out Performance Test 1.
• Open the doors and switch the instrument back
• Ensure all settings are correct. on.
If the Main PCB or Interconnect PCB has been • Ensure the speaker emits a 'double-beep' and
replaced: pauses the initialization.
• Initialise the instrument.
• Ensure the speaker tone is audible after
initialization.

ClearVue Service Manual Issue 08 198

 Item Part Number Qty. Description
Fuse Replacement
To replace the Mains inlet fuses: Mains Inlet
1 A79210104 1 Fuse - T6.3A,
• Disconnect the Main power cable.
250V
• Open the fuse door - the fuses are held in a
carrier. Mains Inlet
• Fuse kit A79210104 contains 2 x T6.3A, 250V 2 A79210104 1 Fuse - T6.3A,
fuses. 250V

To replace the internal fuses: Mains Board

• Ensure the Mains power and battery isolation 3 A79210152 1 F1 PSU Fuse -
switches are in the 'Off' position. F12A, 250V

• Remove the electronics box cover (see Section Battery Board

5-4-11-1). F1 Battery
4 A79210152 1
• Fuse kit A79210152 contains 3 x F12A, 250V Fuse 1 - F12A,
fuses. 250V

Battery Board
F2 Battery
5 A79210152 1
Fuse 2 - F12A,
250V

ClearVue Service Manual Issue 08 199

Coverslip Dispense Motor Assembly Parts Note
Replacement Always apply the tensioning force as close to the
Follow either Procedure 1 or Procedure 2 mounting block centreline as possible.
depending on the type of Coverslip Dispense
Tensioner fitted to the ClearVue instrument:

Item Part Number Qty. Description

Procedure 1:
1 AP1856 1 Dispense
Dispense Motor Assembly Motor
To remove the dispense motor assembly: Assembly

• Remove the touch-screen assembly (refer to the

Display PCB section to remove the Display PCB,
then the Touch Screen or Proximity Switch
section to remove the touchscreen).
• Loosen the 2 fixing screws which secure the
pulley mounting block to release the belt tension.
• Remove the belt from the pulley on the dispense
motor shaft.
• Remove the 2 fixing screws which secure the
motor assembly to the horizontal plate.
• Disconnect the electrical connector from the rear
I/F PCB.
When replacing the dispense motor assembly:

• When fitting the motor pulley tighten the clamp

screw to 1.2Nm.
• Set the top face of the motor pulley to a height
of 17mm from the mounting plate as shown.
• Tension the belt using a spring balance to apply
3kg of force to the pulley mounting block whilst
tightening the screws.

ClearVue Service Manual Issue 08 200

Slip Dispense Opto Switch Assembly
To remove the slip dispense opto switch assembly:
• Disconnect the electrical connector from the
touch-screen PCB.
• Snip the cable-tie to release the wires.
• Release the push-fit rivets from above the
horizontal plate to allow the opto switch to be
removed.
To refit the slip dispense opto switch follow steps 1
to 3 in reverse. Item Part Number Qty. Description

1 AP15203 1 Timing Belt

And Then.
• Initialise the instrument.
• Carry out Performance Test 3.
• Carry out Performance Test 1.

Item Part Number Qty. Description

1 A78320005 1 Opto Switch

Assembly

Slip Dispense Timing Belt

To remove the slip dispense timing belt: Procedure 2:
• Remove the timing belt from the pulleys as
described in Dispense Motor Assembly. Dispense Motor Assembly
• Remove the 2 fixing screws to allow the timing To remove the dispense motor assembly:
belt clamp to be removed.
• Remove the slip dispense opto cover and the
• The timing belt should now be free to be display cable cover (refer to the Display PCB
removed. section).
To refit the timing belt follow steps 1 to 3 in reverse. • Loosen the belt tensioner locking screw to
Note release the belt tension.
• Remove the motor cover.
Ensure the timing belt is tensioned as described in
Dispense Motor Assembly. • Remove the belt from the pulley on the slip
dispense motor shaft.

ClearVue Service Manual Issue 08 201

• Remove the 2 fixing screws which secure the Item Part Number Qty. Description
motor assembly to the horizontal plate.
• Disconnect the electrical connector from the rear 1 AP1856 1 Dispense
I/F PCB. Motor
Assembly

Slip Dispense Home Opto Switch Assembly

To remove the slip dispense home opto switch:
• Remove the touch screen assembly (refer to the
Display PCB section to remove the Display PCB,
then the Touch Screen or Proximity Switch
section to remove the touchscreen).
When replacing the dispense motor assembly: • Disconnect the electrical connector from the
touch-screen PCB.
• When fitting the motor pulley tighten the clamp
screw to 1.2Nm. • Snip the cable-tie to release the wires.

• Set the top face of the motor pulley to a height • Release the push-fit rivets from above the
of 17mm from the mounting plate as shown. horizontal plate to allow the opto switch to be
removed.
• Tension the belt using a spring balance to apply
1.7-1.8kg of force to the belt tensioning bracket To refit the slip dispense opto switch follow steps 1
whilst tightening the locking screw. to 3 in reverse.

Item Part Number Qty. Description

1 A78320005 1 Opto Switch

Assembly

ClearVue Service Manual Issue 08 202

 To refit the gripper link assembly follow steps 1 to 3
Slip Dispense Timing Belt in reverse.
To remove the slip dispense timing belt: Note
• Remove the timing belt from the pulleys as
Ensure all washers are in place at the ends of the
described in Dispense Motor Assembly. There is
linkage bars.
no need to remove the opto cover and the
display cable cover.
• Remove the 2 fixing screws to allow the timing
belt clamp to be removed.
• The timing belt should now be free to be
removed.
To refit the timing belt follow steps 1 to 3 in reverse.
Note
Ensure the timing belt is tensioned as described in
Dispense Motor Assembly above..

Item Part Number Qty. Description

1 A79210057 1 Link Assembly

Item Part Number Qty. Description Gripper Actuator Assembly

To remove the gripper actuator assembly:
1 AP15203 1 Timing Belt
• Remove the 2 mounting plate fixing screws from
And Then. above the horizontal plate.
• Initialise the instrument. • Withdraw the leadscrew from the flanged lead-
• Carry out Performance Test 1. nut by sliding the actuator assembly out in the
direction shown.
• Remove the 4 actuator fixing screws to release
Gripper Actuator Parts Replacement the mounting plate.
To replace the gripper actuator assembly follow
Gripper Link Assembly steps above in reverse order.
To remove the gripper link assembly:

• Remove the M5 screw to allow access to the

retaining pin.
• Use a pair of pliers to remove the retaining pin to
release the long linkage arm.
• Remove the clevis pin to release the short
linkage arm.

ClearVue Service Manual Issue 08 203

 Front I/F PCB Parts Replacement
To remove the front I/F PCB:
• Disconnect all electrical connectors.
• Remove the 4 fixing nuts to allow the PCB to be
lifted off the spacer mounts.
To refit the front I/F PCB follow steps 1 and 2 in
reverse.

Item Part Number Qty. Description

1 A79220051 1 Actuator
Assembly

And Then.

• Check the gripper stop cam (refer to the

Checking and Adjusting Short Gripper Stop Cam
section).
• Initialise the instrument.
• Carry out Performance Test 2.
• Carry out Performance Test 1. Item Part Number Qty. Description

1 A79220026 1 Front I/F PCB

And then.

• Initialise the instrument.

• Use the INPUTS screen to check that the load,
unload and access door all operate correctly
(refer to the I/O Tab – Inputs section).
• Carry out Performance Test 1.

ClearVue Service Manual Issue 08 204

Rear I/F PCB Parts Replacement Input Motor Assembly Parts Replacement
To remove the rear I/F PCB: To remove the input motor assembly:
• Disconnect all electrical connectors. • Remove the 3 casting fixing screws to allow the
• Disconnect the pipework leaving the 3 short mountant bottle support casting to be removed.
pipes attached to their respective pressure • Disconnect the electrical connectors from the
transducers. front I/F PCB and cut any cable ties to free the
• Use a small screwdriver to release the PCB from wires.
the 4 PCB mountings to allow the PCB to be • Loosen the 2 fixing screws securing the motor
removed. bracket to the vertical plate to allow the belt
To refit the rear I/F PCB follow steps 1 to 3 in tension to be released.
reverse. • Remove the belt from the pulley and lift the motor
bracket off the fixing screws.
Note
• Remove the 4 fixing screws which attach the
Ensure all electrical connectors and pipework are motor to the bracket.
correctly routed and that all the pipework is fully
To refit the motor assembly follow steps 1 to 5 in
pushed home.
reverse.

Note
Ensure all wires are neatly cable-tied in their original
bundles.
Note
When refitting the timing belt, tension it to 2kg using
a spring balance.

Item Part Number Qty. Description

1 A79220027 1 Rear I/F PCB

And then.

• Initialise the instrument.

• Carry out the Mountant Bottle Pneumatic Test.
• Carry out the Vacuum System Test.
Item Part Number Qty. Description
• Carry out Performance Test 1.
1 A79220047 1 Input Motor
Assembly

And then.
• Initialise the instrument.
• Carry out Performance Test 2.

ClearVue Service Manual Issue 08 205

 Disassembly of Input Rail Assembly
Input Rail Assembly Parts Replacement
To disassemble the input rail assembly:
Input Rail Assembly Removal
• Remove the 4 pairs of fixing screws to allow the
To remove the input rail assembly: assembly to slip apart.
• Follow the instructions in the Input Motor • Pull the bearing blocks off the leadscrew at either
Assembly section - including removal of the 2 end.
highlighted fixing screws. • Undo the pulley clamp to allow the pulley to be
• Disconnect all the electrical connectors. removed.
• Remove the input rail which should now only be • The carriage assembly can be removed from the
connected by the 2 location dowels. leadscrew by screwing it off the end.
• Release the push-fit rivets to remove the opto
switch.
• Remove the 2 proxy fixing screws to release the
proximity switch.
To reassemble the input rail assembly follow steps
1 to 6 in reverse.

