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Operating Instructions

TECNOMAT LineFilling Line for Petri Dishes

Filling Unit – Feeder Unit – Embossing Unit – Stacking Unit

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Contents

Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . 5

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Contents of package, unpacking, transport . . . 10

Overall view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1. Preparing for operation . . . . . . . . . . . . . . . 121.1 Setting up the stacking unit . . . . . . . . . . . . . . 12

Connecting the collecting table to the filling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . .12Connecting the stacking unit to the filling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1.2 Setting up the embossing unit . . . . . . . . . . . . 14Installing the dish guide . . . . . . . . . . . . . . . . 14Connecting stacking unit, embossing unit andfilling unit via positioning plate . . . . . . . 15

1.3 Setting up the filling unit . . . . . . . . . . . . . . . 16Checking the voltage . . . . . . . . . . . . . . . . . . . 16Manual feed of petri dishes . . . . . . . . . . . . . . 17

1.4 Setting up the feeder unit . . . . . . . . . . . . . . . 18Fitting the stand feet . . . . . . . . . . . . . . . . . . . 18Connecting feeder and filling units . . . . . . . . 19

2. Operating instructions . . . . . . . . . . . . . . . . 202.1 Operating instructions for the filling unit . . . 20

Adjusting the filling chamber . . . . . . . . . . . . 20Adjusting the dish diameter . . . . . . . . . . . . . 21Setting the dish height . . . . . . . . . . . . . . . . . . 22

2.2 Operating instructions for the feeder unit . . . 24Preparing the feeder unit . . . . . . . . . . . . . . . . 24

2.3 Operating instructions for the stacking unit . . . . . . . . . . . . . . . . . . . . . . . . . 24Adjusting the stacking mechanism . . . . . . . . 25Setting the stacking contact . . . . . . . . . . . . . . 26Switching on the stacking unit . . . . . . . . . . . 27

2.4 Operating instructions for the embossing unit . . . . . . . . . . . . . . . . . . . . . . . 28Adjusting the embossing unit . . . . . . . . . . . . 28Adjusting the dih height . . . . . . . . . . . . . . . . .28Adjusting the dish diameter . . . . . . . . . . . . . 29Setting the embossing punch . . . . . . . . . . . . 29Adjusting the embossing punch . . . . . . . . . . 30Embossing the petri dishes . . . . . . . . . . . . . . 30

3. Trial run . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313.1 Trial run without nutrient solution . . . . . . . . 31

Programming a trial run . . . . . . . . . . . . . . . . 31Starting a trial run . . . . . . . . . . . . . . . . . . . . . 31Ending a trial run . . . . . . . . . . . . . . . . . . . . . . 32

3.2 Trial run with nutrient solution . . . . . . . . . . . 32Fitting a sterile tubing set in the pump . . . . . 32Programming the filling procedure . . . . . . . . 32Setting the pump SPEED . . . . . . . . . . . . . . . 33

4. Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . 34Calibration procedure . . . . . . . . . . . . . . . . . . 34

5. Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

6. General precautions for the entire TECNOMAT Line . . . . . . . . . . . . . . . . . . . . 36

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7. Trouble shooting . . . . . . . . . . . . . . . . . . . . . 37

8. Looking after the TECNOMAT Line . . . . 38Cleaning the drop tray in the stacking unit . . 38Cleaning the drop tray in the filling unit . . . . 38Overview of spare parts for stacking unit . . . . . . . . . . . . . . . . . . . . . . . . . 39embossing unit . . . . . . . . . . . . . . . . . . . . . . . 40filling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 41feeder unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Wiring diagram TECNOMAT Line . . . . . . 45

Declaration of Conformity

INTEGRA Biosciences (Switzerland) hereby confirms that theproduct

TECNOMAT Line

consisting of

Filling Unit 102 000Stacking Unit 105 000Feeding Unit 112 000 / 112 001Embossing Unit 107 000 / 107 001

is in accordance with the following directives and standards:

73/23/EEC Low voltage equipment89/336/EEC Electromagnetic compatibilityIEC/EN 61010-1:2001-02ICE/EN 61326-1+A1:1998+A2:2000

February 21, 2003 Elmar Morscher Thomas NeherCEO Quality Manager

Edition 03/03

© Copyright

INTEGRA Biosciences AG – Switzerland

All rights reserved. This manual may not be copied or reproduced inwhole or in part in any way without the prior express written per-mission of INTEGRA Biosciences AG.

The company reserves the right to make alterations without prior notice.

Notwithstanding the above statements, INTEGRA Biosciences AGaccepts no liability for possible mistakes or their consequences arisingfrom this manual.

Manual article number: 102461

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General

Throughout the manual and on the instruments of the TECNOMAT Line,the following symbol will be used to indicate general precautionarymeasures:

Warning: Indicates possible danger of injury or damage to property.Follow the instructions given in the operating instructions.

Installation: Location and conditions

Ambient conditions for the control unit:Temperature range: 5- 40°CMax. relative humidity: 80% up to 31°C, decreasing linearly to 50% at40°C.Voltage fluctuation: ± 10% from nominal value.Contamination: grade 2 according to IEC 664.

The instruments may not be located in a place susceptible to water sprayor where access to chemicals is possible.The proper location: - According to IP 21

- With stable base

If the conditions pertaining to the location of the instrument are not ful-filled, function and safety cannot be guaranteed.

Dangers involved when safety precautions are not observed

TECNOMAT is a state-of-the-art instruments with respect to current tech-nology and are safe to use. Some danger may exist if the instruments areused by untrained personnel. Any person given the task of operating TEC-NOMAT must first read the operating and safety instructions and under-stand them fully or be thoroughly trained by a superior in the use of theinstrument before operating the instrument.

Safety at work

Independent of any safety precautions listed here, all other relevant safe-ty aspects - e.g. GLP, GMP, professional trade associations, Departmentof Health, trade supervisory authorities - must be observed.

