BactoScan FC

Type 73700

Operator's Manual GB
 Contents

Safety Precautions, Other Langauges ............................................................................ 3

1. Introduction .................................................................................................................. 13
1.1 About This Manual ................................................................................................ 13
1.2 Introduction to IMTTM and Individual Bacteria Counting .................................. 14
1.3 Laser Precautions .................................................................................................. 15
1.4 Warranty Policy ..................................................................................................... 16
1.5 Parts Subject to Wear ............................................................................................ 16
2. Using Integrated Milk Testing ...................................................................................... 17
2.1 The Integrated Milk Testing™ Concept ................................................................ 17
2.2 The IMT User Interface ......................................................................................... 18
3 The BactoScan Method ................................................................................................. 21
3.1 General .................................................................................................................. 21
3.2 The Flow System ................................................................................................... 21
3.3 The Counting Module ........................................................................................... 22
3.4 BactoScan FC Specific Applications .................................................................... 22
4. Daily Start-up Routines ................................................................................................ 23
4.1 Preparations ........................................................................................................... 23
4.2 Opening a Work Session ....................................................................................... 24
4.3 Logging On ............................................................................................................ 26
4.4 Active Units Check ............................................................................................... 26
4.5 Performance Check ............................................................................................... 27
5. Analysing Samples ....................................................................................................... 31
5.1 Conveyor ............................................................................................................... 31
5.2 Handling Samples .................................................................................................. 32
5.3 Typing In Batch and Sample Information ............................................................. 32
5.4 Starting and Stopping Modes ................................................................................ 34
5.5 Liquids Low Message and Removing Liquid Container Pipettes ......................... 36
6. Shut-down ..................................................................................................................... 37

(continued)

FOSS Electric
69, Slangerupgade
DK 3400 Hillerød, Denmark
T: +45 70 10 33 70
P/N 579649 F: +45 70 10 33 71
Issue 8 GB e: [email protected]
February 2001 W: www.foss.dk
 7 Checks and Sample Re-testing ...................................................................................... 39
7.1 Performance Checks .............................................................................................. 39
7.2 Trouble Shooting ................................................................................................... 44
8. Errors and Error Correction .......................................................................................... 49
8.1 Errors and Warnings .............................................................................................. 49
8.2 Correcting Bar Code Read Errors Using Conveyor 4000 ..................................... 63
9. The Presentation Application ....................................................................................... 71
9.1 Mode Symbols ....................................................................................................... 71
9.2 Manual Mode ........................................................................................................ 72
9.3 Result and Batch Lists ........................................................................................... 74
9.4 Entering Batch Name and Number of Samples ..................................................... 74
9.5 The Information Window ...................................................................................... 74
9.6 The Menu Bar ........................................................................................................ 77
9.7 BCS Monitor ......................................................................................................... 84
10. Preparation of Reagents .............................................................................................. 91
10.1 General Information ............................................................................................ 91
10.2 Preparation of Stock Solutions ............................................................................ 92
10.3 Preparation of Ready-for-Use Solutions ............................................................. 94
10.4 Storage Time and Conditions .............................................................................. 96
11. Maintenance................................................................................................................ 97
11.1 Regular Maintenance ........................................................................................... 97
11.2 Other Maintenance .............................................................................................. 99
11.3 Replacements ..................................................................................................... 100

2
Safety Precautions, Other Langauges

1.3 Précautions de sécurité laser

Le BactoScan FC est un produit de classe I contenant un laser placé dans une enceinte
protégeant l’opérateur contre tout risque pour autant que l’instrument soit employé de
manière conforme.

Le laser se trouve derrière le boîtier gris sur la paroi AR de la partie “humide” de

l’instrument.
Attention
l’application de procédures et/ou l’emploi de moyens de contrôle et de réglage
autres que ceux spécifiés dans le présent manuel risquent d’exposer à une radiation
dangereuse. Il n’est prévu aucune procédure de réglage pouvant être effectuée par
l’opérateur. Tous les réglages doivent impérativement être réalisés par un ingénieur
ayant les qualifications requises.

10.2.2 Solution contrôlée de réactif à colorant (Staining Rea-

gent Stock Solution), pour ± 7.000 échantillons
Verser ± 8 litres d’eau purifiée dans une bouteille de 10 litres, puis ajouter
soigneusement le contenu d’un emballage de poudre tampon (Buffer Powder).

Agiter le mélange jusqu’à dissolution de la poudre. Ensuite ajouter le contenu d’un

flacon d’agent colorant (Bottle of Staining Medium), 500 ml de détergent (Detergent)
correspondant à un flacon, puis ajouter lentement jusqu’à la marque indiquant le niveau
de 10 litres (± 2%) de l’eau purifiée afin d’éviter la formation de mousse.

Se conserve à l’abri de lumière pendant au maximum 6 semaines.

DANGER!
Eviter le contact de la peau avec l’agent colorant (Staining Medium)! Porter des
gants de manipulation !

Nota:
La durée de conservation de l’agent colorant (Staining Medium) est limitée. La date
limite de conservation est indiquée sur le flacon.

3
 NL

1.3 Voorzorgsmaatregelen met betrekking tot Laser

[Laser Precautions]

De BactoScan FC is een Klasse I [Class I] laserproduct en bevat een laser. De laser

wordt geheel door de kast afgeschermd en bij normaal gebruik bestaat er geen gevaar
voor laserstraling.

De laser wordt achter de vierkante grijze doos op de achterwand van het “natte” deel van
het instrument geplaatst.
Waarschuwing
Gebruik van controlemiddelen of aanpassingen in de uitvoering van procedures
anders dan die welke in deze handleiding zijn beschreven kan tot gevaarlijke
blootstelling aan straling leiden. Er bestaan geen aanpassingsprocedures voor de
laser die door de operator kunnen worden uitgevoerd; alle aanpassingen moeten
door een gediplomeerde onderhoudsmonteur worden uitgevoerd.

10.2.2 Kleurreagens Grondstofoplossing [Staining Reagent

Stock Solution], voor ongeveer 7.000 monsters
Giet ongeveer 8 liter gezuiverd water in een 10-liter fles en voeg voorzichtig één pak
Bufferpoeder [Buffer Powder] toe.

Roer het mengsel tot de poeder is opgelost. Voeg, wanneer de poeder is opgelost, één
fles kleurmiddel [Bottle of Staining Medium], 500 ml detergens [Detergent] (één
fles) toe en vul langzaam tot aan de 10-liter merkstreep “2% met gezuiverd water
aan om schuimvorming te voorkomen.

Maximaal 6 weken in het donker opslaan.

GEVAAR!
Wees voorzichtig dat het kleurmiddel [Staining Medium] niet met uw huid in
aanraking komt! Draag handschoenen!

Opmerking
Het kleurmiddel [Staining Medium] heeft een beperkte houdbaarheid; de uiterste
datum staat op de fles.

4
S

1.3 Laserskydd såtgärder

BactoScan FC är en klass I laserprodukt och innehåller en laser. Lasern är fullständigt
skyddad av höljet, och det finns ingen risk för laserstråling vid normal användning.
Lasern placeras bakom den fyrkantiga grå boxen på bakstycket av instrumentets “våta” del.
Försiktighet
Användning av kontroller eller justeringar eller genomförande av procedurer
utöver de i denna handbok specificerade kan medföra farlig strålningsexpone-
ring. Det finns inga justeringsprocedurer för lasern som skall utföras av operatö-
ren; alla justeringar skall utföras av en kvalificerad serviceingenjör.

10.2.2 Färgningsreagens stamlösning (Staining Reagent Stock

Solution) för ca 7.000 prov
Häll cirka 8 liter renat vatten i en 10 liters flaska och tillsätt försiktigt ett paket
buffertpulver (Buffer Powder).
Rör blandningen tills pulvret har lösts upp. När pulvret har löst upp tillsätts en flaska
färgmedel (Bottle of Staining Medium), 500 ml renande medel (Detergent) (en flaska),
och fyll långsamt upp till 10 liters märket ± 2 % med renat vatten för att undvika
skumbildning.
Förvaras mörkt i upp till 6 veckor.
FARA!
Se till att färgmedlet (Staining Medium) inte kommer i kontakt med huden!
Använd handskar!

Observera
Färgmedlet (Staining Medium) har begränsad livstid; sista förbrukningsdag står
på flaskan.

5
 N

1.3 Forholdsregler ved bruk av laser

BactoScan FC er et klasse I laserprodukt og inneholder laser. Laseren er fullstendig
avskjermet av dekselet, og det foreligger ingen fare for laserstråling ved normal bruk.
Laseren er plassert bak den grå firkantede boksen ved bakre vegg på den “våte” delen av
instrumentet.
Forsiktig
Bruk av kontrollfunksjoner eller innstillinger eller bruk av prosedyrer på annen
måte enn det som er spesifisert i foreliggende brukermanual kan føre til farlig
strålekontakt. Brukeren skal ikke foreta noen innstillinger; alle innstillinger skal
utføres av kvalifisert fagperson.