Note
When refitting the opto switch ensure the wires are
routed as shown to leave clear access to the
leadscrew end slot.
Note
When screwing the 2 halves of the rail back
together, ensure the faces are properly aligned.
Item Part Number Qty. Description

1 A79210006 1 Input Rail

Assembly

2 AP15155 1 Timing Belt

3 59920128 1 Proximity
Switch

4 A79220058 1 Opto Switch

ClearVue Service Manual Issue 08 206

Bearing and Pop-Out Pin • Ensure the chamfers on the latch pins are facing
the correct way.
To remove the bearing and pop-out pin:
• Use Loctite 222 on the countersunk fixing
• Remove the countersunk screw, and
screws.
subsequently the bearing and spacer.
Note
• Withdraw the pop-out pin and spring from the
rail. If only the retractable latch requires removal, this
To refit the bearing and pop-out pin follow steps 1 can be done without disassembling the load rail -
and 2 in reverse. wind the carriage as far towards the pop-out pin as
possible and the latch will protrude from the load
Note rail.
Ensure the flat on the pop-out pin is on the correct
side, and that the pin moves freely without
snagging.

Item Part Number Qty. Description Item Part Number Qty. Description

1 AP15199 1 Bearing 1 A79210030 1 Latch

Complete
Carriage Assembly 2 A79210019 1 Latch
To remove the carriage assembly: Complete

• Withdraw the leadscrew from the lead nut. And Then.

• Remove the 2 grub screws to release the latch • Initialise the instrument.
pins.
• Carry out Performance Test 2.
Note
The head of the bearing grub screw is a press fit in
the inner race of the bearing.
• Remove the latch housing from the carriage
bracket by removing the 2 countersunk fixing
screws.
When reassembling the carriage assembly:
• Ensure all parts are free from burrs and move
freely without snagging.

ClearVue Service Manual Issue 08 207

Display PCB Parts Replacement And then.

To remove the display PCB: • Initialise the instrument.

• Remove the outer instrument covers (refer to the • Use the 'X-Spot' function to check touch screen
Outer Case Removal section). operation (refer to the Eng tab – Page 7/7
section).
• Remove the Opto cover and the Display Cable
cover. • Adjust the viewing angle and brightness of the
screen as required (refer to the Adjusting the
• Remove the 2 fixing screws which hold the
Screen Settings section).
display screen assembly to the horizontal plate.
• Use the INPUTS screen to check the operation
• Turn the display screen over and remove the
of the debris door (refer to the I/O Tab – Inputs
invertor PCB cover as shown.
section).
• Disconnect all the connectors to the display
• Use 'Testslip' (refer to the Eng tab – Page 2/7
PCB.
section) and 'Slip QC' (refer to the Eng tab –
• Remove the 4 SEMs to allow the display PCB to Page 6/7 section) to check the operation of the
be removed. coverslip dispense sensors.
To refit the display PCB follow steps 1 to 6 in
reverse.

Item Part Number Qty. Description

Invertor PCB
1 A79230139 1
Cover

SEM Pan Pozi

2 AP14377 2 M3 x 6 LG.
MSZNPL

3 A79220025 1 Display PCB

SEM Pan Pozi

4 AP15094 4 M3 x 10 LG.
MSZNPL

ClearVue Service Manual Issue 08 208

Inverter PCB Parts Replacement Touch Screen or Proximity Switch Parts
Replacement
To remove the invertor PCB:
• Follow the first 3 steps of the Display PCB Display Touchscreen Removal
section.
To remove the display touchscreen
• Disconnect the 2 connectors to the invertor
• Remove the display PCB, refer to the Display
PCB.
PCB section.
• Slide the invertor PCB out.
• Remove the display touchscreen.
To refit the invertor PCB follow steps 1 to 3 in
reverse.

Item Part Number Qty. Description

Item Part Number Qty. Description
Display
Invertor PCB 1 AP15052 1
1 AP14914 1 Touchscreen
(INVC191)
Proximity
And then. 2 59920128 1
Switch
• Initialise the instrument.
• Use the 'X-Spot' function to check touch screen
operation (refer to the Eng Tab – page 7/7
section).
• Adjust the viewing angle and brightness of the
screen as required (refer to the Adjust the Screen
Settings section).
• Use the INPUTS screen to check the operation
of the debris door (refer to the I/O Tab – Inputs
section).
• Use 'Testslip' (refer to the Eng Tab – Page 2/7
section) and 'Slip QC' (refer to the Eng Tab –
Page 6/7 section) to check the operation of the
coverslip dispense sensors.

ClearVue Service Manual Issue 08 209

Proximity Switch Removal • Remove the various sets of fixings shown to
enable the assembly to be separated.
To remove the proximity switch:
When reassembling the slide guide assembly:
• Follow steps 1 and 2 above.
• Ensure the mating edges / faces of all
• Remove the proximity switch.
components are fully butted-up to one another.
Refitting Display PCB and Proximity Switch
• When fitting the slide guide assembly to the
To refit the display PCB and the proximity switch horizontal plate, push the assembly so that it
follow the above steps in reverse. butts-up to the linear guide and then check that
Note it is square to the plate using an engineer’s
square.
Ensure the fold of the ribbon cable stays within the
recess on the touchscreen.
Note
If changing the proximity switch, use a piece of
Armaflex tape to hold the new switch in place.
If the Touchscreen Has Been Replaced

• Initialise the instrument.

• Use the 'X-Spot' function to check touch screen
operation (refer to the Eng Tab – Page 7/7
section).
• Adjust the viewing angle and brightness of the
screen as required (refer to the Adjust the screen
Settings section). Item Part Number Qty. Description
• Use the INPUTS screen to check the operation
Slide Guide
of the debris door (refer to the I/O Tab – Inputs 1 A79210018 1
Assembly
section).
• Use 'Testslip' (refer to the Eng tab – Page 2/7 Slide Main
2 A79230076 1
section) and 'Slip QC' (refer to the Eng Tab – Guide
Page 6/7 section) to check the operation of the
Slide Guide
coverslip dispense sensors. 3 A79230078 1
Leaf Spring
If the Proximity Switch Has Been Replaced

• Use the INPUTS screen to check the operation Basket

of the doors (refer to the I/O Tab – Inputs 4 A79230077 1 Support Slide
section). Rail

Slide Guide
Slide Guide Parts Replacement
5 A79230079 1 Mounting
Note Block
The leaf spring can be replaced with the slide guide And then.
in-situ; remove the lower main guide fixing screw
and pull the leaf spring out. • Initialise the instrument.
• Carry out Performance Test 2.
To remove the slide guide assembly:
• Carry out Performance Test 1.
• Remove the 4 assembly fixing screws.
To disassemble the slide guide assembly:

ClearVue Service Manual Issue 08 210

Slip Dispense Carriage, End Stop and • Gripper alignment (refer to the Checking and
Support Arm Parts Replacement Adjusting Gripper to Gripper Alignment section).
To remove the support arm: • Needle height (refer to the Checking and
Adjusting the Needle Height section).
• Remove the coverslip hopper if fitted.
• Coverslip dispense end stop height (refer to the
• Push down the dispense head cleaning station. Coverslip Dispense End Stop Height section).
• Remove the pneumatic line to the slip dispense
• Carry out the 'Auto slip' function (refer to the Eng
carriage.
Tab – Page 6/7 section).
• Remove the timing belt clamp; refer to the
• Carry out the 'test slip' function (refer to the Eng
Coverslip Dispense Motor Assembly section.
tab – page 2/7 section).
• Remove the 8 carriage fixing screws to allow the • Carry out a Bead Test (refer to the Carry out a
support arm to be removed. Bead test section).
To remove the slip dispense carriage:

• Remove the coverslip hopper if fitted.

• If the support arm has not been removed
disconnect the pneumatic pipe to the carriage.
• Remove the slip dispense banjo fitting.
• Remove the 2 fixing screws.
• If the support arm has not been removed then
push the dispense head cleaning station down
and push the support arm backwards to allow
removal of the slip dispense carriage.

Item Part Number Qty. Description

1 A79210026 1 Support Arms

To refit the support arm follow steps 1 to 5 in

reverse.
Note
Ensure that the alignment face on the arm is butted-
up to the linear guide carriages.
Note To refit the carriage follow steps 1 to 5 in reverse.
Ensure that no debris gets stuck under the support Note
arm during fitting as this could make it impossible to
Ensure that the slip dispense carriage butts up
set the end stop correctly.
against the support alignment faces.
And then.
Note
• If support arm has been changed check the
Ensure that no debris gets stuck under the slip
following:
dispense carriage during fitting as this could make it
impossible to set the end stop correctly.

ClearVue Service Manual Issue 08 211

And then. Camera Board Replacement
• Check the coverslip dispense end stop height To remove the camera board:
(refer to the Coverslip Dispense End Stop Height
• Remove the 4 fixing screws shown and the 2
section).
push-fit rivet (not shown) to allow the 2 camera
• Carry out the 'Auto slip' function (refer to the Eng covers to be removed.
tab – Page 6/7 section).
• Disconnect the ribbon cable from the camera
• Carry out the 'test slip' function (refer to the Eng board.
Tab – Page 2/7 section).
• Release the 2 fixings which secure the camera
To remove the slip dispense end stop: mounting block to the horizontal plate.
• Remove the coverslip hopper if fitted. To refit the camera board follow steps 1 to 3 in
• Remove the slip dispense opto cover. reverse order.
• Remove the fixing screw.

To refit the end stop follow steps 1 to 3 in reverse.

Note
Ensure that end stop sits flush against the alignment
face when fitted and tightened. And then.
Note • Initialise the instrument.
Apply blue Loctite 242 to the threads of the fixing • Use the 'Snapshot' function to check that the
screw. image shows the grippers (refer to the ENg Tab
– Page 5/7 section).
And then.
• Check jaw / slide alignment using Production
• Check the coverslip dispense end stop height test 5 (refer to the Eng Tab – Page 1/7 section).
(refer to the Coverslip Dispense End Stop Height
• Carry out Performance Test 1.
section).
• Carry out Performance Test 2.
• Carry out the 'Auto slip' function (refer to the Eng
tab – Page 6/7 section).
• Carry out the 'test slip' function (refer to the Eng
Tab – Page 2/7 section).