Qualification of operating personnel

Normally, a technical laboratory qualification is required.

Specialist knowledge of using and dispensing liquids is required whenusing TECNOMAT if all danger is to be avoided.This applies specifically to the liquids selected for dispensing and anypotential hazard involved and to the decision as to whether such liquidsshould be dispensed with TECNOMAT.

Personnel with no formal laboratory qualification do not, as a rule, pos-sess the degree of specialist knowledge required and must hence be trainedby qualified personnel and subsequently supervised.

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Safety Precautions

Safety aspects for the user company

The supervisors of operating personnel must have read and understoodall the safety precautions involved and must ensure that these are adheredto. They must also ensure that operating personnel also understand andobserve all safety rules.

Prior to operating TECNOMAT, the supervisor must ensure that no otherdangers exist, especially if other instruments and systems are also beingused.

If necessary, additional safety instructions must be compiled by the super-visor. The user company must, if necessary, in order to exclude all pos-sible danger, compile explicit safety instructions and have these signedby the staff responsible. In addition, clear competences must be estab-lished as to who is responsible for the operation of TECNOMAT so thatthese potential dangers can be reduced to an absolute minimum.

Changes in configuration / design by user

No changes may be made to TECNOMAT. Any parts that become defec-tive must be replaced by original INTEGRA Biosciences parts.TECNOMAT may not be altered in design or in any of their safety aspectswithout the express written permission of INTEGRA Biosciences. In par-ticular, no alterations may be made to any of the protective functions.Any alteration made releases INTEGRA Biosciences from any liabilityfor damage caused.

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Fuses 230/240 V: T 0.4 A (2x) 230/240 V: T 1.0 A110/115 V: T 0.8 A (2x) 110/115 V: T 2.0 A

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Dosing quantities 0.5 - 99 ml – – – –

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UV lamp 253.7 nm – – – –

Sound pressure level < 79 dBA < 79 dBA < 79 dBA < 79 dBA < 79 dBA

Overvoltage category II I I II I

Art. No. 102 000 112 000 112 001 107 000 (220 V) 105 000107 001 (110 V)

Degree of contamination 2 2 2 2 2

Depth 300 mm 390 mm 390 mm 410 mm 490 mm

Net weight 15 kg 13 kg 16 kg 10 kg 13 kg

Filling delay 0.1-9.9 seconds – – – –

Petri dish diameters/ 89-96mm/ 89-96mm/ 89-96mm/ 89-96mm/ 89-96mm/Petri dish heights 14-20.5 mm 14-20,5 mm 14-20,5 mm 14-20.5 mm 14-20.5 mm

Dosing rate 600 ml/min – – – –

Dosing accuracy ca. 2% – – – –

Filling rate ca. 900 dishes/h ca. 900 ca. 900 ca. 900 dishes/h ca. 900 dishes/h(15 ml) dishes/h dishes/h (15 ml) (15 ml)

(15 ml) (15 ml)

Length 450 mm 600 mm 1075 mm 230 mm without 810 mm with tabledish guide 330 mm without table300 mm withdish guide

Height Total 610 mm 700 mm 700 mm 280 mm 450 mmWithout magazine 280 mm – – – –

Magazine 330 mm – – – 240 mm

Power supply 20 VA 10 VA 10 VA 75 VA 10 VASettable 100/115/230/240 V 24 V 24 V 230 V, 50 Hz 24 V

50/60 Hz 50/60 Hz 50/60 Hz 110 V, 60 Hz 50/60 Hz

Technical Data

TECNOMAT Line Filling Unit Feeder Unit Embossing Unit Stacking Unit100 200

To guarantee optimal operation and settings, please ensure that thefollowing set-up sequence is adhered to:

1. Stacking unit

2. Embossing unit (optional)

3. Filling unit

4. Feeder unit

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TECNOMAT – Automatic unit for filling petri dishes with nutrientsolutions

Stacking unit – for the stacking of filled petri dishes

Collecting table

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Feeder unit - for feeding empty petridishes into the filling unit

Embossing unit - for embossing filledpetri dishes

Filling unit - with peristaltic pump

Positioning plate

Fig. 1

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Transport

When transporting over longerdistances, use only original pack-aging. Fix transport arm in posi-tion with foam rubber.

No special packaging is necessarywhen transporting over shorterdistances, e.g. within a building.

Remove the stacking magazine.

When transporting over longerdistances, use only original pack-aging.

Ensure that the Plexiglass parts areproperly protected.

No special packaging is necessarywhen transporting over shorterdistances, e.g. within a building





Unpacking

Remove transport packaging butretain for future use.

Use grips to remove the fillingunit.

Remove foam rubber from undertransport arm.


Remove carefully from carton. Donot lift with Plexiglass.


Remove carefully from carton.


Remove stacking unit carefullyfrom carton.

Remove square piece of foam rub-ber from stacking mechanism.

Package contents

1 Filling unit1 Filing chamber with integrat-

ed protective cover and UVlamp

1 Stainless steel stacking mag-azine

1 Complete tubing set(diameter 8x12 mm)

1 Power cable2 Fuses T 0.8A with export

instrument (100-120 V)1 Phillips screwdriver1 Operator’s manual

1 Feeding unit1 Hex-key SW 51 Positioning plate1 Open stacking magazine

1 Embossing unit2 Positioning plates

1 Stacking unit with cover1 Connecting cable (black

point)1 Collecting table1 Positioning plate4 Screws2 Stand feet

Filling unit

Feeding unit

Embossing Unit

Stacking unit

Technical Data

Page

Setting up the stacking unit ................................................... 12

Connecting it with the filling unit ............................................ 12

Electrical connections .............................................................. 13

Adjusting the stacking mechanism........................................... 25

Setting the stacking contact...................................................... 26

Setting up the embossing unit ............................................... 14


Adjusting the dish height/diameter ..................................... 28/29

Adjusting the embossing punch ............................................... 30

Setting up the filling unit ....................................................... 16

Checking the voltage................................................................ 16


Connecting the stacking magazine.............................................17

Adjusting the dish height/diameter ..................................... 21/22

Setting up the feeder unit ...................................................... 18

Connecting the feeder unit and the filling unit......................... 19


Trial run without nutrient solution

Trial run with nutrient solution

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Please adhere to the prescribed set-up sequence (see page 8) !