10.2.2 Fargereagens stamløsning (Staining Reagent Stock

Solution) for omlag 7.000 prøver
Hell omlag 8 liter renset vann i en 10-liters flaske, og tilsett forsiktig en pakke bufferpulver
(Buffer Powder).
Rør i blandingen til pulveret er oppløst. Når pulveret er oppløst: Tilsett en flaske farge-
middel (Staining Medium) og 500 ml rensemiddel (Detergent) (en flaske), og hell
langsomt opp til 10-liters merket ± 2 % med renset vann for å unngå at det skummer.

Lagres mørkt i inntil 6 uker.

FARE!
Vær forsiktig; Staining Medium må ikke komme i kontakt med huden! Bruk
hansker!

Merk
Staining Medium har begrenset holdbarhet; flasken er merket med holdbarhets-
dato.

6
I

1.3 Precauzioni per l’impiego del Laser

BactoScan FC è un prodotto contenente un dispositivo laser Classe I. Il laser è totalmente
schermato da un armadio e non vi è rischio di radiazioni laser durante il normale funziona-
mento.
Il dispositivo laser è collocato dietro la scatola grigia quadrata sulla parete posteriore della
parte “a umido “ dello strumento.

Attenzione
L’uso di comandi o regolazioni, nonché l’esecuzione di procedure diverse da
quelle specificate nel presente manuale, possono causare una nociva esposizione
alle radiazioni. Non sono previste procedure di regolazione del laser che possano
essere eseguite dall’operatore; tutte le regolazioni devono essere eseguite da un
tecnico qualificato all’assistenza.

10.2.2 Soluzione reagente di colorazione, utile per ca. 7.000

campioni.
Versare circa 8 litri di acqua depurata in un contenitore da 10 litri e
aggiungere delicatamente una confezione di polvere tampone (Buffer
Powder).
Agitare la miscela fino a che la polvere non sia completamente dissolta, dopo di che
aggiungere un flacone di mezzo di colorazione (Staining Medium), 500 ml di detergente
(Detergent) (un flacone) e raggiungere lentamente, in modo da evitare la formazione di
schiuma, l’indicatore dei 10 litri ± 2 % con acqua depurata.

Conservare al riparo dalla luce per un periodo fino a sei settimane.

PERICOLO!
Prestare estrema attenzione a che il mezzo di colorazione (Staining Medium)
non venga a contatto con la cute! Indossare guanti di protezione!

Note
Il mezzo di colorazione (Staining Medium) ha un periodo di validità limitata;
controllare la data di scadenza riportata sul flacone.

7
 SF

1.3 Laser Varotoimenpiteet

The BactoScan FC on Class I -luokan laser-tuote ja sisältää laseria. Laser on suojattu
täydellisesti kotelolla eikä normaalissa käytössä ole laser-säteilyn vaaraa.
Laser on sijoitettu laitteen “märän” osan takaseinässä olevan harmaan kotelon taakse.
Varoitus
Muiden kuin tässä käsikirjassa eriteltyjen säätöjen tai toimenpiteiden suorittaminen
saattaa johtaa vaaralliseen laseraltistukseen. Operaattori ei voi suorittaa laserin
säätöjä, vaan kaikki säädöt on teetettävä ammattitaisoisella huoltohenkilöllä.

10.2.2 Värjäävä reagenssi varastolious (Staining Reagent Stock

Solution), n. 7.000 näytteelle.
Kaada noin 8 litraa puhdistettua vettä 10 litran pulloon ja lisää varovasti yksi pakkaus
puskurijauhetta (Buffer Powder).
Hämmennä seosta, kunnes jauhe liukenee siihen. Jauheen liuettua lisää yksi pullo väriainetta
(Bottle of Staining Medium), 500 ml (yksi pullo) puhdistusainetta (Detergent) ja täytä
hitaasti 10 litran merkkiin saakka ± 2 % puhdistetulla vedellä. Näin estät vaahtoamisen.
Säilytä pimeässä 6 viikkoon asti.
VAROITUS!
Huolehdi siitä, että väriainetta (Staining Medium) ei joudu iholle! Käytä suojakäsi-
neitä!

Huom!
Väriaineella (Staining Medium) on rajoitettu käyttöikä; viimeinen käyttöpäivä on
merkitty pulloon.

8
ES

1.3 Precauciones de seguridad láser

El BactoScan FC es un producto láser de Clase I. Contiene un láser completamente blindado
por el gabinete y no existe riesgo de radiación láser durante su uso normal.
El láser está situado detrás de la caja gris cuadrada en la pared posterior de la parte “húmeda”
del instrumento.
¡Atención!
Cualquier uso de dispositivos de control o ajuste o realización de procedimien-
tos que no sean los que se especifican en este manual, pueden provocar una
exposición a radiaciones peligrosas. Ningún procedimiento de ajuste del láser,
debe llevarse a cabo por el operario. Todos los ajustes deben ser realizados por
un ingeniero de servicio calificado.

10.2.2 Solución colorante reactiva almacenada (Staining

Reagent Stock Solution) para aproximadamente 7.000 mues-
tras
Eche aproximadamente 8 litros de agua purificada en una botella de 10 litros añadiendo
cuidadosamente un paquete de tampón en polvo (Buffer Powder).
Revuelva la mezcla hasta disolverse el polvo. Una vez disuelto, añada una botella de agente
colorante (Bottle of Staining Medium), 500 ml de detergente (Detergent)(una botella)
y llene lentamente hasta la marca de 10 litros (± 2%) con agua purificada para evitar que
haga espuma.
Se conserva hasta 6 semanas en lugar oscuro.
¡PELIGRO!
¡Procure de que el agente colorante (Staining Medium) no entre en contacto con
su piel! ¡Use guantes!

Observe:
El agente colorante (Staining Medium) tiene una vida de almacenamiento
limitada; ver sello en botella.

9
 P

1.3 Precauções com o laser

O BactoScan FC é um produto laser de Classe I e contém um laser. O laser está totalmente
protegido pelo gabinete, e nno há qualquer risco de radiaHno de laser durante o uso normal.
O laser está localizado atrás da caixa quadrada cinzenta na parede posterior da parte
“húmida” do instrumento.
Advertência
A aplicaHno de controlos ou reajustes de desempenho a outros procedimentos
que os especificados neste manual podem resultar em exposiHno perigosa a
radiaHno. Nno há procedimentos de reajuste do laser a serem realizados pelo
operador; todos os reajustes deverno ser realizados por um engenheiro
qualificado para a assistência técnica.

10.2.2 Solução de Reagente para Marcar em Stock (Staining

Reagent Stock Solution), para aprox. 7.000 amostras
Deitar aproximadamente 8 litros de água purificada numa garrafa de 10 litros e adicione,
cuidadosamente, um pacote de Pó Tampno ( Buffer Powder).
Agite a mistura até que o pó esteja dissolvido. Quando o pó estiver dissolvido, adicione um
Frasco de Agente de Marcar (Bottle of Staining Medium), 500 ml de Detergente
(Detergent) (uma garrafa), e encha lentamente até à marca de 10 litros ± 2 % com água
purificada para evitar a formaHno de espumas.
Armazenar em local escuro por até 6 semanas.
PERIGO!
Tenha cuidado para que o Agente de Marcar (Staining Medium) nno entre em
contacto com a sua pele! Use luvas!

Observar
O Agente de Marcar (Staining Medium) tem um prazo de validade limitado; a
data de expiraHno do produto está marcada no frasco.

10
GR

1.3 ÁóöáëéóôéêÜ ÌÝôñá ËÝçæåñ

 BactoScan FC       Class I       .

              ! "  
!"    #   !     $  $ .

     %       &  &  "  
  " ‘"& (’  " "  &".
* $
+     $ $ "% " !      " "
! , "   "( " ,   & !  ", "  
!" %   !"  #. . "  " ! ! 
(%  "   " (     $. / 
"%   %(    ! (  .

10.2.2 . " 0 !  " 1! (Staining Reagent Stock

Solution), &   . 7.000 !&
45  . 8   %       !    "  % 
     0 # $ 7 (Buffer Powder).
0   &    ! "%  . 0,( ! "%   % 
  " B  1! (Staining Medium), 500  .   . B 
1% ( (Detergent) (   " )  &  &- &   
  10   ± 2 %  %     &    ,(& , .

.           6 #!! .

ÐÑÏÓÏ×Ç! ÊÉÍÄÕÍÏÓ!
*  5   %  B  1!   ,$   ! 
 ! S  & !

Óçìåßùóç

 B  1!      $ ! $  ; 
  $5 & ,     " .