ClearVue Service Manual Issue 08 212

Lift Motor Parts Replacement • Tension the belt using a spring balance to apply
2kg of force to the assembly whilst tightening the
screws.

Note
Ensure the tensioning force is applied as close to
the centreline of the fixing screws as possible.
And Then.

• Carry out Performance Test 2.

• Carry out Performance Test 1.

Item Part Number Qty. Description

1 A79220055 1 Lift Motor

Assembly

2 AP15241 1 Timing Belt

Timing Belt Removal

To remove the timing belt:

• Loosen the 2 fixing screws to release the belt

tension.
• Remove the timing belt from the pulleys.

Lift Motor Assembly Removal

To remove the lift motor assembly:

• Remove the timing belt as described above.

• Completely remove the 2 fixing screws to allow
the motor assembly to be removed.
• Disconnect the electrical cable from the front I/F
PCB.
• Remove the 4 screws which attach the motor to
the mounting plate.

Refitting the Lift Motor and Timing Belt

When refitting the lift motor and timing belt:

• Ensure the top edge of the motor pulley is 17mm

from the mounting plate face as shown. The
correct torque for the pulley clamp is 1.2Nm.

ClearVue Service Manual Issue 08 213

Lift Block Leadscrew Parts Replacement
To remove the lift block leadscrew:
• Remove the cap-head screw which fixes the
drive transfer plate to the lift block.
• Remove the timing belt (refer to the Lift Motor
section).
• Remove the clamp and pulley from the bottom
of the leadscrew.
• Remove the bearing block from the top of the
leadscrew.
• The leadscrew and drive transfer plate can now
be removed.
To replace the lift block leadscrew: Item Part Number Qty. Description
• Position the new assembly so that the drive
1 A79210126 1 Drive Transfer
transfer plate can be loosely fixed to the lift block.
Plate Kit
• Move the lift block to the bottom of its travel then
tighten the screw to secure the drive transfer And then.
plate to the lift block. • Check the alignment of the leadscrew by moving
Note the lift block from top to bottom using a 0.1Nm
torque.
Use Loctite 222 on the screw thread.
Note
• Raise the lift block to the top of its travel and fit
the bearing block. Timing belt must be removed or lift motor must be
• Refit the pulley and clamp to the bottom of the disconnected from front I/F PCB to carry out torque
leadscrew. The correct torque for the pulley test.
clamp is 1.2Nm. • Initialise the instrument.
Note • Carry out Performance Test 2.

Ensure the thrust washer is in place as shown. • Carry out Performance Test 1.

• Tension the timing belt (refer to the Lift Motor

section).

ClearVue Service Manual Issue 08 214

Miscellaneous Tests for Other Replacements
Parts Replaced • Tests Required After Replacement

Suction Cup • Carry out Performance Test 1.

• Initialise the instrument.

Opto Cableform Long
(Slotted) • Use the INPUTS screen to check the operation of the sensor when open
and obscured (refer to the I/O Tab – Inputs section).

• Initialise the instrument.

Opto Cableform Short
(Slotted • Use the INPUTS screen to check the operation of the sensor when open
and obscured (refer to the I/O Tab – Inputs section).

• Use the INPUTS screen to check the operation of the filter switch and
extraction fan (refer to the I/O Tab – Inputs section).
Fan Microswitch
• The feedback frequency should be > 80Hz with the unload door open.

• The feedback frequency should be > 50Hz with the unload door closed.

• Check, and adjust if necessary, the gripper alignment (refer to the

Checking and Adjusting Gripper-to-Gripper Alignment section).

• Check, and adjust if necessary, needle height (refer to the Checking and
Adjusting the Needle Height Section).

• Check, and adjust if necessary, the coverslip transfer head hard stop
position (refer to the Checking and Adjusting the Coverslip Transfer Head
Short and Long Gripper Jaws Hard Stop Section).

• Carry out ProdTst6 (refer to the Eng Tab – Page 1/7 section).

• Refit the covers (refer to the Outer Case Removal section).

• Carry out a Bead Test (refer to Carry out a Bead Test section).

• Carry out Performance Test 2.

• Carry out Performance Test 1.

ClearVue Service Manual Issue 08 215

 • Replacing the gripper arm is the reverse of
Gripper Jaws
removing the gripper arm.
To remove the gripper jaws: And then.
• Switch off the ClearVue.
If the short gripper is replaced:
• Manually push the gripper over to the right (as
• Check and set the gripper to gripper alignment
shown below) for better access.
(refer to the Checking and Adjusting Gripper-to-
• Remove the single M4 socket head cap screw
Gripper Alignment section).
that fixes the gripper jaw to the support arm.
• Check and set the needle height (refer to the
• Slide the gripper arm off the dowel pin to remove
Checking and Adjusting the Needle Height
it.
section).
• Check and set the coverslip transfer head hard
stop (refer to the Checking and Adjusting the
Coverslip Transfer Head Hard Stop section).
• Check and set the gripper stop cam (refer to the
Checking and Adjusting Short Gripper Stop Cam
section).
• Run production test 6 to set slide out position
(refer to the Eng tab – Page 1/7 section).
• Run Performance test 1 & Performance test 2.
If the long gripper is replaced:

• Check and set the gripper to gripper alignment

Note (refer to the Checking and Adjusting Gripper-to-
Gripper Alignment section).
The gripper jaws can be a tight fit on the dowel pins
and also tend to get stuck with mountant. If the jaws • Run production test 5 to set Parameter 92 (refer
are difficult to remove, then use the slots shown to the Eng tab – Page 1/7 section).
below to pry a gripper jaw off the support arm. • Run production test 6 to set slide out position
(refer to the Eng tab – Page 1/7 section).
• Run Performance test 1 & Performance test 2.
If both grippers are replaced carry out all tests.

To replace the gripper arm:

• When replacing the long gripper inspect the

paint on the new gripper arm to ensure that it is
undamaged.

ClearVue Service Manual Issue 08 216

Decay Reservoir • Refit the back panel & main instrument cover
(Outer Case Removal).
The Decay Reservoir A79210153 has been
replaced by the Decay Reservoir A79210177. Use • Inspect covers and filter.
A79210177. • Check operation of the debris door.

To retrofit the decay reservoir: • Complete Performance Test 1.

• Record all actions in the Service Record Book.
• Complete Performance Test 3.
Important notes:
• Remove the main instrument cover and back
panel (Outer Case Removal). • You must complete sections 1 to 12 above for
• Remove and discard the decay reservoir, fixing optimum performance.
screws and pipe from the lower solenoid • If in doubt about any step, contact Epredia
assembly. Service.
• Fix the cable tie base to the electronics box using • All hyperlinks are to the relevant pages within this
the M4 CSK Slotted screw provided. manual.
• Place the decay reservoir onto the cable tie base
and secure in place with cable tie.

Note
Handle the new decay reservoir with care. Handle at
the ends only to avoid contamination of the
ventilation hole.
• Connect a length of pipe between the elbow
coupling in the lower solenoid assembly and the
decay reservoir. Use the pipe provided in the kit
due to the potential change in length.

• Re-check the decay time. It should be between

2.8 and 3.2 seconds. If it is outside of these limits
adjust the regulator accordingly and re-test.

Note
The vacuum must be within the limits -4.5psi + or –
0.5. If it is necessary to adjust the vacuum outside
its limits of -4.5 + or – 0.5 for the decay time to be
within the within the limits 2.8 to 3.2 seconds, this is
unacceptable, and would usually indicate that the
decay reservoir is faulty, and needs to be replaced.

ClearVue Service Manual Issue 08 217

Software Update
To update the current software version:

• Navigate to the Disc screen from the Options

menu.

• Insert the floppy disk containing the software

update into the disk drive.
• Press 'Software Update'.

• The following screen should appear.

• If the software update is successful, the

ClearVue will power-down and then reboot.
• After power-up and initialisation, navigate back
to the Disc screen and check that the software
and FPGA version numbers have been updated.

ClearVue Service Manual Issue 08 218

Chapter 10 – Service Schedule
• Glass filters.
Ensure all ClearVue service bulletins
have been received. • Dispense carriage skirt.
• Syringe.
Note modification strike label - include • Batteries (if required) and repeat battery test.
any outstanding updates in the service. • Air filter (if required by Service Contract level).
H - Clean / visually inspect (and lubricate as
Test instrument for earth continuity and required).
insulation resistance.
Note
If the instrument fails, do not proceed When lubricating linear rails use a LIGHT
with the service until the cause has MICROTOME OIL - NOT GREASE!
been established and rectified.
1. Load rail, unload rail and lift block (clean basket
A - Take event log. wear debris).
• Check log for stall recoveries (check motors / 2. Lubricate vertical lift rail.
assemblies highlighted). 3. Lubricate basket unload rail (2 carriages).
• Check log for phantom baskets (check input rail 4. Lubricate load rail spring plungers (4 off).
mechanisms). 5. Load rail spring plungers (ensure free
B - Ensure software is up to date. movement).
Check the following: 6. Lift block spring plunger (ensure baskets
retained positively).
• Software code version.
7. Lift block (ensure no loose play in block).
• FPGA revision level.
8. Basket open (ensure sprung loaded arm moves
• Profile.
freely).
• Store the Parameters file.
9. Lubricate basket open rail.
C - Put a dry basket through the instrument to
10. Lubricate basket open spring loaded arm.
check operation.
11. Slide guide block (moving freely, not damaged).
D - Perform battery test while removing the covers.
12. Lubricate slide guide block rail.
E - Torques. 13. Slide alignment spring (replace if damaged).
• Lift block < 0.1Nm across entire length. 14. Basket close arm (moving freely).
F - Belt tensions. 15. Lubricate basket close arm rail.
Check the following: 16. Coverslip transfer head (no excessive play).
17. Check for wear and reset the position of the
• Coverslip transfer head.
coverslip dispense end stop.
• Coverslip dispense.
18. Pipework (replace any chaffed / kinked pipes).
• Load rail.
19. Backlash on syringe drive (tighten knurled
• Vertical lift mechanism.
screws if required).
G - Replace. 20. Fans (ensure turning and quiet).
Replace the following: 21. Baskets (where possible check for
• Suction cup. wear/breakages).