Overall view

➧➧

➧➧

➧➧

➧➧

➧➧

➧➧

➧➠

➠➠

Filling Unit

➠

Filling UnitStacking Unit

Filling UnitStacking Unit

Emboss-ing Unit

Filling Unit

Feeding Unit

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Stacking unit with collecting table

Collecting table

Stand foot

Connecting the collecting table to the filling unit

● Screw the two feet onto the bottom left of the collecting table.

● Loosen the four screws at the right hand lower edge of the stackingtable.

● Position the collecting table against the stacking unit and connect withthe four screws. Ensure that the short screw is located at the guide angleat the rear of the table.

Position the stacking unit alongside and to the left of the filling unit.

Connecting the stacking unit to the filling unit

Information for using the positioning plates: The positioning plates areused to fix the distance between the stacker, the embosser and the filler.The positioning plates are marked for use with 3 types of petri dish: 89 - 91 mm, 92 - 96 mm, 94 - 97 mm.

● Have positioning plate ready (see fig. 4).

There are four holes on the positioning plate. Each of the holes is des-ignated with a particular dish diameter.

Locate the hole with the dish diameter required.

● Position the plate in such a way that the hole designated with the re-quired dish diameter is at the forward position facing the user = FRONT.(Example given for dish diameter 94 - 97 mm).

● Insert the left-hand front foot of the filling unit into hole A of the posi-tioning plate.

1.1 Setting up the stacking unit

1. Preparing for operation

Fig. 3

Fig. 4

Fig. 2

External diameter

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● Insert the right-hand front foot of the stacking unit into hole B of thepositioning plate.

The dish exit guide of the filling unit must fit into the corresponding sec-tion ① of the table.

Electrical connections for operating filling unit/ feeder unit/ stack-ing unit:

NB: Check the operating voltage on the filling unit. The voltageused must correlate with that shown on the instrument plate.

● 1. Connect cable ① with yellow marking to the filling unit.

● 2. Connect cable ② with the black points to stacking unit.

● 3. Connect cable ③ to filling unit and power supply.

● 4. Connect foot switch (optional accessory - art. no. 101 010) to socket ④ .

Filling unit with guide Embossingunit

Stackingunit

Fig. 5

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If the TECNOMAT is to be operated with an embossing unit:

● Position the embossing unit between the stacking and the filling units.

1.2 Setting up the embossing unit

Installing the dish guide

● Raise the plastic cover.

● Firmly connect the dish guide.

● Adjust the height of the embossing unit using the adjustable front feetso that the dish guide has the same height as the exit guide of the fill-ing unit and the stacking unit.

Embossing unit - view from above

Embossing unit

Dish guide

Stacking unitFillingunit

Fig. 6

Fig. 7

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Electrical connections when using TECNOMAT Line and emboss-ing unit:

Filling system with accessories

Embossingunit

Stacking unit

Connecting stacking unit, embossing unit and fillingunit via positioning plate

The holes in the positioning plates are intended for use with four differ-ent dish diameters (88,5-90 / 90-92 / 92-94 / 94-96 mm).

● Determine the lid diameter for the dishes to be used.

● Read off the diameter selected on the positioning plate and positionthe plate in such a way that the selected diameter points towards theuser.

● Position the instrument on the positioning plate in such a way that thefront feet fit into the holes indicating the dish lid diameter.

NB: Check the operating voltage on the filling unit. The operatingvoltage indicated on the instrument name plate must be identicalto that actually used.

The following sequence must be adhered to:

The embossing unit POWER switch is thus the main switch for theentire TECNOMAT Line.

● 1. Connect cable ③ to the embossing unit and filling unit.

● 2. Connect cable ④ with the black point to the filling and stacking units.

● 3. Connect cable ⑤ from the feeder unit to the filling unit.

● 4. Connect the power cable ② to the embossing unit and connect toa source of power.

● 5. Switch on the power switch on the filling unit ① .

● 6. Socket ⑥ for foot switch (optional accessory - art. no. 101 010).

Positioning plate for connecting stacking unit -embossing unit - filling unit

Fig. 8

Fig. 9

Fig. 10

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1.3 Setting up the filling unit

Checking the voltage

Disconnect from the power supply and check the voltage. If nec-essary, reset to correct voltage:

The voltage selector in the window at the rear of the instrument shouldcorrespond to the voltage actually used. If this is not the case, the TEC-NOMAT Line could be damaged.

● Pull out the drawer containing the voltage selector.

● Remove voltage selector ① and replace in such a way that the desiredvoltage appears in window ② .

Selection possibilities:

100 = 100 V fuses: T 0.8 A (= T 800 mA)120 = 110-120 V fuses: T 0.8 A125 = 125 V (should be wired by authorised personnel only)220 = 220-230 V fuses: T 0.4 A (= T 400 mA)230 = 230 V240 = 240 V fuses: T 0.4 A

● Reinsert the drawer containing two fuses into the power supply socket.

● Recheck the voltage shown in the window.

● Reconnect to the power supply.

Voltage selector

Voltage selector

Fuse

Filling unitCover

Filling chamber

Peristaltic pump head Fig. 11

Fig. 12

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Stainless steelstacking magazine

Manual feeding of petri dishes

Manual feeding of petri dishes takes place without a feeder unit via thestainless steel stacking magazine:

● Position the filling unit with its operating panel facing forwards.

● Connect the stainless steel stacking magazine into the correspondinggroove ① of the filling chamber.

UV lamp

The UV lamp functions only when the protective cover is closed!