11
 D

1.3 Vorsichtsmaßnahmen für das Lasergerät

Die BactoScan FC ist mit einem Lasergerät der Klasse 1 ausgerüstet, für das be-
sondere maßnahmen getroffen werden müssen, um den Bediener zu schützen.
Das lasergerät ist hinter einem grauen Deckel auf dem hinterwand eingebaut.

Vorsicht
Durch Bedienvorgänge, Einstellungen oder Verfahren, die nicht in diesem
Handbuch bescrieben sind, können Personen gefährlicher Laserstrahlung
ausgesetzt werden. Es gibt keine Einstellungen des Lasergeräts, die der Bediener
ausführen kann. Sämtliche Einstellungen müssen von einem geschulten service
Techniker durchgeführt werden.

10.2.2 Farbstoffbasislösung für ca. 7.000 Proben

8 Litern gefiltertem Wasser in eine 10 Literflasche geben, und eine Packung Puffer-
pulver zugeben.
Die Mischung rühren, bis sich das Pulver aufgelöst hat. Wenn die Chemikalie aufgelöst
ist, eine Flasche Farbstoff und 500 ml Reinigungsmittel (eine Flasche) zugeben und
langsam bis zur 10 Litermarke ± 2% mit gefiltertem Wasser auffüllen, um schäu-
men zu vermeiden.

Lichtgeschützt bis zu 6 Wochen lagerfähig.

VORSICHT!
Vermeiden Sie Hautkontakt mit dem Farbstoff!
Tragen Sie Schutzhandschuhe!

Hinweis
Der Farbstoff ist nur begrenzt haltbar, das Ablaufdatum ist auf der Flasche
vermerkt.

12
 1. Introduction
1.1 About This Manual
This BactoScan FC Operator’s Manual describes the daily routine operation of the BactoScan
FC instrument with the Conveyor 4000.
A general description of the user interface and the System 4000 software is found in Chapter
2, Using Integrated Milk Testing. This issue of the Operator’s Manual is based on System
4000 Software version 4.x.x.
Focus in this manual is on the operational routines. The relevant theory behind the instrument
and maintenance instructions is found in the Integrated Milk Testing™ Reference Manual,
P/N 491647.
A schematic overview of the BactoScan FC documentation can be seen in fig. 1-1. The
structure of this operator’s manual is as follows:
Chapter 1 - 3: Introduction to the BactoScan FC and Integrated Milk Testing™
Chapter 4 - 6: Basic routines for running the instrument
Chapter 7 - 8: Performance checks and problem solving
Chapter 9: A systematic description of the presentation application
Chapter 10: Preparation of reagents
Chapter 11: Maintenance
Chapters 4 - 6 are for new operators, whereas chapters 7 - 9 are for more specific problem
solving.

Operator’s BSC Reference Manual

Manual
Starting Up Part 1. System 4000 Part 2. The Instrument Part 3. Calibration and
Software Quality Control
Measuring Introduction to Introduction to the IMT Quality Assurance
System 4000 Software Instruments Overview
Shutting Down The System Manager The BactoScan FC Instrument Calibration Control

The Presentation The Setup Application Conveyor options and

Application Pipette 4000
Solving Problems The Presentation
Application
Preparing Reagents The PHA Application
Maintenance The Calibration
Application
The Host Application
The Service Application
13
 1.2 Introduction to IMTTM and Individual Bacteria
Counting
Integrated Milk TestingTM (IMT) is the most comprehensive analysis solution for testing of
• Compositional milk quality
• Hygienic milk quality
IMTTM is especially designed to benefit milk payment schemes and dairy herd improvement.
The Integrated Milk Testing concept comprises:
• Milk analyser units for
• Milk Components and Freezing Point Determination
• Somatic Cell Counting
• Bacteria Counting
• Shared Software platform
• Shared Conveyor and Pipette Systems
• Bar-code reader
• Printer
BactoScan FC is designed for individual bacteria counting, as opposed to plate count of
colonies.
This third generation BactoScan is based on flow cytometry, which allows the flow system
and reagents concept to be modified and simplified when compared to earlier versions of the
BactoScan instrument. The main target of the new design has been to reduce maintenance/
start-up time and costs, increase productivity and give more value of ownership.
The BactoScan FC is available in a number of versions with different speeds and sensitivity.
This Operators Manual covers all versions, indicating differences between versions where
it is relevant.
The instrument is used in Central Laboratories to analyse the bacteria contents in milk
producers raw milk samples for payment purposes. The results can also be used for screening
hygiene status at the farm level.
Dairies can use the bacteria count to monitor incoming raw milk to avoid contamination.
The common user interface and data handling offered by System 4000 software allows
BactoScan FC sample ID and results to be handled in exactly the same way as the results from
other members of the IMT family. This ensures uniform and streamlined data handling and
makes life easier for operators working on several types of IMT instrumentation.

14
1.3 Laser Precautions
The BactoScan FC is a Class I laser product and contains a laser. The laser is totally shielded
by the cabinet, and there is no risk of laser radiation during normal use.
The laser is placed behind the square grey box on the back wall of the “wet” part of the
instrument.
Caution
Use of controls or adjustments or performance of procedures other than those
specified in this manual may result in hazardous radiation exposure. There are
no adjustment procedures for the laser that are to be performed by the operator;
all adjustments are to be carried out by a qualified service engineer.

Avoid Exposure
Laser radiation is
Emitted from this
aperture

15
 1.4 Warranty Policy
A warranty period of 12 months is granted for material and production errors in instruments,
accessories, spare parts, exchange parts, reagents and disposables. The warranty period for
reagents and disposables cannot exceed the date of expiry.
Parts subject to wear are only covered by the warranty if the wearing down is due to
extraordinary circumstances such as defective materials or production errors. Wearing parts
contained in the instrument are listed in the operators’ manual.
The warranty applies only if Foss instructions concerning reagents, disposables, preventive
maintenance and daily cleaning are followed. Only reagents supplied by Foss may be used
unless otherwise stated.

1.5 Parts Subject to Wear

The following parts subject to wear are included in the accessories:
Tubes: Silicon Ø 1/3 P/N 123182
Silicon Ø 0.85/1.4 - 101287
Silicon Ø 4/7 - 094789
PVC Ø4/6 - 557157
PVC Ø2.5/4.5 (blue) - 528570
Tygon Ø1/16”/1/8” - 183103
Nylon Ø4/6 - 027045
PE Ø3/16” - 198770
PE Ø4/6 - 552190
O-rings: Ø2.8/0.5 - 555433
Ø2.3/0.9 - 349407
Ø3/1 - 198499
Ø7/1.5 - 368357
Ø21.2/3 - 301853
Other parts: Pipette P/N 349332
Stirrer - 558791
Stub - 555128
Stub - 555235
Union - 219121
Filter - 278754
Filter - 537787
Filter - 557413
Filter - 556373
One-way valve - 558684
Stub w. pipe - 557850
16
 2. Using Integrated Milk Testing
2.1 The Integrated Milk Testing™ Concept
BactoScan FC is an instrument in the range of Foss Electric Integrated Milk Testing
instruments using a common platform consisting of System 4000 Software and a standard
conveyor system, allowing vital functions to be performed in a similar fashion:
- Sample handling
- Instrument operation
- Data handling
The basic principles of operation are the same, independent of the actual instrument:
- MilkoScan
- Fossomatic
- CombiFoss
- BactoScan
These instruments all share the Foss Electric Integrated Milk Testing concept (IMT).
Figure 2-1 provides an overview of the elements that constitute the Integrated Milk Testing
concept. As it is seen, System 4000 software, Conveyor 4000 and Conveyor 5000basic can
be combined with the following range of instruments
• MilkoScan 4000
• Fossomatic 5000
• Fossomatic 5000basic
• BactoScan 8000S
• BactoScan FC (with Conveyor 4000 only)
• CombiFoss 4000 (the combination of MilkoScan 4000 and Fossomatic 400)
• CombiFoss 5000 (the combination of MilkoScan 4000 and Fossomatic 5000)
• CombiFoss 5000basic (the combination of MilkoScan 4000, Fossomatic 5000basic
and Conveyor 50000basic)
System 4000 Software
MilkoScan Fossomatic CombiFoss CombiFoss BactoScan BactoScan
4000 5000 4000 5000 8000S FC

Fossomatic CombiFoss
5000basic 5000basic
Conveyor Systems
Pipette Systems
Optional OEM modules: Printer, Bar Code Reader, Software etc.

17
 2.2 The IMT User Interface
When purchasing an IMT configuration, you receive the measuring unit and a PC with
System 4000 software (and possibly the optional Conveyor 4000 or Conveyor 5000basic).
The PC is controlled by a keyboard and by a trackball. All the results from the measuring unit
are shown on the PC’s colour monitor, which is placed above the keyboard. The following
sections describe how to operate the basic devices of this configuration:
- The trackball
- The keyboard
- The function keys
- The Windows system
and provide an overview of the application elements in the System 4000 software.