ClearVue Service Manual Issue 08 219

22. Basket sliders (ensure clean runners and 6. Lay down 20 beads with covers off. Wear safety
smooth movement). glasses.
23. Basket sliders (ensure white sliders are clean 7. Prep a dry basket with the covers off. Wear
and not heavily stained). safety glasses.
24. Xylene tray. 8. Prepare 2 baskets of wet slides and get
25. Waste tray. customer acceptance of the quality - During the
second basket, switch off the Mains power and
26. Output rail drip tray / camera cover.
ensure that the battery backup system will
27. Coverslip dispense carriage and its vacuum
complete the processing.
chamber.
J - Replace debris liner and covers.
28. Lubricate coverslip dispense rail.
• Ensure all door sensors are working from
29. Dispense head cleaning station.
Production Services.
30. Dispense head.
• Coverslip a full basket to prove system is
31. Camera lens.
working satisfactorily.
32. Gripper eccentric. K - Take event log and store results on floppy disc
33. Lubricate gripper rail (2 carriages). with note of serial number and date - Return to
34. Gripper stripper mechanism. your local service representative.
35. Coverslip transfer head end stop. L - Update service history book with parts
36. Coverslip transfer head: check for smooth replaced and significant actions taken.
movement of the sprung blocks.
M - Electrical safety tests.
37. Slip dispense opto’s
• Test instrument for earth continuity and
38. Carry out Daily and Weekly cleaning tasks; refer
insulation resistance.
to the Daily Tasks section and the Weekly Tasks
If the instrument fails, do not allow back into
section.
service until problem has been found and
I - Test.
rectified.
1. Coverslip transfer head vacuum setting.
Do NOT carry out Flash (HiPot) tests.
2. Coverslip transfer head vacuum decay.
Repetition of such tests could result in reduced
3. Coverslip dispense carriage vacuum.
protection against hazards.
4. Ability to pressurise and de-gas the mountant
Always ensure that the Service Schedule you are
bottle.
following is the correct version.
5. Final test motor / mechanism tests (store results
on floppy disc with note of serial number and
date - Return to your local service
representative).

ClearVue Service Manual Issue 08 220

Routine Maintenance Schedule

ClearVue Service Manual Issue 08 221

ClearVue Service Manual Issue 08 222
ClearVue Service Manual Issue 08 223
ClearVue Service Manual Issue 08 224
ClearVue Service Manual Issue 08 225
Chapter 11 – Spares List
General
Part No Description

7411258 Filter (pk. of 6)

9990610 Filter

59920128 Proximity switch Assy

A79220085 Extraction fan Assy

A78320005 Opto Assy cableform

A79210132 Slip pick-up Assy kit

A79210015 Solenoid Assy - pressure de-gas complete

A79210016 Solenoid Assy - vacuum system complete

A79210019 Latch Assy

A79210027 Dispense head cleaning station

A79210030 Latch Assy - self retract

A79210081 Suction cups (pk. of 3)

A79210095 Coverslip dispense skirt and support

A79210105 Front i/f PCB kit

A79210106 Back i/f PCB kit

A79210107 Camera PCB kit

A79210108 Lift block plunger kit

A79220045 Pump Assy

A79210133 Motor Assy kit - transfer head / input rail

A79210135 Motor Assy kit - basket push

A79210136 Motor Assy kit - grippers

A79210137 Motor Assy kit - basket open

A79210138 Motor Assy kit - lift block

A79210139 Motor Assy kit - slip dispense

A79210140 Cleaning station actuator kit

A79220054 Actuator Assy - mountant pump

A79220058 Opto Assy - load rail

ClearVue Service Manual Issue 08 226

Part No Description

A79220059 Coverslip dispense opto

A79230014 Guide bracket

A79230015 Pusher support

A79230016 Slide pusher

A79210141 Coverslip dispense carriage Assy kit

A79210142 Coverslip dispense end stop kit

A79230111 Mountant dispense needle

A79230123 Timing pulley

A79230283 Hardened jaw bit

A79210158 Gripper return plate kit

AP14371 Microswitch

A79220056 Mountant solenoid cableform

A79210143 Solenoid Assy - mountant pump kit

AP15217 Syringe

AP15218 Gear hub clamp

A79210144 Vacuum regulator kit

AP15283 Seal - xylene tray

AP15339 Pump accessory - restrictor

AP15360 Cavro seals (pk. of 4)

P12031 Mains lead (UK)

P12032 Mains lead (USA)

P12033 Mains lead (Schuko)

P12215 Pump accessory - filter exhaust

A79210130 Spring kit

A79210131 Annual service kit

A79220089 Nozzle cap with removal label

AP15415 External USB disk drive

A79230275 Cleaning station seal

ClearVue Service Manual Issue 08 227

Slide Guide Assembly
Part No Description

A79210018 Slide guide Assy

A79230078 Slide guide spring

Electronics Box Assembly

Part No Description

77520137 Mains inlet Assy

A78020114 Floppy disk drive data cable

A78020164 Floppy disk drive power cable

A79210023 Electronics box Assy

A79210104 Mains inlet fuse kit (2 x t6.3a, 250v fuses)

A79210109 Main board PCB kit

A79210121 Processor PCB kit

A79210122 Battery kit

A79210123 Battery PCB kit

A79210124 Interconnect PCB kit

A79210152 Internal fuse kit (3 x f12a, 250v fuses)

A79220063 Fan Assy - electronics box

AP14133 Floppy disk drive

AP15186 PSU

ClearVue Service Manual Issue 08 228

Touch Screen Assembly
Part No Description

A79210125 Display PCB kit

A79210039 Touch screen complete

AP15325 Inverter PCB

AP14939 26-way touch screen cable

AP15324 Touch screen

Leadscrews and Nuts

Part No Description

A79210126 Drive transfer plate

A79210127 Latch carrier kit

Mountant Bottle Assembly

Part No Description

A79210045 Mountant bottle Assy

A79210096 Mountant bottle seal kit

A79220043 Mountant jar - Surlyn coated

Couplings
Part No Description

A79210128 Coupling kit

ClearVue Service Manual Issue 08 229

Covers
Part No Description

A79210032 LH. side Assy

A79210035 Unload door Assy

A79210036 Access door Assy

A79210129 Debris door kit

A79230140 Main cover moulding

A79230142 RH. side cover moulding

A79220088 Filter cover Assy

A79230151 Bottle cover moulding

A79230197 Debris liner

A79230198 Debris tray

Link Arm Assy

Part No Description

A79210057 Link Assy

Belts
Part No Description

A79210145 Belt kit - input motor

A79210146 Belt kit - coverslip dispense

A79210147 Belt kit - lift motor

A79210148 Belt kit - transfer head rotate

Linear Rails
Part No Description

AP15168 Rail - grippers

AP15169 Rail - mountant pump & basket eject

AP15197 Rail - slide guide Assy

AP15202 Rail - coverslip dispense

AP15244 Rail - lift

ClearVue Service Manual Issue 08 230

Chapter 12 – Technical Drawings
• Electrical Drawings
• Pneumatic Drawings

Electrical Drawings
Please refer to the electronic version of
the Electrical Drawings provided.

Always ensure that the Drawings you

are following are the correct version.

ClearVue Service Manual Issue 08 231

Pneumatics Drawings
Pneumatic Assembly Drawing 1

ClearVue Service Manual Issue 08 232

Pneumatic Assembly Drawing 2

ClearVue Service Manual Issue 08 233

Pneumatic Assembly Drawing 3

ClearVue Service Manual Issue 08 234

Pneumatic Assembly Drawing 4

ClearVue Service Manual Issue 08 235

Pneumatic Assembly Drawing 5

ClearVue Service Manual Issue 08 236

Pneumatic Assembly Drawing 6

ClearVue Service Manual Issue 08 237

Pneumatic Assembly Drawing 7

ClearVue Service Manual Issue 08 238

Pneumatic Assembly Drawing 8

ClearVue Service Manual Issue 08 239

Pneumatic Assembly Drawing 9

ClearVue Service Manual Issue 08 240

Appendices
Appendix A1 – Service Fault Codes
A1 Damage Codes
General Code Description