Ensure that the protective cover is correctly placed.

Caution: The UV lamp tends to get hot during the operation. UV radi-ation can cause irritation of the skin and eyes and even cause blindness.Do not look directly into the lamp when it is switched on.

Filling unit

Fig. 13

Fig. 14

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1.4 Setting up the feeder unit

Guide

Filling unit

Fig. 15

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Connecting feeder and filling units

● Have positioning plate available.

The positioning plate stabilises the connection between filling and feederunits and should be positioned under both instruments as follows:

● Insert the two black rubber feet of the filling unit into the two largerholes ① on the positioning plate.

● Insert the front black rubber feet of the feeder unit into the two smallerholes ② on the positioning plate.

If a stacking unit is not to be used, position the collecting table with its4 feet (available as optional accessory: art. no. 102 105) alongside thefilling unit. Insert the dish exit guide into the appropriate groove in thetable.

Feeder unit -front view

● Insert the axle of the open stacking magazine into opening ① on thefeeder unit, making sure that the connection snaps into position.

● Insert the guide pins of the open stacking magazine gently into thefilling chamber of the feeder unit ② .

If necessary, adjust the rubber feet of the filling unit to level the instru-ment.

Fig. 17

Fig. 18

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2.1Operating instructions for the filling unit

On and off key for the filling unit, stacking unitand feeder unit.

For setting the required dosing quantity, intervals,pump speeds.

For transporting empty petri dishes to the feederunit, into the filling chamber of the filling unit andfor starting the programme.

For manual pumping.

Provides the set dosing quantity (0.5-99 ml). Canalso be controlled via foot switch.

For setting and activating pauses. Pauses are selec-table between 0.1 and 9.9 sec. Set to 2.5 sec. ex-factory.

For switching the UV-lamp on/off.

For setting the pump speed. Selectable from 55 -99%. Set to 90% ex-factory.

For calibrating the pump.

Adjusting the filling chamber

● Remove the stainless steel magazine.

If the feeder unit is already connected to the filling unit:● Push stacking magazine to the side.

● Remove protective cover from filling chamber.

● Remove the filling chamber by lifting out.

Measuring petri dishes

● The dish diameter and height should be measured, as shown in theillustration opposite, prior to adjusting the filling unit.

2. Operating instructions

Operating panel of the filling unit Fig. 19

Fig. 20

Adjusting the dish diameter

The filling chamber of the filling unit can be adjusted for petri dishesof diameter 89-96 mm. Adjustment to the dishes to be used can be car-ried out with the three setting screws ② on the vertical guide plate ① :

● Place petri dish lid with its opening downwards onto guide plate ③ .

● Using milled screw ② , adjust the distance between the dish lid andguide to 0.5 - 1.0 mm.

● Place lower part of petri dish between cam ④ and guide ① .

● Using setting screw ② , set distance between dish and guide to 0.5 -1.0 mm.

NB: When adjusting the plates, push them through by hand and ensurethat there is adequate play.

NB: the chamber can be autoclaved. However, subsequent to auto-claving, it must be adjusted.

Spri

ngs

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Setting screws

Guide plate

Fig. 22Range 1 - 2 mm

Mill

ed s

crew

s

①

②

③

Fig. 21

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Setting the dish height

The filling chamber can also be set to a dish height between 14 - 18 mmby adjusting the two screws ⑥ as follows:

● Push a petri dish with its lid into the filling chamber from behind untilit lies under lid guide ⑤ .

● Loosen the two screws ⑥ and adjust the lid guide so that the front ofthe lid guide just touches the lid.

If dishes are to be used which have a height between 18 - 20.5 mm, thesetting procedure is as follows::

● Remove nuts ⑦ from under the four columns of the stacking unit plate⑧ . Adjust the height as described above.

If the height of the plate has to be adjusted frequently, a second fillingchamber should be made available. (Art. no. 101 210).

● Subsequent to adjustment of the dish diameter and the dish height,replace the filling chamber in the filling unit.

● NB: Replace the lid on the filling chamber!

Fig. 23

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2.2 Operating instructions for the feeder unit

The feeder unit is controlled via the control panel on the filling unit. Ithas no power supply or separate operating controls.

150 empty petri dishes can be placed on the conveyor belt of the feederunit. (Optional accessory: feeder unit for 300 petri dishes, art. no.112 001) The empty petri dishes are automatically transported to the fill-ing unit. A mechanical sensor monitors the number of empty petri dish-es on the conveyor belt and .- if necessary - after 30 sec. gives an acousticalarm as a reminder to replenish with new dishes.

Preparing the feeder unit

● Place 8-10 empty petri dishes in the stacking magazine.● Place the desired quantity of empty petri dishes on the conveyor belt

of the feeder unit.

NB: Do not stack the petri dishes higher than the stacking magazine. Inthe case of petri dishes of 17 mm height, this corresponds to approxi-mately 22 empty dishes.

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Collecting table

Stacking unit with collecting table

2.3 Operating instructions for the stacking unit

Operating controls on the stacking unit: ON/OFF switch ① .

The stacking unit is adjusted ex-factory to stack 10 petri dishes.

A hexadecimal switch is located at the rear of the stacker; this can beused to set the number of petri dishes per stack – from 1 to 15. Care shouldbe taken to ensure that the height of the stack does not exceed 230 mm.

Before operating the stacking unit, prepare the filling unit and feeder unitas described from page 16.

Fig. 24

Switch setting No. of dishesper stack

1 12 23 34 45 56 67 78 89 9A 10B 11C 12D 13E 14F 15

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Adjusting the stacking mechanism

The stacking unit is adjusted ex-factory to operate with dishes of dia-meter 92 mm and height 17 mm.

A mechanism for adjusting lid diameter and height is located inside thehousing. The adjusting procedure is as follows:

NB: Always disconnect the instrument before opening.

Setting the dish diameter:

● Unscrew the left-hand panel of the stacking unit.