2.2.1 The Trackball

The instrument is equipped with a pointing device called a trackball placed to the right of
the keyboard. To use the trackball, you simply roll it with your fingers. You will then see an
arrow cursor move around on the display.
The trackball has three buttons; mainly the left one is used:
- Clicking the left button once selects the item you are pointing at (i.e. some text-choices).
- Double clicking the left button executes a choice already indicated or just pointed at.
The arrow on the screen may turn into an hourglass upon making a selection. This indicates
a short wait.

2.2.2 The Keyboard

The keyboard is a standard PC keyboard with which you may already be familiar. To
the right is a small numeric keyboard where digits 0-9 may be typed most conven-
iently, but only when the ‘Num Lock’ light is on (you find it just above the keys).
Should the light be off, press the [Num Lock] key (also on the small keyboard) and
the ‘Num Lock’ indicator will light up again.
2.2.3 Function Keys
Functions frequently used, particularly when analysing samples, have been given special
keys on the top row of the PC keyboard. These are labelled [F1] to [F12]. The purpose of each
of the keys [F1] to [F12] is written on the Function-Key Template placed just above the keys.
Simply pressing the function key directly below the text performs the functions listed in the
lower part of the Function-Key Template. Depressing the function key while pressing the
[Shift] key performs the functions listed in the middle part of the template. Depressing the
[Ctrl] key while pressing the function key performs the functions listed in the upper part.
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12

Ctrl + F Present. Service Calibrate Menu Setup PHA

Sh + F Restart Host Export Printer Block

F Auto Standby Stop Manual Rack >> Status Active LogOn View Ident.
18
2.2.4 The Windows System
Since all information from an IMT instrument is presented on a single display, it is necessary
to use it efficiently. The System 4000 software uses Microsoft Windows. Windows can
divide the display into smaller separate screens (windows), each operating separate applica-
tions. An example of a screen picture using Windows and System 4000 software is seen in
fig. 2-2.

The Menu Bar

The Menu Bar (top of figure 2-2) is a list of pull-down menus available: Window, View,
Commands, etc. If you point and then click the left button of the trackball at any one menu
name in the Menu Bar, a pull-down box will appear, from which you may choose individual
functions.
In figure 2-2, the menu ‘Window’ was selected and the pull-down box is now visible with
more functions to choose from. Note that some of the menu names listed in the Menu Bar
have one letter underlined, example: ‘Window’. When a letter is underlined, the function
may also be activated from the keyboard by simply depressing the [Alt] key and the
underlined letter simultaneously. Sometimes this may be more convenient than using the
trackball.

19
 The Scroll Bars
The scroll bars are shown as long grey strips on the right side of some windows and
sometimes also at the bottom of a window. The scroll bars can be seen on figure 2-2. The
small arrow-buttons may be used to scroll the contents of the window in different directions.
The square button in the scroll bar can also scroll the screen picture.
The square scroll-bar buttons is seen in figure 2-2, and the arrow buttons in figure 2-3.
If you point and click at the arrow button with the trackball, the information in the window
will move or scroll to show information not immediately visible.

Fig. 2-3 If you point and click at the arrow button with the trackball, the
information in the window will move or scroll to show informa-
tion not immediately visible.

2.2.5 Overview of System 4000 Software

The System 4000 software consists of a System Manager and six applications, each of which
covers a confined set of functions.
The System Manager
This program controls all the computer files in which analytical results are stored. A
computer file, called a ‘Work session’, must be named in the System Manager before
analysis may start in the Presentation Application.
The Presentation Application
This application is used when samples are analysed. It enables the identification of groups
of samples (batches), and controls the starting and stopping of the instrument. In addition,
instrument functions like performance check and cleaning are controlled from here.
The PHA Application
This application displays graphically the distribution of pulses (Pulse Height Analysis) as
generated by the instrument. It is used in instrument standardisation.
The Calibration Application
This application is used to store the correlation between results of the reference
method and results from the IMT instrument’s analysis of the same samples. This
correlation (the calibration) is then used to adjust instrument results.
The Host Application
Integrated Milk Testing allows transmission of data to an external computer
(host). This application controls and monitors the flow of data to and from the
external computer.
The Service Application
In the Service Application, the measuring unit as well as the conveyor may be
tested for correct function (or a possible fault located/corrected).
The Set-Up Application
This application is used to set up all the parameters necessary for analysis: compo-
nents to be analysed, sample volume, re-test limits, etc.
20
 3 The BactoScan Method
3.1 General
The BactoScan FC is designed for fully automatic, rapid and reliable determination of the
hygienic quality of raw milk. This is done by counting the total number of Individual
BactoScan Counts (IBC) in a milk sample.
BactoScan FC stains the bacteria with a fluorescent dye and reduces and disperses the milk
components, so the bacteria can be counted. A fluorescence detector detects the light emitted
from the bacteria, when a thin string of the sample is fed through a flow cell below the
detector. The light pulses are converted into electronic pulses and then counted and
displayed on a PC.
In order to avoid interference from other particles, such as fat globules, protein micelles and
somatic cells, the sample is subjected to chemical treatment in order to destroy these
particles. This treatment is performed automatically by the instrument.

3.2 The Flow System

1. The sample is stirred thoroughly with a high-efficiency stirrer, assuring proper mixing
of the cold samples.
2. Now the pipette takes in approximately 5 ml of milk. The first part of the milk is used
for filling/cleaning the system.
3. At the same time, the sample syringe is filled with incubation reagent.
4. Before reaching the incubation unit, milk and incubation reagent both pass through a
100 µm filter.
0.4 ml milk is dispensed into the incubation unit.
5. The sample syringe now dispenses 1.1ml incubation reagent into the incubation unit,
on its way the reagent passes a 0.22 µm filter.
6. The incubation unit is now moved one position to enable filling of the next well.
7. During incubation, the sample and the incubation reagent are thoroughly blended
twice, allowing the incubation reagent to separate all particles, destroy somatic cells,
proteins and fat and to thoroughly stain the bacteria.
8. After 8.5 minutes of incubation, 0.8 ml of the sample is sucked out of the well and passes
through a 100 µm filter. The first liquid is discarded and the rest of the sample is fed
to the measuring syringe at the entrance of the flow cell, ready for injection.
9. The measuring syringe injects the sample into the flow cell and the sheath liquid will
now carry the sample through the flow cell.
10. As the sample string becomes stable, the bacteria pass under the microscope as pearls
on a string. When light from the laser source excites the dyed bacteria, they emit light
pulses (red light) which are detected and counted.

21
 11. The whole flow system is flushed between each milk sample, and all filters are back-
flushed.
After the sample leaves the incubation unit, the well is thoroughly cleaned before it
receives the next sample.
The stirrer is cleaned between each sample, and because of this cleaning procedure the
BactoScan FC stirrer is mandatory.

3.3 The Counting Module

The purpose of the counting module is to scan the mixture of milk and reagents and generate
an electronic impulse for every bacteria in a given sample volume.
Using a phenomenon known as hydrodynamic focusing, the incubated mixture of milk and
reagents are injected into a flow channel as a thin stream surrounded by a sheath fluid of water
(flow cytometry). Presented this way, the bacteria practically appear as pearls on a string,
making it possible to detect their individual presence and count their number.
On their way through the flow channel, the labelled bacteria pass a focused blue laser beam,
and emit red light due to the fluorescent dye attached to them.
The fluorescent light is detected by a highly sensitive detector, which gives an electronic
impulse each time a bacteria passes the laser beam.

3.4 BactoScan FC Specific Applications

3.4.1 The PHA Application
This application displays Pulse Height Analysis graphics as generated by the instrument
when each sample is measured. ‘PHA’ is an abbreviation of Pulse Height Analysis.
The PHA figure of each sample indicates the quality of the measuring. For further
explanation see Section 9.6.1, The ‘Window’ Menu, or refer to the IMT Reference Manual.
The PHA figure can be displayed as a small figure in presentation mode, showing only the
PHA graph, or as a full screen picture with more detailed information concerning the sample.
The small figure is switched on/off by selecting ‘View’ and ‘PHA’. It may be moved by use
of the trackball, clicking in the white square (where PHA is written) with the left key. While
keeping the key depressed, you can move the picture to a convenient place.
If a full PHA display is needed during analysis, click the left key in the grey area of the PHA
curve.
To go back to Presentation Mode, select ‘Window’ and then ‘Presentation’.
The full screen PHA picture may also be displayed by selecting ‘Window’ and ‘PHA’. The
currently analysed sample will then be displayed.
If you point with the cursor at any point on the curve, and click the left-hand trackball button,
a small window will list the number of the channel presently selected and the total pulse count
for that channel.

22
 4. Daily Start-up Routines
This chapter describes the daily start-up routines, checking the active units on the instrument,
and making a suggested start-up control batch sequence. Refer to chapter 10 for detailed
descriptions of preparation of reagents.