PM Preventative maintenance visits scheduled

UP Upgrade requests opened

MOT Motor / Encoder / Actuator failures

ELEC Electrical component issues sensors, displays, downdraft fans

AIR Leaks in pneumatic pipes

MECH This code is a general description that could be used for multiple reasons

ERR Instrument reported errors via UIF

SLIP Coverslip dispense / handling problems

SLIDE Slide alignment / handling problems

BASK Basket (or slider) handling problems

MOUNT Liquid leak - mountant / xylene

REPL Unit replacements

USER User Issues – issue generated by customer actions or inactions

ClearVue Service Manual Issue 08 241

Appendix A2 – Cause Codes
Group Code Root Cause Description

DD-PM PM1 Standard PM

DD-PM PM2 Standard PM and Scheduled Parts

DD-PM PM3 Standard PM and Non-Scheduled Parts

DD-UP UP1 Mandatory Upgrade

DD-UP UP2 Requested Upgrade

DD-UP UP3 Epredia Mandated / Sale-Demo

DD-MOT MT1 Load Rail Motor

DD-MOT MT2 Slider Open Motor

DD-MOT MT3 Basket Lift Motor

DD-MOT MT4 Slide Gripper Motor

DD-MOT MT5 Basket Eject Motor

DD-MOT MT6 Coverslip Dispense Motor

DD-MOT MT7 Transfer Head Motor

DD-MOT MT8 Dispense Head Cleaning Station Lift Motor

DD-MOT MT9 Mountant Pump Motor

DD-MOT EN1 Load Rail Motor - Encoder

DD-MOT EN2 Slider Open Motor – Encoder

DD-MOT EN3 Basket Lift Motor – Encoder

DD-MOT EN4 Slide Gripper Motor – Encoder

DD-MOT EN5 Basket Eject Motor – Encoder

DD-MOT EN6 Coverslip Dispense Motor – Encoder

DD-MOT EN7 Transfer Head Motor – Encoder

DD-MOT EN8 Dispense Head Cleaning Station Lift Motor – Encoder

DD-MOT EN9 Mountant Pump Motor - Encoder

DD-ELEC EL1 Inlet / Fuse Failure

DD-ELEC EL2 PSU Failure

DD-ELEC EL3 Cableform Fault

ClearVue Service Manual Issue 08 242

Group Code Root Cause Description

DD-ELEC PB1 Processor PCB

DD-ELEC PB2 Interconnect PCB

DD-ELEC PB3 Motor Drive PCB

DD-ELEC PB4 Battery Charger PCB

DD-ELEC PB5 Camera PCB

DD-ELEC PB6 Display Interface PCB

DD-ELEC PB7 Rear Interface PCB

DD-ELEC PB8 Front Interface PCB

DD-ELEC EL4 Display Panel

DD-ELEC EL5 Touch Screen

DD-ELEC EL6 Battery Failure

DD-ELEC EL7 Disc Drive Failure

DD-ELEC EL8 Solenoid Coil Failure

DD-ELEC EL9 Opto Sensor – Coverslip Detect

DD-ELEC ELA Opto Sensor – Mechanism Home

DD-ELEC ELB Door Sensor Fail

DD-ELEC ELC Fan Failure

DD-ELEC ELD Filter Switch Fail

DD-ELEC ELE Battery Switch Fail

DD-AIR PN1 Filter Blocked

DD-AIR PN2 Pipe Blocked

DD-AIR PN3 Pipe Detached

DD-AIR PN4 Valve Leak / Seal Failure

DD-AIR PN5 Incorrect Piping

DD-AIR PN6 Suction Cup Dirty

DD-AIR PN7 Suction Cup Position Wrong

DD-AIR PN8 Vacuum Setting Wrong

DD-AIR PN9 Vacuum Release too Fast

ClearVue Service Manual Issue 08 243

Group Code Root Cause Description

DD-AIR PNA Vacuum Release too Slow

DD-AIR PNB Mountant Filler Cap Leaking

DD-MECH ME1 Load Rail Mechanism Fault

DD-MECH ME2 Slider Open Mechanism Fault

DD-MECH ME3 Basket Lift Mechanism Fault

DD-MECH ME4 Slide Gripper Mechanism Fault

DD-MECH ME5 Basket Eject Mechanism Fault

DD-MECH ME6 Coverslip Dispense Mechanism Fault

DD-MECH ME7 Transfer head Mechanism Fault

DD-MECH ME8 Dispense head Mechanism Fault

DD-MECH ME9 Mountant Pump Mechanism Fault

DD-ERR E01..E20 Instrument Reported Error

DD-SLIP CS1 Broken Coverslips

DD-DLIP CS2 Hopper Deformed / Not Sitting Correctly

DD-SLIDE SL1 Broken Slide

DD-BASK BK1 Basket Stuck on Load Rail

DD-BASK BK2 Basket Slider Stuck

DD-BASK BK3 Basket Cannot Lift Through Guides

DD-BASK BK4 Basket Eject Alignment Fail

DD-BASK BK5 Basket Eject Mechanism Fail

DD-MOUNT MN1 Syringe Leaking

DD-MOUNT MN2 Mountant pipe Leaking

DD-MOUNT MN3 Mountant Dispense Needle Blocked

DD-MOUNT MN4 Mountant Dispense Needle Too High

DD-MOUNT MN5 Mountant Dispense Needle Too Low

DD-REPL REP Replacement Instructions

DD-USER USR User Error

ClearVue Service Manual Issue 08 244

Appendix A3 – Parameters
Reset 7
# Name Used For
Value

0 Cam. Skew Correction 7 Correction of camera skew, normally 7

1 Lines down start 60 Lines down from 0 to start capturing data

2 Pixels in start 100 Pixels in from 0 to start capturing camera data

3 Cam. Line width 580 Width of image (divide by 2 for actual pixels)

6 V_GOOD 22 Battery Voltage Threshold

7 V_FAIR 20 Battery Voltage Threshold

8 V_POOR 18 Battery Voltage Threshold

9 V_WARN 16 Battery Voltage Threshold

10 V_DEAD 10 Battery Voltage Threshold

15 Lift Raise AMT. 10 Lift Raise amount Between Slides

45 Slip.Acc 1 Coverslip Carriage Speed Profile

46 Slip.Dec 1 Coverslip Carriage Speed Profile

47 Slip Start 120 Coverslip Carriage Speed Profile

48 Slip Max 140 Coverslip Carriage Speed Profile

49 Slip End 90 Coverslip Carriage Speed Profile

54 Slip Retry Count 2 No. of attempts to get a good coverslip

55 Draw Shift Right 40 Auto set on camera initialisation (used in snapshot)

56 Motor Speed Scale 1 Leave at 1

57 Nozzle Pot Purge Amount 95 Purge amount before entering cleaning station

59 Optic 1 1000 Coverslip dispense optical threshold for 0/1 coverslip(s)

60 Optic 2 275 Coverslip dispense optical threshold for 1/2 coverslip(s)

61 Suckback position 40 Quads after last blob for suckback start

Is -1.8 psi target if set at 18 regulator should pull less than

62 Prep Vacuum Target / 10 18
this when holding a coverslip

63 Vacuum Target 6 For De-gas on bottle

64 Pressure Target 10 For load cycle on bottle

67 Prep Final Pause 150 Pause (10 x 10ms) before removing suction cup

68 Cam Lines Down 150 Where to start pulling camera data from FPGA

ClearVue Service Manual Issue 08 245

 Reset 7
# Name Used For
Value

Max. skew on coverslip (in motor quads, 1 quad =

69 Slip Skew Max 14
0.181mm)

Threshold at which the camera will recognise a slide. If set

Camera Slide Visibility
72 95 to a very low value (eg:20) ClearVue will try very slide
Threshold
position.

Used for image processing, may reduce to 0 for improved

76 Black Image DSP Amt. 10 slide detection. Do not change this parameter unless
directed to do so by a Epredia Service Engineer.

Used for image processing, may reduce to 0 for improved

77 White Image DSP Amt. 20 slide detection. Do not change this parameter unless
directed to do so by a Epredia Service Engineer.

Speed of transfer head rotation when at final coverslip

79 Final Slow Speed 2
preparation

80 Final Slow Position 10 Position of final slow speed in quads above hard stop

81 Prep Form Speed 81 Speed as coverslip attaches to slide

82 Hi Speed Stop 2 80 High speed stop (auto stop) in quads above hard stop

Position carriage move to when measuring coverslip

84 Slip Normal Out 10500
qualities

85 Suckback Speed 130 Speed of pump during suckback

86 Suckback Amount 144 Amount pump moves in quads for suckback

Used to align coverslip dispense with transfer head rotation

90 Slip Out Adjust 130
block. Can be set using ProdTst6.

No. of pixels between top of slide and jaw target value. Can
92 Slide Adjust Target 4
be set using ProdTst5.

Quads to release suction of coverslip when coverslipping

93 Release Suction Quad 15
qauds before hard stop.

Quads to switch off pump when coverslipping – Quads

94 Pump Off Quads 15
before hard stop

Use for aligning slide out (with grippers) to central transfer

95 Slide Out Adjust 435
head. Can be set using ProdTst6

96 Pickup Adjust 2 Quads above carriage to pick up coverslip

97 Slip Put Down Adjust 5 Target of X quads above hard stop during coverslipping

Quads to push basket onto lift block – Increase to push

98 Load On Quads 651
further

ClearVue Service Manual Issue 08 246

Appendix A4 – Accessories
Item Part Number

Coverslip Hopper, Pk. of 2 (24 x 40mm, #1.5, 500 off) A79210050

Coverslip Hopper, Pk. of 2 (24 x 50mm, #1.5, 500 off) A79210051

Coverslip Hopper, Pk. of 2 (24 x 55mm, #1.5, 500 off) A79210052

Coverslip Hopper, Pk. of 20 (24 x 40mm, #1.5, 500 off) A79210074

Coverslip Hopper, Pk. of 20 (24 x 50mm, #1.5, 500 off) A79210075

Coverslip Hopper, Pk. of 20 (24 x 55mm, #1.5, 500 off) A79210076

Gemini Basket with Black Slide Retainer (Pk of 5) A79210064

Gemini Basket with White Slide Retainer (Pk of 5) A79210065

V24 Basket with Black Slide Retainer (Pk of 5) A79210069

V24 Basket with White Slide Retainer (Pk of 5) A79210070

Sakura Basket with Black Slide Retainer (Pk of 5) A79210066

Sakura Basket with White Slide Retainer (Pk of 5) A79210067

Leica Basket with Black Slide Retainer (Pk of 5) A79210072

Leica Basket with White Slide Retainer (Pk of 5) A79210073

Vent Extraction Kit A79210080

V24 Kit A79210071

Sakura Hanger Kit (Pk of 5) A79210068

Cytology Loading Tray A79210092

Offset Coverslip Transfer Head Kit A79210099

Shandon ClearVue Mount XYL 4212

Shandon ClearVue Mount 4211

ClearVue Service Manual Issue 08 247

Appendix A5 – Spare Parts
Item Part Number

Fuse Kit (Pk of 2) A79210104

Carbon Filter 9990610

Carbon Filter (Pk of 6) 7411258

Slip Dispense Skirt and Support A79210095

Suction Cup (Pk of 3) A79210081

Dispense Head Cleaning Station A79210027

Mountant Bottle (Complete) A79210045

Mountant Bottle Seal Kit A79210096

Xylene Tray Seal AP15283

Gripper Return Plate A79210158

Soft Hair Brush P12257

Pure Bristle Brush P12940

ClearVue Service Manual Issue 08 248

Appendix B – Approved Appendix C – Packing
Reagents Instructions
Reagents Ensure the instructions for cleaning have been
followed.
• Xylene
• Toluene Discard chemicals according to local
• Ethanol environmental procedures
• Industrial Methylated Spirit (IMS) - up to 5% • Remove the Debris Tray:
methanol in ethanol 1. Remove any discarded glass
• Isopropanol (IPA) 2. Clean any Mountant off
• Water 3. Dry
• Sodium Hypochlorite (10% in water) • Remove the Dispense head cleaning station:
Mountants 1. Discard any liquid
• Shandon ClearVue Mount XYL 2. Clean with xylene
• Shandon ClearVue Mount 3. Dry
Note • Remove the Xylene tray:

All Mountants are available from Epredia. 1. Discard any liquid

2. Dry
• Remove the Coverslip Hopper
• Remove the Gripper return plate
• Remove the Slip dispense skirt
• Remove the Dispense head and place in a
suitable container to allow it to drain
• Remove the Mountant Bottle and rinse with
xylene, or replace with a fresh bottle
• Pour 25ml of xylene into the clean Mountant
Bottle and Flush the system
• Replace the Dispense Head
• When the Flush cycle is complete, check that the
Mountant Bottle Cap is clear of Mountant
• Place the Dispense Head Cap over the Dispense
Head Needle to prevent the xylene which
remains in the system from leaking out during
transit
Approximately 5ml of xylene will
remain in the system - follow good
laboratory practice when packing
and unpacking.
• Disconnect the Power Lead
• Ensure the Battery Switch has been set to the off
’O’ position
• Follow the Packing Instructions

ClearVue Service Manual Issue 08 249

ClearVue Service Manual Issue 08 250
Appendix D1 – Main Menu

ClearVue Service Manual Issue 08 251

Appendix D2 – Mountant System Screens

ClearVue Service Manual Issue 08 252

Appendix D3 – Options Screens

ClearVue Service Manual Issue 08 253

 below for further information on slip dispense
Appendix E – Understanding values.
Log Files
Voltages
792 Log Macro.xls Information for Values are logged immediately after switch on and
A79210155 issue 1 log tool every hour thereafter. Values are also logged when
Summary a power fail is detected.

This is a quick reference sheet to highlight areas in The voltages readings are in units of approximately
the log file that need to be scrutinised, this could be 10mV. 2400 ≈ 24V.
a sheets that a service engineer could print and file V PSU is the voltage detected from the PSU. This
for reference. will typically be around 24V. Values of 18-20V are
typical at power fail (when the unit is switched off).
Errors
V BATT1 is one of the backup batteries. This will
List of every error in the log file (shows all slips errors
typically be in the range 12-15V depending on state
& not just the ones the user see’s)
of charge. Lower values can be expected during
periods when the unit is running on batteries.
Prep decay chart
V BATT2 is the second of the backup batteries.
Prep decay data in easy to read chart format - see
When the unit is running on batteries, this will show
below for further explanation on prep decay charts.
the total voltage of the two batteries, typically 26-
Warnings 28V immediately after a mains power fail.

List of all the warnings in the log file. The OC and STL signals indicate the charger status.

Hz ELEC is the speed of the electronics box fan.

Prep decay Typically 95-115Hz. This fan should run
Data for every decay time logged. Limits as per the continuously.
decay chart see below for further information. Hz EXTR is the speed of the extract fan. This is 0
when the unit is first switched on or when the filter
Opto chart
is not fitted. The fan has 2 running speeds, 70-90Hz
The absolute values are not critical (typically is the low speed, 115-125Hz is the high speed.
between 200 and 800, acceptable limits are 100 to
°C Elec is the temperature sensor on the battery
900), however an increase in the optical sensor
charger board indicating the approximate internal
reading indicates a reduction in the signal strength
temperature of the electronics box.
typically caused by glass dust on the sensors. The
sensors are housed just in front of the coverslip mp_load
dispense skirt and can be cleaned from below with
a soft brush. Note, when no coverslip is present the See below for a full description of mp_load
value is typically 1300-1400 however it is not
Lift opto
expected that these values will be see on the logs.
Logs when lift top opto seen during eject sequence,
Slip optos we are interested in how much the value varies.
Data for slip opto chart, limits as per chart. Based on the random check of 12 of the last 30
units the value varies between 0 & 11 quads.
Slip dispense
Shows logged values for slips dispense Quad A, B,
C & D values plus error code. Includes a quick
reference table with error quantities shown; see

ClearVue Service Manual Issue 08 254

Slide width • One value is consistent and the other value
varies by 1 pixel.
Actual width of slide = [logged width of jaws] + 5.6
- (2 x [slide thickness]). When you take into account • Both values vary by 1 pixel.
the tolerances on slides and the jaws the logged In any of these cases the unit will run fine.
values should be in the range 18.1mm - 23.4mm.
There have been some units where one of the
Software rejects widths below 16mm and above
values varies by 2 pixels and the other is either
23.7mm. Tab is not all that useful as we are not
consistent or varies by 1 pixel. The majority of the
really interested in the variation but could be used to
time the unit will still handle slides without issues,
see if slides are close to maximum width. May be
however if the jaw y value also varies by the
more useful if plotted on a chart, since it would show
maximum amount or if the jaws are at the maximum
when values are tending to trend upwards, due to
allowable runout you will start to see an increase in
the gripper return plate getting tacky.
error 6(91)’s. A unit may also give errors if the basket
runout is too high, this is not checked and cannot
Basket load
be adjusted.
Shows logged values for stall quad, max & pos, load
If either of the basket top values varies by more than
quad & pos & basket open quads. These are again
2 pixels or both vary by 2 pixels the unit will most
values where we are concerned with variation rather
likely start to give errors. However this is not always
than absolute limits. There are 3 logged values, the
the case since if everything else nominal the unit can
first value is the final stall quad, the second is the
carry on functioning OK. So far the only units that
further the load rail pusher has jumped back when
have exhibited this much variation have also
stalling on the basket. This value would normally be
showed variation in jaw y values and it has been
just less than the first logged quad value. A large
indicative of Camera problems.
difference in both may indicate problems with load
rail belt tensions.
Basket times
Jaw_y Shows all the logged basket processing times and
can be useful for a quick check it the customer has
We are interested in the variation of jaw x & y. Jaw
not been clearing errors in a timely fashion,
y should not vary by more than ±1pixel so the
especially if there are complaints about drying. - see
difference in variation values should be <=2.
below for further information about basket times.
Note
Start of basket
Software version 1.78 issue 8 centres the jaw_x and
jaw_y to fixed positions. Shows the profile version, the set and used
mountant levels, as well as slide threshold (P72).
Jaw_x should be 225 and jaw_y should be 65.
See below for further information about start of
Note basket.
There will be log events of the original jaw_x and y
Software version
positions before adjustment to compare with
previous values taken. Shows software version

Basket top Sorted data

As with jaw y we are looking for consistency across Just used to create the other tabs but can be useful
top 1 & 2 for each of the basket types. if additional data extraction is required.

On most instruments you will see:

• Both values are consistent.

ClearVue Service Manual Issue 08 255

Original data each slide. Any machine running below 1.2 seconds
should be checked by a service engineer and fixed.
Original data untouched, apart from separating
date, time & log entry into separate columns. Decay time with a general trend upwards (more than
2 seconds over 400 slides)
Note
This could be related to temperature and how the
If you sort this tab you may not be able to put it back
restrictor that controls the release of vacuum has
in the correct order as many log entries have
expanded and restricted the flow. Monitor the
identical time stamps.
situation. Check that the machine has a decay
Further Information reservoir fitted and fit where required. Reset the
decay time to 3 seconds.
Prep_decay_chart Decay time above 6 seconds

This will slow the machine down, but will not affect
the quality of the prep. The priority of the customer
should be considered: Prep quality V’s speed of the
machine. Errors are reported if the slip has not been
released after 13 seconds.

Check the scale is 0 to 6 seconds.

The decay (blue line and points) should be 3

seconds }1 second, i.e. between the red lines.

Things to check for:

Decay dropping to 0 for one or more slides

This is likely to be caused by suction cup

contamination. Clean the suction cup and check for
broken slips or excessive overspill. Use the Prep
Decay tab to find the actual value.

General deterioration in decay time

Check for leaks; contaminated suction cup (broken

glass or mountant), damaged suction cup. Check
pipe is pushed into the fittings firmly.

Decay time at or below 2 seconds.

This is the limit for good coverslip quality. Below this

decay time there is a high risk of the slip slapping
down onto the slide causing multiple bubbles on

ClearVue Service Manual Issue 08 256

prep_decay

Date Time Decay time in seconds

07/07/2008 13:39:36 Prep Decay Time 3.33

07/07/2008 13:39:47 Prep Decay Time 3.32

07/07/2008 13:39:58 Prep Decay Time 3.33

Use [ ctrl ] + [ f ] to find the date or time required for the actual decay time value.

mp_load

Date Time Quad Reached Position

End of mp load cycle at

07/07/2008 13:42:47 11187
quad: 11188

End of mp load cycle at

07/07/2008 13:53:24 11203
quad: 11205

End of mp load cycle at

07/07/2008 14:31:22 11189
quad: 11191

This has been used as a development tool along with 'dispense end' values to determine how much mountant
has been dispensed.
The Quad value is from the encoder and is the position actually reached. The position value is the position
demanded of the motor and where it is aiming for.

A difference of more than 100 between quad and position shows there has been some stall on the motor.

The syringe should refill to±0.5mm each time (approx. 165 quads).

333 quads = 1mm of syringe movement.

Basket_times

Date Time Time for each basket

07/07/2008 13:42:47 Total time 03:07

07/07/2008 13:53:24 Total time 03:15

07/07/2008 14:31:22 Total time 02:37

This shows the time taken for each basket.