● Measure the external diameter of the dish lid.

Set the measured value on the scale as follows:● Loosen screw ① and set the measured value on the scale.

● Tighten screw ① .

Setting the dish height:

● Measure the dish height, including the lid.

Set the measured value on the scale as follows:● Loosen screw ② and set the measured value on the scale.

● Tighten screw ② .

● Replace the side panel.

NB: Ensure that the side wall is properly closed (see magnetic con-tact = [C]); otherwise the apparatus will not start.

Fig. 25Open stacking unit - side view

[C][C]

[C]

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Setting the stacking contact

● Push an empty petri dish with lid to just in front of contact pin ① .

● Using setting screw ② , adjust the centre of the contact pin to the sameheight as the lower edge of the dish lid.

Setting the lid diameter:

● Ensure that the connecting cable between filling unit and stacking unitis connected.

● Activate the power switch at the rear of the instrument.

● Press the ON/OFF switch of the filling unit. The stacking unit willmove as if expelling a dish.

Stacking unit - from above

Stacking contact - side view

Fig. 26

Fig. 27

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● Set switch ③ ) to the OFF position. The control lamp ④ alongside thestacking unit will be extinguished.

● Loosen the green screw ② using a Philips screwdriver. Push the steelcover ⑥ on the plastic cover towards the rear in the direction of thearrow.

● Place an empty petri dish with lid in position so that it is between thecontact pin ① and the right-hand rear edge of the cover ⑤ . The steelcover must lie completely on the Plexiglas cover.

● Slide the steel cover towards the front of the instrument. The dish willmove in the direction of the arrow ⑦ and will press against the con-tact pin ① .

As soon as the control lamp lights, slide the steel cover forward about1 mm.

● Tighten screw ② . The position of the cover is now fixed.

Switching on the stacking unit

● Switch stacking unit switch ③ to ON. The lamp will light.

The dishes will now be stacked in the pre-set mode. (See page 24 forsetting procedure).

Fig. 28

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2.4 Operating instructions for theembossing unit

Operating controls on the embossing unit: POWER, HEATING, READY.

POWER: Switches embossing unit and the complete TECNOMATLine on and off.

HEATING: Switches the punch heating on and off.

READY: Lamp lights once operating temperature has been reached.

Embossing unit - front view

Adjusting the embossing unit

The printer has been set ex-factory for a medium petri dish size of 92-96 mm diameter. If other sizes are to be used, the embossing unit shouldbe adjusted as follows:

Adjusting the dish height

● Insert the complete dish into the dish guide.

● Using milled screw ① , adjust the distance between the dish lid andconical roll ② , so that there is a space (approximately 0.5 mm) betweenroll and dish.

Dish guide

Petri dish

Embossing unit - view from above Fig. 30

Fig. 29

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Adjusting the dish diameter

● Using cross-head screw (in opening ⑦ ), set the band mechanism insuch a way that it is pressed back approximately 1-1.5 mm by the pass-ing dish.

Setting rod

Groove

Printer - view from front

Drawer for typecharacters

Setting the embossing punch

Petri dishes can be embossed with a code comprising up to 72 mm. These72 mm must be completely filled with type characters.

- If required a number of characters can be used together in blocks inorder to save space.

- Spaces can be filled with spacer blocks (with or without embossing).

- All characters are shown on the upper surface of the embossing punch.This facilitates the setting of texts.

- The embossing characters can be stored in a drawer on the emboss-ing unit.

● Unscrew the end cap with the groove from the setting rod.

Setting the stack height

Adjusting the embossing pressure

Fig. 31

Fig. 32

Fig. 33

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● Place the letters, numbers, blocks or spaces on the rod in any desiredsequence.

A space (=) should be placed at the beginning and the end of every emboss-ing set.

NB: Two spacer blocks without embossing should never be adjacent toeach other as the space between two characters should never be greaterthan 3.5 mm.

● Replace the end piece.

● Raise the protective cover.

! Caution ! - Never insert the setting rod if the heating block isswitched on.

● Place the entire setting rod in the heating block ④ .

Adjusting the embossing punch

Setting the lettering angle:

In order to ensure that embossing is entirely embossed onto the lowerpart of the dish, the angle of the embossing punch can be adjusted usingcross-head screw ⑤ .

Setting the lettering height:

The hot embossing punch / types should not, if possible, come into con-tact with the dish lid. The height of embossing can be set using cross-head screw ⑥ .

! Caution ! Height and angle of lettering influence each other dur-ing the setting process.

● Re-close the protective cover.

NB: During printing, always cover the embossing punch with protective cover.

! Never touch the hot embossing punch!

Embossing the petri dishes

Carry out a trial run with empty dishes:● 1. Press the POWER key. The printer is now switched on.

● 2. Press the ON/OFF key on the filling unit. The set dosing quantitywill appear in the display.

● 3. Press the HEATING key. After approximately 5 min., the controllamp (READY) will light. The instrument is now ready for operation.

Caution: Never touch the hot embossing types!

Warning: The filling unit should only be operated when theembossing unit is in switched on.

● 4. Place an adequate quantity of petri dishes in the feeder unit or stack-ing magazine.

● 5. Press the AUTO key on filling unit. The petri dishes will be trans-ported through the filling chamber onto the guide and embossed.

Fig. 35Setting the lettering height

Setting the letteringangle

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3.1 Trial run without nutrient solution

Programming a trial run

● Prepare the TECNOMAT Line as described in sections 1 and 2.

● Press the power switch at the rear of the instrument. The software ver-sion (e.g. 1.06) will appear for ca. 3 seconds in the display.

NB: When using the TECNOMAT Line with a printer, always switchon the instrument using the embossing unit power switch.

● Press the ON/OFF switch. The LED will light. Filling unit and feed-er unit are now switched on. The filling volume last set will now appearin the display in ml. The transport arm of the filling chamber will moveto its initial position. The stacking unit will carry out an exiting move-ment.