4.1 Preparations
4.1.1 Start-up
1. Replace the filter in the pipette unit. Lift the spring-loaded disc that holds the filter in
position, remove the old filter, insert the new filter and release the disc.
2. Replace the End of Day solution container with the Incubation Reagent container. Fill
the liquid containers (volumes may vary depending on number of samples run per day):
- Ready-for-use Incubation Reagent.
Any remaining solution from previous day should be thrown out.
- Ready-for-use Sheath liquid: Remains from previous day can be used.
- Check the large container for Rinse and fill up if required. Remains from previous day
can be used.
- Note that all liquids must be above 15 °C at startup.
3. Transfer the pipettes from the holder on the compartment door to the appropriate liquid
containers, note correct pipette for each liquid.
4. Switch on the instrument, printer and conveyor.
5. After having started a work session as described in section 4.2, Opening a Work
Session, click on the Standby button (the only not-greyed button on the screen, see
section 9.1, Mode Symbols) to bring the instrument in Standby mode. Select ‘Normal
standby’.
6. Now the automatic start up procedures will start. The instrument will now warm up and
prime the flow system with liquids.

Note:
Do not remove the pipettes from liquid containers while the instrument is meas-
uring. If this happens, the BactoScan FC will go to Standby, and results could be
effected, see Section 5.5.

In the mean time:

7. Prepare Bacterial Control Sample; store at 2 - 8°C until used, see Chapter 10 for re-
hydration procedure.
8. Prepare rack with a Start-up Control Sample Batch: 3 blanks, 1 bottle containing
Bacterial Control Sample (BCS), and 3 blanks.
Any other samples that have to be measured to comply with your laboratory procedures
23
 can be placed after the last three blanks and included in the Start-up Control Sample
Batch. A low-count milk made from local supply is a relevant supplement to the
Bacterial Control Sample that is described in section 4.5.
- Select ‘Auto’
Alternatively, the Bacterial Control Sample can be measured in manual mode by
selecting the BCS batch type. In all cases, the measuring program used for the BCS
samples should include signal mean display.

9: Measure the control samples.

When the sample rack has been measured:
- Check that blank counts are within acceptable limits, all results should
be below 5 and the average below 3.
- Check the appearance of the PHA graphs for the BCS samples and that
the results of the Bacterial Control Sample conform with the specified
limits. If they do, the result will be accompanied by an OK in the system
remarks column.
If the Bacterial Control Sample is outside the specified limits, then the
Particle Control Sample should be measured, see Chapter 7 for details.
- Check counts and appearance of PHA-graph of low-count milk if
applied.
- When OK, then the instrument is ready to run regular samples.

4.1.2 Switching on the Conveyor (Conveyor 4000 only)

Before you press the ‘Start’ key, make sure that the Conveyor 4000 is switched on. The
switch for the conveyor is placed to the left (when seen from the front) at the back of the
conveyor. The conveyor is ‘ON’ when you can see the red light-emitting diodes illuminated
just behind the pipette.

4.1.3 Printer Check

If you plan to use the printer, then check that it is switched on and that the paper is parked
at the beginning of a new page.
Finally, check that the printer is online, i.e. ready to receive data from System 4000. (Note:
Pressing Shift+F11 brings up the Printer Control Window. Check that the ‘Printer online’
is set ON [X]).

4.2 Opening a Work Session

When the instrument is analysing samples, all results are stored on the PC hard disk.
Analytical results for a given period are automatically stored in a file with a unique name.
A work session is the IMT term for the computer file in which results will be stored.
During one day, several such work sessions may be created, as it is practical to store payment
sample results in another file than dairy sample results, herd improvement results, etc.

24
4.2.1 The System Manager
The System Manager that controls the work sessions is seen in fig. 4-1. To make the
instrument display the System Manager window (fig. 4-1), you must do the following:
- Enter the Presentation Application [Ctrl] + [F1]
- Then enter Stop mode [F3]
- Press [Alt] + F4] simultaneously.

4.2.2 Creating a New Work Session

The System 4000 software will automatically generate a name for the work session. This
name is made up from the calendar date. However, if the instrument is left switched on
overnight, a new work session will not automatically start up in the morning using the date
as name. The instrument will instead propose the date from the day before. To create a new
name, select ‘Work sessions’ and then ‘Create’. The window in fig. 4-2 will then appear.

If the name is satisfactory, click on the OK button with the trackball. If you want to use this
name, but with a small change, click on the input field (where the name is presented) and type
the desired addition or change.
25
 A short remark may also be written in the ‘Remark’ field under the ‘Name’ field.
Note:
When writing in the ‘Remark’ field, do not use [Enter] for a new line. The
cursor will automatically jump to the new line.

4.2.3 Continue a Previous Work Session

To continue a previously initiated work session, select ‘Work sessions’ and then ‘Select’ in
the System Manager window (fig. 4-1). A list of previous work sessions will appear. Click
on the desired work session.
When you have completed the above, click on the ‘Start’ button displayed in figure 4-1.

4.3 Logging On
The Log-On/Off procedure is used to ensure that trained personnel only perform certain
critical operations.
Log on by pressing [F8], and type in your password followed by [Enter]. Be careful to enter
the exact password, as the System 4000 software is sensitive to the use of small or capital
letters.
When you have logged on, go to Standby by pressing [F2], or by clicking on the ‘Standby’
button.

4.4 Active Units Check

It is important to control which units are currently in use (i.e. active). Examples of units that
may be declared active/inactive are: The Printer, the Conveyor, the analyser instrument, etc.
Press function key F7, or select ‘Commands’ and ‘Active units’ to see the ‘Active Units’-
window as in Fig. 4-3.

26
Even though the unit is switched on, it will not be used if it is declared inactive, so check that
all the units to be used are declared active. Move the cursor with the Trackball to the small
boxes and click to set the unit active [X] or inactive [ ].
If you plan to use the printer, then check that it is switched on, that the paper is parked at the
start of a new page, and check that the printer is Online as described in Section 4.1.2, i.e. ready
to receive data.

4.5 Performance Check

With the new generation of BactoScan, daily adjustments of the instrument are reduced to
near zero. This is because the BactoScan FC, being based on Flow Cytometry technology,
is a stable and reliable instrument. The instrument is calibrated and adjusted at Foss, any
other adjustments required will be done by Foss service technicians at the regular service
visits.
Check the performance of the BactoScan FC by using the Bacterial Control Sample. This
sample will indicate whether the instrument is adjusted correctly, and also whether reagents
have been prepared according to specifications and are functioning correctly.
The only exception is the Enzyme, to which the Bacterial Control Sample is only slightly
sensitive. The Enzyme is used to break down the components in milk that will disturb the
counting of bacteria. There are no milk components in the Bacterial Control Sample;
therefore a supplementary reading on a low-count milk sample is a way of indicating whether
the Enzyme is doing the job efficiently.
The Particle Control Sample is indifferent to reagents, as it is already stained with a
fluorescent dye. Measuring the Particle Control Sample gives indications of the stability and
mechanical functionality of the instrument. Changes in the shape or the position of the PHA
graph indicate that something in the optical alignment or other mechanical adjustment is off-
centre. A more detailed trouble-shooting guide is found in Chapter 7.
The Bacterial Control Sample should be measured as a Batch Type called BCS Check. By
selecting this batch type, the control sample will be measured three times from the same
bottle and the results will be checked against the lot specifications stored in the software
program. See section 4.5.4 regarding entering of lot data. The software will compare the
individual counts and the signal mean value with the stored data. The measuring program
used must have Signal Mean selected if this value is to appear on the display.
As this batch sequence is measured daily or several times during the day, it is convenient to
store it as a specific batch type as described in the Reference Manual.
Remember to use the correct Lot ID when entering new batches, or when creating a batch
sequence which involves BCS samples. Also remember to change Lot Data when starting
to use a new lot of control samples.

4.5.1 Start-up Control Batch Sequence

The BCS sample is also part of the Start-up Control Sample Batch. As this sequence is
repeated every working day, it is convenient to create a batch sequence consisting of a normal
blank sample check batch (for example 3 bottles with blank solution), a BCS sample batch
and yet another normal blank sample check batch, plus any locally defined control samples.
27
 4.5.2 Blank-Count Check
Apply one blank sample to remove carry-over from the previous samples, then measure four
blank samples in Manual mode (as described in section 2.5) or Auto mode (see section 2.8).
All results should be below 5 and the average below 3. The lids of the instrument must be
closed during measurement. Refer to section 7.1.1 if results are too high.