Time is dependent on the number of slides in the basket, the decay time and how long the customer takes to
clear any errors.

ClearVue Service Manual Issue 08 257

Start_of_basket

Profile W
Date Time Used B Set
Version Set

11/09/2008 11:27:49 87 5 5 12 Slide Thresh: 095

11/09/2008 11:34:03 87 5 5 12 Slide Thresh: 095

11/09/2008 11:38:36 87 5 5 12 Slide Thresh: 095

The profile version controls the shape of the bead and affects the prep quality.

'Used' is the volume setting used for the basket.

'B Set' is the volume set for black sliders.

'W Set' is the volume set for white sliders.

Slip_dispense
This page shows you how many slips have been dispensed, the engineering error code with how many errors,
plus the % of errors in that category.
If double slips are reported find out if there are actually 2 slips dispensed on the carriage together. If so check
the end stop height, if not, use the Autoslip to reset the thresholds for no slip and double slips. If length errors
are reported check there is sufficient vacuum on the carriage.

Raw Log Files

The following text is the cycle of one basket through ClearVue. This is the pattern you should see when looking
at raw log files. Each line has a description of what is happening.

Basket detection has started.

09/11/2008 11:27:40 GOOD INPUT STALL DETECTED: quad: 13554 Min Quad seen:13554 Pos:13623

Basket has been detected by load rail, 1 basket found.

09/11/2008 11:27:40 Input Rail basket count = 01

Basket has been loaded to lift

09/11/2008 11:27:42 Basket loaded to lift success @ quad = 14169 and position = 14213
Camera jaw_x and jaw_y are re-tested to ensure no change in image has been seen. Ignore NEW POS 500
value.

09/11/2008 11:27:43 camera JAWY_Y re-tested from below, old pos=065 new pos=500

This line shows the prep head has checked the pin width on the prep transfer head and has detected a normal
(around 40 ) prep head in the END position.

09/11/2008 11:27:43 Prep head pin width: 0040

This line is showing the calculated position of the jaw using a different method, values should closely resemble
that of the above jaw_x and jaw_y by +/1 1 pixel.

09/11/2008 11:27:43 AUX CAM INIT NEW: jaw_x, 226, jaw_y, 064 OLD: jaw_x, 225, jaw_y, 065 USED:0

ClearVue Service Manual Issue 08 258

This line shows a check the camera does on the image; it takes one image and examines the image for HALO
effects which are often caused by dirty or out of focus lenses. Clean values greater than 6/7 should be
investigated. Typical values are 2/3

09/11/2008 11:27:43 Camera Lens QC Check: High thresh: 037, Low Thresh :039, CLEAN VALUE :002

This shows the quad of the basket open slider when fully opened.

09/11/2008 11:27:45 Basket slider opened @ 11043

Basket processing is about to begin. OFFSET target is parameter 92 value. Jaw at is current jaw_y value.

09/11/2008 11:27:47 Start of basket. OFFSET TARGET=004 JAW_AT:065

Detection of basket top has started, first picture has been taken and analysed as shown. It can be seen that
both basket top values are the same value and equal to white strip bot. this indicates the basket is not in view
of the camera and therefore is a smaller 20 slide basket. White strip bot value is the lowest part of the white strip
the camera can see. Notice BIG,SMALL value is 1 which indicates the lift is at BIG basket position.

09/11/2008 11:27:47 (BIG BASKET CODE) Basket top 1,00085, Basket top 2,00085, White Strip bot,00085,
BIG(1)SMALL(0),1 At lift quad, 09610
Second basket top position, now at SMALL basket position. You can see the basket top values are 71 and 69.
two pictures are taken for basket top, one is 11 quads higher than the other. This gives the values of 71 and 69
and are different to white strip bottom - this means a valid basket top has been found. Notice BIG,SMALL VALUE
is 0 indicating lift at SMALL position.

09/11/2008 11:27:49 (BIG BASKET CODE) Basket top 1,00071, Basket top 2,00069, White Strip bot,00085,
BIG(1)SMALL(0),0 At lift quad, 09059

The lift and camera have worked out from all the info above, the correct position to move to for processing the
basket. This is known as the final 1st slide position.

09/11/2008 11:27:49 (BIG BASKET CODE) Final 1st Slide Position,08723, Total Slides to Process,00020,
Basket top1,071, top2,069

This values shows the colour of the basket slider, low values indicate BLACK sliders, high values for white.

09/11/2008 11:27:49 Basket slider white percent : 001

First slide position has been reached. Quad and target values should be within 1 quad of each other.

09/11/2008 11:27:49 Lift @ 1st slide position, quad:08723, pos:08723, Target:08723

A quick reminder of the profile version and mountant settings used on this basket.

09/11/2008 11:27:49 start of basket processing - Profile V:87 @ setting :05 Black:05 White:12 Slide Thresh:095

This chunk of events shows a complete cycle of removing the slide and performing the prep, these events should
be repeated 20 times for small baskets. Pos values indicate what is visible to the camera, pos0 is current slide
slot, 1 is next and 2 is after next slot. Values of 15 will detect a slide as present. Decreasing the camera slide
threshold parameter will increase these numbers but will more likely cause ClearVue to grab slides not present.
Decay time is another important number here, which gives indication to machine performance within the
pnumatic system.

09/11/2008 11:27:50 pos_0:050 pos_1:043 pos_2:090 @ quad:08723 Slide No:01

09/11/2008 11:27:50 Gripper detected slide ok, final pos adjust = :-14 Quad 1:56582 Quad 2:57221 Width of
Jaws: 21.94 mm

ClearVue Service Manual Issue 08 259

09/11/2008 11:27:52 DISPENSED SLIP PROPERTIES -> qa:10194 qb:10194 qc:10468 qd:10468 er_no:00

09/11/2008 11:27:52 Good slip, optics at, 00292, 00230

09/11/2008 11:27:54 dispense end @ Qd:12085 pos:12087 Suckback end @ Qd:12032 pos:12029 with
timer:00042

09/11/2008 11:28:00 Prep Decay Time - 03.42

Finally we reach basket end, which shows the total time to process the basket.

09/11/2008 11:31:23 Basket processing finished Total time, 03:30

This quad value is that of the lift when the flag passed the upper lift opto. Variation in this value should be minimal.

09/11/2008 11:31:30 Lift TOP opto seen->not seen at:03468

ClearVue Service Manual Issue 08 260

Index
Slide Grippers ....................................................... 13
A Slide Guide Assembly ........................................... 13
Abort a Basket ........................................................... 38 Vertical Lift and Lift Block ...................................... 12
Adjust the Change the Time and Date Setting ............ 94 Build Subassembly Tests............................................ 65
Adjust the Coverslip Position ...................................... 90 Disk Drive Check .................................................. 68
Adjust the Mountant Dispense Volume ....................... 97 Electronics Sub-Assembly Tests ........................... 66
Adjust the Screen Settings ......................................... 94 Inspecting the Basket Open and Lower Slide
Alter the Slide Sensing Parameter ............................ 100 Retention .............................................................. 69
Appendices .............................................................. 241 Inspecting the Cleaning Station Assembly ............. 72
Appendix A1 – Accessories ................................ 241 Inspecting the Covers and Filter ............................ 72
Appendix A2 – Cause Codes .............................. 242 Inspecting the Coverslip Dispense......................... 70
Appendix A3 – Parameters ................................. 245 Inspecting the Coverslip Transfer Drive.................. 71
Appendix A4 – Accessories ................................ 247 Inspecting the Coverslip Transfer Head ................. 70
Appendix A5 – Spare Parts................................. 248 Inspecting the Input Rail ........................................ 68
Appendix B – Approved Reagents ...................... 249 Inspecting the Mountant Bottle and Lines ............. 72
Appendix C – Packing Instructions ..................... 249 Inspecting the Mountant Dispense Head and Needle
Appendix D1 – Main Menu ................................. 251 ............................................................................. 70

Appendix D2 – Mountant System Screens .......... 252 Inspecting the Mountant Pump Actuator and Syringe
............................................................................. 72
Appendix D3 – Options Screens ......................... 253
Inspecting the Output Pusher and Upper Slide
Appendix E – Understanding Log Files................ 254
Retention .............................................................. 71
Further Information........................................ 256
Inspecting the Output Rail ..................................... 71
Inspecting the Pneumatic Circuit ........................... 73
B Inspecting the Slide Grippers ................................ 69
Basic Operation ......................................................... 23 Inspecting the Slide Guide Assembly..................... 69
Daily Tasks ........................................................... 24 Inspecting the Vertical Lift and Lift Block ............... 68
Weekly Tasks ....................................................... 24 Performance Test ................................................. 68
Basic Structure .......................................................... 12
Basket Eject and Upper Slide Retention................ 13 C
Basket Open and Lower Slide Retention ............... 12
Change the Carbon Filter ............................................ 25
Camera ................................................................ 14
Change the Coverslip Transfer Head Position ............. 92
Cleaning Station Assembly ................................... 14
Change the Purge Tray and Debris Tray ..................... 29
Covers and Filter .................................................. 14
Change the System Language .................................... 95
Coverslip Dispense ............................................... 13
Cleaning ................................................................... 105
Coverslip Transfer Head ....................................... 13
Cleaning the Camera .......................................... 119
Input Rail .............................................................. 12
Cleaning the Coverslip Transfer Head ................. 118
Mountant Bottle .................................................... 14
Cleaning the Dispense Head Cleaning Station ..... 109
Mountant Dispense Head ..................................... 13
Cleaning the Gripper Return Plate ....................... 116
Mountant Pump Actuator and Syringe .................. 14
Cleaning the Mountant Bottle Cap ...................... 106
Output Rail ........................................................... 13
Cleaning the Mountant Bottle Seal ...................... 107
Pneumatic Circuit ................................................. 14
 Cleaning the Mountant Dispense Needle ............ 114 ENG Tab - Page 4/7 ............................................. 56
Cleaning the Slide Grippers ................................ 117 ENG Tab - Page 5/7 ............................................. 57
Cleaning the Slip Dispense Carriage ................... 112 ENG Tab - Page 6/7 ............................................. 58
Cleaning the Slip Dispense Skirt ......................... 115 ENG Tab - Page 7/7 ............................................. 60
Cleaning the Suction Cup ................................... 110 Engineers' Log Extraction ......................................... 176
Cleaning the Touch Screen................................. 115 Example of Varistain Gemini Basket ............................ 21
Cleaning the Xylene Tray Seal ............................. 108
Cleaning and Maintenance Precautions .................... 101
F
Company Information ................................................... 3
Fill the Dispense Head Cleaning Station ...................... 30
Compatibility .............................................................. 19
Fill the Mountant Bottle ............................................... 28
Contact address .......................................................... 3
Fit the Extraction Kit ................................................... 26
contents....................................................................... 4
Flush the System ........................................................ 32
Coverslipping Method ................................................ 22
Front view of ClearVue ................................................ 20
Create the Engineers Log ........................................... 95
Functional Tests ......................................................... 61