Setting the dosing quantity e.g. 15.0 ml:

● Press key UP/DOWN until 15.0 appears in the display.

Setting the interval e.g. 1.0 sec.:

● Press the PAUSE key. The control lamp will light.

● Press the UP/DOWN key until 1.0 appears in the display.

NB: After approximately 4 sec., the display will again show theset dosing quantity.

Switch on the UV-lamp:

Caution: The lid of the filling chamber must be closed duringthis procedure.

● Press the UV key. The control lamp and UV lamp will light.

Starting a trial run

The petri dishes will now pass through the filling chamber and are opened.The pump will pump for 2 sec. After 1 sec. interval, the dishes are closedand transported onwards.

● 1. Press the AUTO key. The control lamp will light and transport ofthe petri dishes through the filling chamber begins.

● 2. Press AUTO key again. The control lamp will extinguish. The trans-port mechanism in the filling chamber will come to rest.

● 3. Press the PUMP key and hold it pressed. The control lamp willlight and the pump will run as long as the key is kept pressed.

NB: The PUMP function can be used to fill the tubing.

● 4. Press the DISP key. The control lamp will light. 15 ml will be pumpedat intervals of 1 sec.

This function enables the filling unit to be used separately as a peristalticpump. Can also be optionally controlled via the foot switch.

● 5. Press the DISP key again. The pump will stop and the control lightwill be extinguished.

3. Trial run

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● 6. Press the PAUSE key. The control lamp will extinguish. The inter-val function is now switched off.

● 7. Switch off the UV-lamp by pressing the UV key.

Ending a trial run

● Press the ON/OFF key. The instrument is now switched off.

The test run is now complete.

3.2 Trial run with nutrient solution● Connect the TECNOMAT Line as described in sections 1 and 2.

Fitting a sterile tubing set in the pump

● Move the pump head lever ① to the right.● Insert the tubing set in the tubing groove.● Move the lever to the left. ● Immerse the aspiration end of the tube into the medium to be used or

connect it to the optional medium processor MediaClave.

NB: A filling nozzle is attached to the end of the tubing set. Theprotective tube of the nozzle should always protrude (see drawing).

● Insert the filling nozzle along with its protective tubing into the noz-zle holder of the filling chamber ② . Ensure that it is pushed in as faras it will go.

Programming the filling procedure

● Press the POWER switch at the rear of the filling unit. The softwareversion installed (e.g. 1.06) will appear in the display for approx. 3 sec.

NB: When using the TECNOMAT Line with an embossing unit,always switch on the instrument using the embossing unit powerswitch.

● Switch on the instrument with the ON/OFF switch. The LED will light.Filling unit and feeder unit are now switched on. The filling volumelast set will now appear in the display in ml. The transport arm of thefilling chamber will move to its initial position. The stacking unit willcarry out an exiting movement.

Setting the dosing quantity:

● Press the UP/DOWN key until the desired dosing quantity has been set.

Setting the interval required:

● Press the PAUSE key and activate the UP/DOWN key until the desiredvalue has been set.

After 4 sec., the display will again show the set dosing quantity.

Filling the filling tube:

● Press the PUMP key until the filling tube has been filled up to the fill-ing nozzle.

Protective tube

Filling nozzle of tubing set

Fig. 36

Fig. 37

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Setting the pump SPEED

● Press the SPEED key. The control lamp will light.● Press the UP/DOWN key until the desired speed has been set.

After 4 sec. the display will again show the set dosing quantity.

NB: If the stacking unit has been connected as described from page12, switch the stacking unit switch to the ON position.

● Switch on the UV lamp by pressing the UV key

Starting the filling procedure /Switching on dish transport:

The petri dishes will now pass through the filling chamber and will beopened, filled and transported onwards.

● Press the AUTO key. The control lamp will light. The filling proce-dure will now begin.

Ending the filling procedure /Interrupting the procedure:

● Press the AUTO key. The control lamp will be extinguished.

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The performance of the integrated peristaltic pump is dependent on thetubing diameter, aspiration height from the reservoir and type and tem-perature of the nutrient medium used. For these reasons, the TECNO-MAT Line should be calibrated according to the relevant operating con-ditions. The calibration vessel used can be either a petri dish or a mea-suring cylinder.

Prior to calibration, the tubing set should be inserted (see page 32), therespective stacking magazine inserted and a sufficient number of petridishes and corresponding liquid available.

If a printer is used, this must be connected and switched on prior to cali-bration.

Switch the stacking unit on and off with the ON/OFF switch.

Calibration procedure:

Prepare the TECNOMAT Line as described in sections 1 and 2.

● 1. Press the power switch at the rear of the filling unit. The softwareversion installed (e.g. 1.06) will appear for ca. 3 sec. in the display.

NB: When using the TECNOMAT Line with an embossing unit,always switch on the instrument with the embossing unit powerswitch.

● 2. Press key ON/OFF. Filling unit and feeder unit are now switchedon. The filling volume last set will now appear in the display in ml.The transport arm of the filling chamber will move to its initial posi-tion. The stacking unit will carry out an exiting movement.

● 3. Press PUMP key until the aspiration tube is full.

● 4. Press the UP/DOWN key until the desired dosing quantity in ml (=required value) is displayed.

● 5. Fill two or three petri dishes. In doing so press the AUTO key. Thepetri dishes will pass through the filling chamber and will be opened,filled, closed and transported onwards.

● 6. End the filling process by pressing the AUTO key.

● 7. Remove the filled petri dishes from the stacking unit and determinethe volumes (actual value).

● 8. Press CALIB key for three seconds until the control lamp in the CALIBkey lights. The display will show the desired required value in ml.

NB: After 4 seconds, the control lamp of the CALIB switch willextinguish automatically. If no entries are made during this time,the current actual value will remain set.

● 9. Enter the actual value via the UP/DOWN key.