4.5.3 Check Measurement Level

The above checks and the instrument calibration are designed to ascertain that the instrument
measures at a correct level. You can check this by using Bacterial Control Samples at regular
intervals during the day. Use the BCS batch type in Manual mode (section 2.5) or Auto mode
(section 2.8), as described under Start-up. Check on the Results list that the results are
acceptable.
Since this procedure is often performed daily or several times daily, IMT instruments feature
a convenient function for automating this task:
- In the ‘Presentation-Application’, select the batch list by pressing [F11] until the word

‘Batches’ appears as can be seen in fig. 4-4. (In fig. 4-5 ‘Results’ are shown).
- With the screen showing ‘Batches’ (as seen in fig. 4-4), select ‘Edit’ with the trackball.
- Then select ‘Insert sequence’. (Pressing [Ctrl] + [S] would produce the same result).

The window seen in fig. 4-6 will appear.

- Point and click with the trackball at the grey button to the right of the input field. A list
of choices will be then displayed.
- Point and click at the preferred selection.
28
This procedure will result in batches being automatically inserted into the batch list.
Samples that match the contents of the batch list must now be prepared and analysed:
- Place the samples in racks in the exact same number and sequence as indicated on the
batch list.
- Place the first rack on the conveyor.
- Start analysis by pressing [F1] ‘Auto’.
-
Note
It may very well be desirable to check the same batch sequence several times
during the day, and possibly within the same work session. But you cannot have
two batches with the same name within a single work session. This means you
will have to rename the control batch sequence each time in order to repeat it, or
perhaps a more convenient solution will be for you to define several identical
batch sequences with different names, and include them during the days work.
You define the Batch Names, but remember to use the correct Lot Name for the
lot of control samples presently being used.

4.5.4 Entering Lot Data for BCS Samples

The values and limits, against which the software checks the Bacterial Control Sample
(BCS) when it is measured as a BCS Batch Type, have to be stored in the instrument before
analysing these samples.
These values and limits have to be entered each time you start using a new lot of Bacterial
Control Samples. These data are supplied in the box together with the samples.
Procedure:
- In the S4000 Application folder there is an icon named “Lot editor”.
- Double click on this icon to start up an editor where you can enter new lot data and store
them in the instrument, or edit an existing set of lot data.
- Enter the Lot Name (ID) and the values supplied by Foss, using the Tab key or the
Trackball to switch between the fields.
- Press the Save button to store these data when correctly entered.

Editing existing data:

Press the Select Tab at the top of the editor page.
Select the desired Lot ID and press the Load button.

29
30
 5. Analysing Samples
5.1 Conveyor
Your analyser may be equipped with a Conveyor 4000.
- Fig. 5-1 and Fig. 5-2 show a Conveyor 4000 configuration.

31
 5.2 Handling Samples
The BactoScan FC can measure “cold” samples down to 2 °C, but the recommended sample
temperature is 5 - 8 °C.
Before placing the samples on the conveyor, turn them upside down several times to mix
possible cream on the lids with the contents in the bottles.
Note:
Do not shake the samples, as this may cause damage to the bacterial cells,
especially if the samples are old or preserved with sodium azide.

5.3 Typing In Batch and Sample Information

5.3.1 Results/Batches
When running samples, one of the following two lists may be displayed:
- ‘Batches’, where the name of the batch (e.g. the route number of the tanker) and the
number of the sample (e.g. number of farms on the route) are displayed, see fig. 5-3.

- ‘Results’, where all results of analysed samples are displayed, see fig. 5-4.

To shift between these two lists, click with the trackball in the Menu Bar (Batches or
Results), or simply press function key F 11.
To be able to type in batch information, press F11 to be in ‘Batches’.

5.3.2 Identifying Batches and Samples

Before samples can be analysed, the batch to which they belong must be identified, i.e. the
number of the Milk Producer must be typed in for Herd Improvement samples, or the Milk
Tanker Route for Payment samples.
In the Presentation Application, many batch identities may be typed in and stored in advance,
to be used before and during analysis of the samples.
Press F12 to identify a Batch of samples. The window seen in fig. 5-5 will appear.

32
Two other ways of entering the batch identification window are to point at an empty line with
the trackball and double-click, or to press ‘Enter’ when the pointer is in ‘Tracking Mode’,
i.e. placed at the end of the list of batches. These methods will have the same effect as
pressing F12.
Batch
Enter the batch identification. Alphanumeric characters may be used, max. 8 or 10 characters
(this depends on the general set-up of the instrument).
The batch identification number must be one that has not been used before in this work
session. If a number must be repeated for some reason, this may be done by adding a letter
to the number; i.e. batch ID ‘123456’ may be used again if ‘123456a’ is entered the second
time.
Total
Enter the number of samples in the batch. Note that various conveyor types count in different
ways, and that this may have consequences for your ‘Total’ value:
- The system counts sample bottles. The ‘Total’ value must correspond to the number of
sample bottles that are to be assigned to this batch. Empty bottles are counted and must
be included the ‘Total’ value.
Empty rack positions and pilot samples are not counted and should not be included in
the ‘Total’ value.
Batch Date
The Batch Date is the date at which the samples were produced. The batch date must always
be a date equal to or earlier than the Lab. Date. The date will initially be the lab. date, but
once a batch date is entered, this date will be used for the following batches until a new date
is entered.
33
 Lab. Date
The Lab. Date is the date at which the samples are analysed in the laboratory. The format is
as for the batch date. The date is automatically set to today’s date, but this may be manually
overwritten. Once a date is manually entered, this date will be used for the following batches
until a new date is entered (or the date is updated by the System 4000 Software).
Program
The Measure Program to be used for analysis of the samples is selected here. Once selected,
the same program is suggested for the following batches of samples.
To select another measuring program, press the button to the right of ‘Program’ in fig. 5-5
and select between the displayed programs as seen in fig. 5-6.
Batch Type
The Batch Type identifies to the instrument how the sample is to be analysed, and how results
should be stored in the computer file. Select ‘Normal’ for all typical laboratory milk samples.
(See the IMT Reference Manual for more details).

5.4 Starting and Stopping Modes

5.4.1 Auto, Standby and Stop Modes
These modes are controlled either by use of the Function Keys F1-F3, or by pointing and
clicking with the trackball at the symbols placed in the upper left corner of the Presentation
Application window. The symbols can only be selected when they are black (not when they
are grey).
The modes are as follows:

34
 - Auto mode (Key F1) is the mode in which samples will be automatically analysed, if
Batch Identification data have been keyed in, and samples have been placed in a rack
on the conveyor.
Auto mode is only available when the instrument is already in Standby mode.
- Standby mode (Key F2) is the mode in which short pauses may be made between
feeding new samples to the instrument.
- Stop mode (Key F3) is used whenever the instrument should not be used for a longer
period. When Stop mode is selected the instrument will go through a Rinse procedure
before reaching Stop mode.
- A ‘Quick stop’ should not be used during normal routine, as no rinsing of the system
will take place before Stop mode is reached. Quick stop requires the tick-off to be
removed from the “Rinse” box in the window that appears when you select Stop.
Otherwise the lengthy Rinse procedure that normally takes place at the end of the day
will be activated.
- When the instrument has stopped, it will perform no other flow system operations until
commanded to do so.

5.4.2 Procedures for Starting (Auto)

Place the rack with samples to be analysed to the right of the stirrer and press ‘Auto’. Now
the samples will be analysed.
If for some reason you want to stop analysing before all samples are measured, press
‘Standby’.
When you are ready to analyse again, press ‘Auto’. The instrument will now continue the
entered batch. While analysing one batch, you may identify other batches to be analysed
next.
The results are displayed on the ‘Results’ list. Press F11 to see it.
If you have not entered new batch information before a batch is measured, the window shown
in fig. 5-7 is displayed.

35
 5.5 Liquids Low Message and Removing Liquid Con-
tainer Pipettes
If the level of any of the 3 liquids are sensed to be running low, an error message will be shown
and the analyser will go to Standby. There will remain enough reagents to measure the
samples already in the incubation wheel.
If the pipettes are removed from liquid containers while the analyser is measuring, the
consequences will vary (see Section 8, Errors and Warnings).

1) Removing the pipette from the Sheath Liquid or Rinse containers. The liquid pressure
will drop. There will be an error warning for sheath- or rinse liquid pressure low. The
analyser will go to Standby, and no results will be provided (marked by an asterisk on
the result list).

2) Removing the pipette from the Incubation Reagent container. The analyser will go to
Standby, but the samples already in the incubation wheel will be measured normally.

36
 6. Shut-down
When you have finished the day’s work, you might consider measuring one Bacterial Control
Sample to check performance. Check results.
Check the Sheath Flow in the Service Program/BactoScan/Available Tests menu.
1) Replace the Incubation Reagent bottle in the trolley with a container of End of Day
Solution. Place the pipettes for Incubation Reagent and Rinse in the End of Day
container.
Note that the End of Day solution must be above 15 °C.
Discard any remaining Incubation Reagent.
2) Go to Stop mode <F3>.
3) Transfer analysis results to diskette or transmit to Host Computer if required. Use ‘Data
Export’ <Shift> + <F8>.
4) Clean the conveyor and surrounding parts with a moist cloth.
5) Close the System 4000 Application <Alt> + <F4>.
The System Manager menu will appear, and you can switch off and leave the instrument
until the next day.
6) Switch off the monitor, conveyor and printer.