D
G
Degas the Mountant Bottle......................................... 32
General Description .................................................... 12
Design Purpose ......................................................... 19
Special design features of the ClearVue ................ 12
Disposal of Sealed Lead Acid Batteries ........................ 8

E I
I/O Tab ....................................................................... 43
Earth Continuity and Insulation Resistance Tests ........ 62
I/O Tab – I2C ........................................................ 45
Electronics Assembly ................................................. 15
I/O Tab – INPUTS ................................................. 43
Back Interface Board ............................................ 18
I/O Tab – LINKS.................................................... 46
Battery Board and Batteries.................................. 17
I/O Tab – OUTPUTS ............................................. 44
Camera Board ...................................................... 18
I/O Tab – VOLTAGES ........................................... 46
Electronics Box - Miscellaneous Items .................. 17
Identification of Parts (front) ........................................ 20
Front Interface Board............................................ 18
Identification of Parts (rear) ......................................... 20
Interconnect Board ............................................... 17
Identifying Problems with Slides
Main Board .......................................................... 15
Diagnosis Flowchart ............................................ 142
Mains inlet and power supply................................ 15
Excessive Bubbles .............................................. 130
Miscellaneous Items ............................................. 18
Prepared Slides – Troubleshooting ...................... 131
Motors ................................................................. 18
Individual Motor Tests................................................. 62
Overview .............................................................. 15
Basket Eject Motor Test ........................................ 63
Processor Board .................................................. 15
Basket Open Motor Test ....................................... 63
Pumps (Air) ........................................................... 18
Coverslip Dispense Motor Test.............................. 63
Sensors ................................................................ 18
Coverslip Transfer Head Motor Test ...................... 62
Solenoid valves..................................................... 18
Dispense Head Cleaning Station Motor Test ......... 64
ENG Tab .................................................................... 50
Gripper Motor Test ............................................... 63
ENG Tab - Page 1/7 ............................................. 51
Input Rail Motor Test............................................. 62
ENG Tab - Page 2/7 ............................................. 53
Lift Block Motor Test ............................................. 62
ENG Tab - Page 3/7 ............................................. 55
 Mountant Pump Motor Test .................................. 64
Inside ClearVue .......................................................... 20 P
Install the Offset Coverslip Transfer Head ................... 98 PARAM Tab ............................................................... 43
Instrument Verification Tests....................................... 74 Parts Replacement ................................................... 177
Carrying Out a Bead Test ..................................... 88 Outer Case Removal ........................................... 178
Checking and Adjusting Gripper-to-Gripper Alignment Parts Replacement by Sub-Assembly ................. 182
............................................................................ 81 Safety ................................................................. 177
Checking and Adjusting Short Gripper Stop Cam . 86 Tools Required ................................................... 177
Checking and Adjusting the Coverslip Transfer Head Parts Replacement by Sub-Assembly
Hard Stop Checking the Position .......................... 84 Basket Open & Dispense Head Cleaning Station
Checking and Adjusting the Coverslip Transfer Head Assembly Parts Replacement ............................. 184
Sprung Pads ........................................................ 80 Basket Push Motor Assembly Parts Replacement192
Checking and Adjusting the Needle Height ........... 83 Camera Board Replacement ............................... 212
Checking and Setting Coverslip Dispense Optical Coverslip Dispense Motor Assembly Parts
Sensors ................................................................ 87 Replacement ...................................................... 200
Checking Door Sensors and Filter Switch ............. 86 Coverslip Transfer Head Motor Assembly Parts
Checking Software, FPGA and Pump Profile Version Replacement ...................................................... 190
............................................................................ 85 Display PCB Parts Replacement ......................... 208
Checking the Coverslip Transfer Head Position ..... 87 Electronics Box Individual Component Replacement
Coverslip Dispense End Stop Height .................... 84 ........................................................................... 195
Coverslip Dispense System Test ........................... 80 Electronics Box Parts Replacement .................... 193
Mountant Bottle Pneumatic Test ........................... 78 Front I/F PCB Parts Replacement ....................... 204
Performance Test 1 .............................................. 75 Gripper Actuator Parts Replacement ................... 203
Performance Test 2 .............................................. 77 Gripper Jaws ...................................................... 216
Performance Test 3 .............................................. 78 Input Motor Assembly Parts Replacement ........... 205
Resetting Parameters ........................................... 86 Input Rail Assembly Parts Replacement .............. 206
Vacuum System Test............................................ 79 Inverter PCB Parts Replacement ......................... 209
Introduction to ClearVue............................................. 10 Lift Block Leadscrew Parts Replacement ............ 214
Introduction and Safety......................................... 11 Lift Block Parts Replacement Procedure ............. 183
Safety ............................................................. 11 Lift Motor Parts Replacement .............................. 213
Miscellaneous Tests for Other Replacements ...... 215

L Mountant Pump Actuator Assembly Parts

Replacement ...................................................... 188
Level the ClearVue before Use ................................... 25
Mountant Solenoid Assembly Parts Replacement 187
Load a Basket............................................................ 36
Mountant Syringe Parts Replacement ................. 188
Pump Assembly Parts Replacement ................... 184
M Rear I/F PCB Parts Replacement ........................ 205

Maintaining the Xylene Tray Level ............................... 27 Slide Guide Parts Replacement ........................... 210

Maintenance ............................................................ 101 Slip Dispense Carriage, End Stop and Support Arm
Parts Replacement ............................................. 211
Manually Abort a Basket ............................................ 38
Solenoid Assembly Parts Replacement ............... 189
MOTOR Tab .............................................................. 48
Touch Screen or Proximity Switch Parts Replacement
........................................................................... 209
Vacuum Regulator Parts Replacement ................ 189
Prepare the ClearVue for Storage ............................. 104 System Interfacing ...................................................... 21
Production Services ................................................... 41 System Specifications ................................................ 21
Introduction .......................................................... 42 Electrical Specifications ......................................... 21
Purge the System ...................................................... 33 Environmental Specifications ................................. 21
Physical Specifications .......................................... 21

R
Rear of the ClearVue .................................................. 20 T
Remove and Replace the Coverslip Hopper ............... 34 Technical Drawings .................................................. 231
Remove Baskets from the Load & Unload Rail............ 39 Electrical Drawings.............................................. 231
Remove Baskets from Vertical Lift .............................. 40 Pneumatics Drawings ......................................... 232
Remove Slides during Coverslipping........................... 39 Troubleshooting ....................................................... 120
Remove the Mountant Bottle .................................... 103 Error Code Cross-Reference Table ..................... 126
Replacing Seals ....................................................... 102 Error Screens...................................................... 121
Identifying Problems with Slides .......................... 129
Perform a Bead Test ........................................... 128
S
Quick Reference to Errors ................................... 125
Safety Information ........................................................ 7
Telephone Support ............................................. 121
Chemical Safety ..................................................... 8
Troubleshooting Tables ............................................ 143
Environment ........................................................... 9
Basket Jams ....................................................... 154
General Safety ........................................................ 7
Breaking Coverslips ............................................ 152
Introduction ............................................................ 7
Breaking Slides ................................................... 157
Warranty Statement................................................ 9
Coverslip Mis-Dispense....................................... 150
Select the Coverslip Position ...................................... 91
Coverslip Position Wrong on Slide....................... 146
Service Schedule ..................................................... 219
Coverslip Vacuum Faults ..................................... 167
Routine Maintenance Schedule .......................... 221
Dispense Head Dirty ........................................... 146
Settings ..................................................................... 89
Dispense Needle Dirty/Blocked ........................... 148
Shutting Down the ClearVue ...................................... 35
Excessive Drying of Slides................................... 160
Slide Retainer Types .................................................. 97
Extraction System Faults ..................................... 162
Software Update ...................................................... 218
Loss of Parameters and Settings ........................ 161
Spares List ............................................................... 226
Machine Dead – No Power ................................. 144
Belts................................................................... 230
Mountant Dryback .............................................. 148
Couplings ........................................................... 229
Mountant Overspill .............................................. 147
Covers ............................................................... 230
Mountant Pump and Syringe Faults .................... 169
Electronics Box Assembly................................... 228
Part Broken Coverslips ....................................... 159
General .............................................................. 226
Pneumatics for Mountant Bottle .......................... 163
Leadscrews and Nuts ......................................... 229
Skewed Coverslips ............................................. 159
Linear Rails ......................................................... 230
Slide Jams .......................................................... 149
Link Arm Assy .................................................... 230
Slides not Coverslipped ...................................... 155
Mountant Bottle Assembly .................................. 229
Slides too wet ..................................................... 159
Slide Guide Assembly ......................................... 228
Touch Screen Assembly ..................................... 229
Start up the ClearVue ................................................. 30 U
Symbols....................................................................... 3 Unload a Basket ......................................................... 37
Update the System Software...................................... 96
USA Distributor ............................................................ 3 V
View through the Access Door.................................... 20