● 10. Press the CALIB key. The CALIB control light will extinguish.The actual value (= required value) of the dosed quantity will appearin the display. The pump is now calibrated.

4. Calibration

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If necessary, the instrument memory can be reset as follows:

● Switch off the filling unit with the power switch.

● Press the power again after approx. 5 secs switch and, at the same time,the CALIB key until the display is extinguished.

● Press the ON/OFF key of the filling unit. This switches the instrumenton again.

If the RESET procedure has been used, a new calibration (see page 34).must be carried out using the tubing set to be used.

Subsequent to reset, the following values are set:

Filling quantity: 20 mlSPEED : 90 % of max. pump speedPAUSE: 2.5 sec. This function is activated only on

pressing the PAUSE key.

5. Reset

● Repeat the procedure as and when necessary.

The quantity dosed can be filled into a measuring cylinder instead of apetri dish. In this procedure, insert the filling nozzle into a measuringcylinder and press the DISP key to fill the measuring cylinder with medi-um. Proceed as from point 7 above.

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6. General precautions for the entire TECNOMAT Line

• The TECNOMAT Line should only be used for the applications described.

• Those screws that can only be unscrewed using a tool according to DIN VDE 0789 part 100 mayonly be opened by personnel from INTEGRA Biosciences Service or by those who have been trainedand authorised by INTEGRA Biosciences.

• The power plug may only be replaced by authorised personnel.

• Before opening the instrument, the power plug must be disconnected. This will avoid the dangerof electric shock.

• The approved ambient temperature extends from +5 °C to 40 °C. The humidity may be maximum80%, decreasing in linear fashion to 50% at 40 °C. During storage and transport, the temperaturemay be between -15 °C and +70 °C.

• Before connecting the instrument to the power supply, the voltage indicated on the name plate (atthe rear of the instrument) should be compared with the actual voltage to be used. Wrong voltagescan damage the instrument (see notes on setting the voltage...).

• Always use original accessories provided by INTEGRA Biosciences.

General

• In an emergency, switch off the system using the POWER switch on the embossing unit.

• Never insert filling tubing whilst the pump is in operation.

• Never remove the filling chamber when the instrument is in operation.

• Protect eyes and skin from direct or stray UV radiation.

• Use only original tubing sets from INTEGRA Biosciences. Wrong tubing can damage the pumphead.

• Use only petri dish sizes which have diameters and heights that are suitable for the filling unit.

• Never attempt to touch the pump when in operation.

Filling unit

• In an emergency, the feeder unit can be switched off by pressing the ON/OFF key of the fillingunit or the POWER switch of the embossing unit.

• Do not stack petri dishes higher than the stacking magazine. This corresponds to 22 empty dishesof 17 mm height.

• NB: Never move the transport arm to the rest position manually.

Feeder unit

• Do not touch the hot embossing types (burn injuries)

• Allow the hot types to cool inside the instrument.

• Use the POWER switch to switch off in an emergency.

Embossingunit

In an emergency, switch off the stacking unit by pressing the ON/OFF switch on the filling unit orthe POWER switch on the embossing unit.

• Before opening the side panel, always ensure that the instrument is disconnected from the powersupply.

• The maximum stacking height is 230 mm.

Stackingunit

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7. Trouble shooting

Display Possible cause Remedy

001 • Pump blocked • Please call your local dealer.002 • End-switch transport • Press ON/OFF key

defective (time monitoring) Please call your local dealer.003 • Transport overloaded • Press ON/OFF key. Carefully move

or falsely inserted petri back transport arm. Remove dishes the blocked dish. Carefully move

the transport arm forwards.005 • No voltage on motor • Please call your local dealer.

(fuse defective) 006 • Foot switch defective • Please call your local dealer.007 • Dish contact defective • Please call your local dealer.

UV lamp doesn’t light • Lamp defective • Have replaced by service• Lamp not installed • Have service install lamp• Protective cover on filling • Check the position of the cover

chamber not properly placed

Dishes are filled • Filling level contact defective • Please call your local dealer.irregularly • Filling contact not • Adjust dish diameter

properly activated (see pages 21)

Cover falls onto • Filling chamber not • Adjust filling chamberplate too early properly adjusted (see pages 20)

Apparatus does not start / • Fuse defective • Replace fuse, connect to powerno display • No voltage supply, switch on main switch

Filling unit

Transport arm stops • Eliminate cause of blockage • Switch off filling unit with ON/OFF key. Press ON/OFF key again. The transport arm will automatically move to rest position.

Instrument doesn’t • No connection to filling • Connect to filling unitfunction unit • Switch on filling unit with

ON/OFF switch

Feeder unit

No voltage at • Check power plug and/or fuse. POWER switch:

Heater doesn’t heat • Fuse defective • Check fuses

READY lamp • Lamp defective • Have service replacedoesn’t light:

Embossingunit

Errors are registered both in the display and acoustically. The display blinks. Relays and motors switch off automatically.

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NB: Prior to cleaning, disconnect the power.

Agar residues may be removed using soapy water or normal warm water.Use cotton wool, a brush or a sponge for this purpose.

● Never use aggressive solutions like e.g. nitro-diluter or similar prod-ucts.

● Never use an open flame on the instrument.

● Never try to remove residues by scratching or scraping.

Cleaning the drop tray in the stacking unit

● Remove the side panel of the stacking unit (see page 25).Below the adjusting device there is a removable droppings dish. This servesas a collecting dish for drops of medium.

● Remove the tray and clean.

Cleaning the drop tray in the filling unit

● Remove the filling chamber and clean if necessary (may also be auto-claved).

● Gently raise the transport arm, remove the tray and clean.

8. Looking after the TECNOMAT Line

Display Possible cause Remedy

Instrument refuses • Stacking unit not • Switch on with ON/OFFto stack switched on

• No connection to filling • Connect to filling unitunit

• Side panel not properly • Check the closing mechanism ofclosed panel (see page 25)

Apparatus does not • Setting of dish height and • Open side panel and set the scalestack properly diameter incorrect to the correct dish height and

diameter (see pages 25/26)

Apparatus stacks too few • Stacking number incorrectly • Set hexadecimal switch toor too many dishes set – max stack height correct dish height (see page 24)

230 mm

Dishes conveyed but • Stacking contact • To set correctly, see page 26not stacked not activated of operating manualgestapelt

Stackingunit

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Item no. and description of the marked spare parts (e.g. )see page 43/44.

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Spare Parts TECNOMAT Stacker

Page Position No. Item No. Description39 1 105 207 Positioning plate39 2 105 335 Connection cable stacker-filler39 9 105 208 Tray39 11 105 008 Microswitch lid39 20 105 305 Bosch motor for lifting/output39 22 105 260 Microswitch release39 24 102 336 Microswitch39 27 105 225 Side rode39 41 105 025 Microswitch39 43 105 315 Printed circuit board 39 47 105 030 Socket 5-pole39 54 105 036 Spring39 64 105 212 Sliding rail for lift/push mechanism39 65 105 220 Connecting rod for lifting mechanism39 66 105 056 Switch on/off39 67 105 057 LED lamp39 75 105 263 Microswitch housing release39 86 105 337 Tower, complete39 92 105 338 Plexi glass lid, complete39 92,1 105 074 lid shackle39 92,2 105 202 Knurled screw39 102 105 010 table complete (50 x 50 cm))

Spare Parts TECNOMAT Embosser

Page Position No. Item No. Description40 0 101 400 Fuse 1,0A slow40 1 107 200 Positioning plate 92 - 94 mm / 94,1 - 96 mm40 2 107 201 Positioning plate 88,5 - 89,9 mm / 90 - 91,9 mm40 3 101 375 Mains cable Swiss Plug40 3 101 380 Mains cable Schuko Plug40 3 101 385 Mains cable USA Plug40 4 107 080 rod for letters cpl.40 5 107 325 Drawer for storing digits40 6 107 111 Front panel, complete40 12 107 326 Sliding rail for drawer (left)40 13 107 327 Sliding rail for drawer (right)40 21 107 240 Thermo regulator 0-300¡C 230VAC40 21 107 245 Thermo regulator 0-300¡C 115VAC40 23 107 236 Foot (with adjusting screw)40 26 107 250 Relay 2UK 10A 230VAC40 26 107 255 Relay 2UK 10A 115VAC40 34 107 112 Back panel, complete40 53 107 265 Cartridge type heater HHP/T 115VAC40 53 107 260 Cartridge type heater HHP/T 230VAC40 64 107 052 Sliding rail for dishes, complete (short)40 66 107 275 Motor 230VAC, 40rpm40 66 107 280 Motor 115VAC, 36rpm40 80 107 113 Petri dish driving unit40 80,12 107 367 Protecting glass40 80,21 107 077 Band transport wheel aluminium40 80,6 107 061 Spring (short)40 92 107 085 Conveyor belt40 116 107 114 Petri dish guidance unit40 116,13 107 094 Conical wheel, PVC, black

Spare Parts TECNOMAT Line

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Page Position No. Item No. Description40 116,14 107 095 Round wheel, PVC, black40 135 107 115 Sliding rail for dishes, complete (long)40 116.20 107 101 Spring (long)

Spare Parts TECNOMAt Filler

Page Position No. Item No. Description41 2 102 461 Manual TEC-Line E/D/F41 3 101 375 Mains cable Swiss Plug41 3 101 380 Mains cable Schuko Plug41 3 101 385 Mains cable USA Plug41 4 102 395 Fuse 0.4 A for 230 V41 4 102 400 Fuse 0.8 A for 115 V41 4 102 401 Fuse 2.5 A for circuit board 141 4 102 402 Fuse 0.4 A for circuit board 241 5 101 015 Silicone tubing 8 x l2 mm complete41 6 102 462 Side wall, right41 10 102 440 Bosch Motor pump complete41 15 102 455 Printed circuit board with front panel, complete41 17 101 010 Foot switch with connection cable41 18 101 275 Peristaltic pump head complete41 18,2 101 280 Bed for tubing set41 18,3 102 279 Plexi glass cover for pump with holder41 25 102 420 Bosch Transport Motor41 32 102 478 Microswitch41 43 102 371 Connecting rod (short)41 45 102 483 Microswitch (over load)41 47 102 373 Connecting rod (long)41 50 102 523 Plug plate, complete41 52 102 260 Ultra violet lamp socket41 53 101 065 Ultra violet lamp41 54 102 240 Rail with bearing, complete41 62 102 489 Microswitch (ultra violet lamp)41 66 102 245 Microswitch filling contact, complete41 70 102 524 Relay board, complete41 71 102 525 Side wall, left41 75 102 105 Delivery table 65 x 50 cm41 84 101 030 Filling nozzle for tube 8 x 12 / 6 x 10 mm41 85 102 205 Lid to filling chamber41 86 102 503 Petri dish storage41 87 102 210 Filling chamber, complete 41 88 102 526 Cover complete41 94 102 265 Tray

Spare Parts TECNOMAT Feeder

Page Position No. Item No. Description42 1 112 201 Pushing tower42 1,24 112 220 Microswitch42 1,42 112 234 Microswitch42 1,8 112 250 Motor, feeding mechanism,40 rpm42 15 112 245 Motor, conveyor belt, 20 rpm42 20 112 255 Printed circuit board, complete42 24 112 260 Connector cable feeder-filler42 27 112 202 Plexi glass shield, complete (feeder 100)42 27 112 203 Plexi glass shield, complete (feeder 200)42 46 112 316 Microswitch transport belt42 61 112 289 Transport band (feeder 100)42 61 112 309 Transport band (feeder 200)42 63 112 317 Tower42 75 112 270 Optical sensor42 82 112 200 Positioning plate

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Notes Notes Notes

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