37
38
 7 Checks and Sample Re-testing
7.1 Performance Checks
In this chapter you will find procedures, such as performance checks, weekly checks, and
problem solving, which are not included in basic operating procedures. For further theoreti-
cal explanations, please refer to the IMT Reference Manual. The checks and the instrument
calibration are designed to ascertain that the instrument measures at a correct level. This can
be checked by using control samples with a known bacterial contents.
Foss supplies a Bacterial Control Sample and a Particle Control Sample. We suggest that you
measure the Bacterial Control Sample at regular intervals during the day, and the instrument
will check the results against the lot-specific limits stored in the software. If limits are
exceeded, the Particle Control Sample described below helps identifying where the problem
lies. If the Particle Control Sample is measured correctly, then the measuring system is OK,
and the problem is most likely to be found in the sample preparation areas.
Use Manual mode or Auto mode. Check that results are acceptable.

7.1.1 Blank-Count Check

Measure five blank samples in Manual mode or Auto mode. All results should be below 5
counts (IBC/µl) and the average below 3.
If the results are too high, the reason is most likely a poor blank solution. Prepare a new
solution and measure 10 blank samples. Observe that the results drop to an acceptable level.
If this does not help, go to Stop, so the system is completely rinsed, then go to Auto and try
again.
If the Blank value is still too high, then try cleaning the incubation wheel and pipettes (refer
to section 11). Also, clean and check the Inline Filter and the Intake Filter, and check or
replace the Sheath Liquid and Rinse Filters (also described in section 11)
If the error still exists, call your local Foss Service Engineer.

7.1.2 Repeatability Check

Repeatability checks are carried out to estimate the repeatability at different levels. Each
repeatability check consists of two or more (up to 9) repeated samplings from the same
beaker with the standard deviation computed. This can be done in two ways:
1) Select ‘Manual Mode’ and ‘Settings’. In settings, click on the arrow to the right in the
sample type box and select ‘Repeat’. Enter number of repeatability checks (number of
samples). Select the same beaker if you want continuous sampling. Click on ‘Store’ and
on ‘Measure’ to start the repeatability check. When the check is complete, the result is
presented.
3) The repeatability check may also be performed in Auto mode. Press <F12> to get Batch
Data Input. Enter name and number of samples to include and select sample type
‘Repeat’. Place the correct number of samples in a rack on the conveyor. Click on
‘Store’ and ‘Auto’. Now the instrument takes two or more samples from each sample
beaker and displays the average result.
If the sample volume is too small for the number of sample repeats selected, the rack
will move on to the next sample, and the Result List will display an empty line. 39
 7.1.3 Carry-over
Carry-over checks are performed to see if a substantial amount of sample is carried over from
one sample to the following. The reference manual describes how to compensate for carry-
over.
In Auto mode, the Carry-over batch-type must be used to check the carry-over effect by
analysis of alternating high-count milk samples and blank samples.
Prepare samples in a rack. Each set consists of one milk sample with a high content of bacteria
(>1,000 IBC/µl) and two samples with blank liquid. Place the samples in the order: milk,
blank, blank, milk, blank, blank, and milk, blank, blank, etc.
1) Select ‘Manual Mode’ and ‘Settings’. In settings, click on the arrow to the right in the
sample type box and select ‘Carry-over’. Enter number of checks (number of sample
sets). Click on ‘Store’ and on ‘Measure’ to start the check. When the check is complete,
the result is presented.
2) The carry-over check may also be performed in Auto mode. Press <F12> to get Batch
Data Input. Click the arrow to the right of Sample Type and select ‘Carry-over’. Enter
batch name and number of sets to include. Place the correct number of samples in
correct order in a rack on the conveyor. Click on ‘Store’ and ‘Auto’.
Now the instrument will carry out the analyses and display the new calculated carry-over
together with the carry-over used earlier. The Carry-over should be below 0.5%. Press
‘Accept’ to store the new value or ‘Reject’ to use the old one.

7.1.4 Bacterial Control Sample (BCS)

The preparation of the Bacterial Control Sample is described in chapter 10.
Measure the sample during start-up and if required at regular intervals during the day (see
chapter 4).
The Bacterial Control Sample should be measured as a BCS sample type in Auto or Manual.
The sample will then be measured 3 times and the program will calculate count and signal
mean.

40
Count and signal mean are displayed in the results list (if selected in the Measure Program)
and in the PHA picture.
Values for count and signal mean are compared by the instrument to lot-specific limits for
each of the individual measurements and for the average of the measurements.

If the Bacterial Control Sample is within specified limits, the bottle will be marked green and
an OK will appear on the result list in the system remarks field.
IF the BCS result is outside limits: Measure the Particle Control Sample as described
below and refer to the trouble shooting.
Inserting Lot Data
When a new lot of Bacterial Control Samples are to be used, the relevant Lot Data must be
entered. There is an Icon for this Lotedit program on your Windows screen picture. Activate
this program, and you will get this picture:

41
 You can either enter data under the Edit tab from the sheet enclosed with the samples, or look
under the Select tab to see if data for this Lot ID are already entered.
Press Save to enter the new data, otherwise the program will compare the results of the new
lot to “old” data.

7.1.5 Particle Control Sample (PCS)

The Particle Control Sample consists of dyed plastic particles suspended in a buffer. Their
size and fluorescence intensity is similar to the stained bacteria in milk samples, and since
the sample has a well-defined PHA picture and is insensitive to reagents and incubation, it
is of excellent use in trouble shooting. This sample is normally employed to determine where
the problem is to be found if the Bacterial Control Sample does not yield the desired results.
The particle control sample should be measured as a PCS sample type. The program will then
calculate count, signal mean, signal width and noise level.
Count and signal mean are displayed in the results list (if selected in the Measure Program)
and in the PHA picture. Noise level and signal width values are only displayed in the PHA
picture.

Signal mean, signal width and appearance of the PHA-graph are very important character-
istics of the Particle Control Sample.

Note
As these figures will differ slightly from instrument to instrument, we recom-
mend that a printout of the PHA-graph is made at the first service visit and kept
for trouble shooting purposes.

Procedure:
- Place the bottle containing Particle Control Sample Concentrate on a magnetic stirrer
for at least 20 minutes.
- After mixing, dispense 5 drops of concentrate into 20 ml of blank solution in a suitable
container, for example a sample bottle with lid. Replace the lid on the PCS Concentrate
bottle. If a larger volume is required, then dispense to the same ratio of PCS Concentrate
and blank solution, for example 10 drops in 40 ml or 1.4 ml concentrate in 100 ml of
blank solution.
- Place lid(s) on sample bottle(s) and turn upside down a few times.
- Measure on the BactoScan
Diluted Particle Control Sample should be used within one hour.

42
43
 7.2 Trouble Shooting
If the Bacterial Control Sample is outside limits:
Check that the signal mean, signal width and appearance of the PHA-graph for the Particle
Control Sample is OK:
Signal mean value for the Particle Control Sample should be within ± 10 % of the value
found at the latest service visit.
Signal width value for the Particle Control Sample should not have increased by more than
50 % of the value at the latest service visit.
There are now six alternative situations:
Alternative 1:
The first alternative shows perfect PHA pictures of Bacterial Control Sample and Particle Control Sample
BCS Control Sample: PCS Control Sample:
Signal Mean OK Signal Mean OK
Count OK Count OK

Situation: All OK
Action to be taken: None

44
Alternative 2:

BCS Control Sample: PCS Control Sample:

Signal Mean Low Signal MeanOK
Count Low (peak of count OK) Count OK

Situation: Poor Incubation Liquid

Action to be taken: Make new Incubation Liquid

Alternative 3:

BCS Control Sample: PCS Control Sample:

Signal Mean OK Signal MeanOK
Count Low (peak of count low) Count OK

Situation: BactoScan Control Sample incorrectly made

Action to be taken: Make new BactoScan Control Sample

45
Alternative 4:

BCS Control Sample: PCS Control Sample:

Signal Mean Low Signal Mean Low
Count Low (peak of count OK) Count OK

Situation: Reduced light (energy)

Action to be taken: If Signal Mean is within limits, increase setpoint.
If Signal Mean is out of limits, check Laser and Microscope adjustment
(call service engineer)

Alternative 5:

BCS Control Sample: PCS Control Sample:

Signal Mean OK Signal Mean OK
Count Low (peak of count low) Count Low (peak of count low)

Situation: Incorrect dilution of sample

Action to be taken: If the count is reduced by less than -10%, change the two tubes between
the homogenisers and the Incubator Valve Block.
If the count is reduced by more than -10%, check the Intake Unit for block-
age and leaks.
46
Alternative 6:

BCS Control Sample: PCS Control Sample:

Signal Mean High Signal Mean High
Count High (peak of count OK) Count OK

Situation: Increased light (energy)

Action to be taken: If Signal Mean is within limits, decrease Setpoint.
If Signal Mean is out of limits, check Laser and Microscope adjustment
(call Service Engineer)

This figure shows a Bacterial Control Sample that has been measured three times and is out
of limits (counts and mean are too high), followed by three PCS samples:

47
48
 8. Errors and Error Correction
8.1 Errors and Warnings
The tables in the following pages list errors and warnings that may occur during operation
of the BactoScan FC and the surrounding units (Conveyor/Pipette/PC etc.). The lists present
those messages that are most relevant during normal operation. For a complete list of all
possible errors and warnings, please see the description of the Service Application in the
IMT Reference Manual.
Error and warning messages are composed of a code, where the first part (NNN) identifies
the source, followed by at three digit number (XXX), which identifies the actual error/
warning. Then follows a clear text which in most cases are self-explanatory: The complete
syntax is NNNxxx<text>. The following list explains which source unit gives which ID in
the error codes:
Error code Source unit
PCCXXX PC-Controller. This unit is the „main-brain“ of the system, where
data are collected, where User Interface is controlled, and from
where data is transmitted to computers and printers.
HOSTXXX Host application
PCIOXXX PCIO. This function communicates with, and synchronises, the
pipette, conveyor, and analyser.
CONVEYORXXX Conveyor 4000
PTUXXX, Pipette 4000
BSCFCXXX BactoScan FC

8.1.1 BactoScan FC Errors and Warnings

Type: A message can be a warning (W) or an error (E). The syntax W/3/E seen in a
few cases indicates that if a warning is issued three times in a row in Auto mode,
it will be changed to an error.
Warning’s: Give information to the operator regarding action that must be taken as soon as
possible, typically containers that are about to be empty.
Error: The analyser will always stop any further sample intake and the analyser will
go towards Stand-by mode, but depending on the actual error, it may try to
complete the samples already taken in.
There are 6 levels of BactoScan FC warnings/errors, with different consequences:
1: Warning.
2: Warning, result critical.
3: Warning, result fatal.
4: Error, normal Stand-by.
5: Error, one result fatal, normal standby.
6: Error, all result’s fatal, quick standby.
49
 Critical (level 2):
Warnings in the list marked critical will normally suppress the result, but in Setup, this
can be changed to showing the result together with a mark that indicates a possibly
suspect result.

Fatal (levels 3, 5 and 6):

For Errors/Warnings that are marked fatal in the list, no result can be given, regardless
of the set-up.

Only the Warnings/Errors that can be handled by the operator are listed here, for a full list,
please refer to the IMT™ Reference Manual.
Reaction
on error’s Reset Corrective action
Text Type Description
and on I
warning’s
Wait until voltage is within
Mains
specified range and re-
Main voltage is
start analyser.
5 voltage E 6 No outside the
If error still exists, call
select specified
service engineer.
range

Incubation
If problem is permanent,
wheel
6 W 2 No call service engineer.
temperature
low
Incubation
If problem is permanent,
wheel
7 W 2 No call service engineer.
temperature
high
Sheath
If problem is permanent,
liquid
10 W 2 No call service engineer.
temperature
low
Sheath
If problem is permanent,
liquid
11 W 2 No call service engineer.
temperature
high
Sheath
Call Technical service
12 liquid NTC E 6 No
open
50
 Sheath liquid E 6 No C all Technical service
13
N TC short
Rinse W 2 No If problem is permanent, call
14 temperature service engineer.
low
Rinse W 2 No If problem is permanent, call
15 temperature service engineer.
high
Laser W 1 No If problem is permanent, call
18 temperature service engineer.
low
Laser W 1 No If problem is permanent, call
19 temperature service engineer.
high
Flow cell W 2 No If problem is permanent, call
22 temperature service engineer.
low
Flow cell W 2 No If problem is permanent, call
23 temperature service engineer.
high
Flow cell start W 1 No If problem is permanent, call
30 temperature service engineer.
too low
Rinse E 6 No C ontainer has been empty If problem is permanent, call
pressure low for some time. Pump service engineer.
31
faulty. Leak in rinse
system.
Rinse W 1 No
32
pressure high
Sheath liquid E 6 No C ontainer has been empty If problem is permanent, call
pressure low for some time. Pump service engineer.
33
faulty. Leak in sheath liquid
system.
Sheath liquid W 2 No Air in the filter. De-air the filter.
34
pressure high
Waste E 6 No Faulty pump. Leak in If problem is permanent, call
35 chamber vacuum system. service engineer.
vacuum
Incubation E 4 Yes Pressure across filter is C hange to Standby, wait until
reagent filter too high when transferring analyser is in STAN DBY,
36 pressure too milk and incubation mount new filter and select
high reagent. AUTO with reagents start-up.

Incubation E 5 Yes Pressure across filter is C hange to Standby, wait until

reagent filter too high when not under analyser is in STAN DBY,
37 rest pressure load. mount new filter and select
too high AUTO with reagents start-up.

Incubation E 4 Await STAN DBY, re-fill

reagent container and select AUTO .
38
container
empty
Rinse E 4 Await STAN DBY, re-fill
39 container container and select AUTO .
empty
Sheath liquid E 4 Await STAN DBY, re-fill
40 container container and select AUTO .
empty
Waste E 4 Await STAN DBY, select
container full STO P without rinse, empty the
41
container, select STAN DBY,
and select AUTO .
51
 42 Milk intake too 3, 5 Yes Milk intake time exceeds Check pipette and intake unit
slow W/3/E 2.5 seconds. for blockage or restrictions. If
problem is permanent, call
service engineer.

43 Milk intake too 2, 5 Yes Milk intake time < 0.5s If problem is permanent, call
fast W/3/E service engineer.

44 Ball dispenser 1 W 2 Yes Ball movement time If problem is permanent, call

exceeds 2.5 seconds service engineer.

45 Ball dispenser 2 W 2 Yes Ball movement time If problem is permanent, call

exceeds 2.5 seconds service engineer.

46 Incubation well 2, 6 Yes Timeout for filling Rinse Check throttle for Rinse liquid
filling W/3/E liquid up to sensor IncLs1. in DVU, replace if required.
(INC_LS1) exceeds 4.5 seconds
47 Incubation well 1, 4 Yes Timeout for filling Rinse Check throttle at exit of
filling (INC_ W/3/E liquid up to sensor IncLs2. INC_V9, replace if required.
LS2) exceeds 4.0 seconds
48 Sample transfer 3, 6 Yes Air in tube to Flow Cell Check sample volume in well
bubble sensor. W/3/E after sample transfer. after homogeniser 1/2. Call
(INC_OS8), 1 service engineer.

49 Sample transfer 2, 6 Yes Liquid in tube after Replace filter.

bubble sensor. W/3/E emptying sample waste
(INC_OS8), 2 and/or flushing of well.
Filter blocked.
50 Sheath liquid W 2 Sheath liquid through Flow Check set point for sheath
flow rate Cell flows too fast/too liquid pressure.
slow.
52 Incubation E 5 Yes Filter missing or not Mount new filter. Check that
reagent filter mounted correctly. filter is mounted correctly and
missing. not tilted.

52
8.1.2 Errors and Warnings from Other Units
These messages differ slightly from BactoScan FC messages as far as grouping and action
to be taken is concerned.

Warning: Normal warnings. These warnings are meant as information only and do not
require immediate action on the part of the operator, but should be remedied as
soon as possible.
Critical: Critical Warnings must be handled as described in the list. Critical Warnings
may influence results and will therefore always cause the result to be marked
as defined in the Setup Application in System 4000 Software, so that the results
can be treated in accordance with laboratory precedence, e.g. re-tested.
Error: When an error message occurs, the instrument goes to stand by. The error must
then be corrected as described in the list
I: Error messages are normally removed once the corrective action has been
taken. However, if the ‘I’ column is marked, the error message does not
disappear automatically, even if the problem is solved, until the operator has
checked the error in the information window by pressing the ‘I’ key.

Unit Error Text Ty- Cr- Re- Description Corrective action

pe iti- set
cal on
I

Host Host output buffer E No No The host has not Check host and connections
001 full collected data, and Contact local service engineer
the buffer is now
full ( 45 samples )

Host Messages in host W No No Check host and connections

002 queue Contact local service engineer

Host Host connection is W No Yes Check host and connections

003 switched off Check active units
Contact local service engineer

Host Network host W No Yes Check host and connections

004 connection is not Contact local service engineer
OK

53
 Unit Error Text Type Criti- Reset Description Corrective action
cal on I

Conveyor000 Cover off error E/W The covers are reported removed from Contact local service engineer
the conveyor.

Conveyor001 Fibre sensor W The conveyor calibration is defect Try to restart system
calibration error Make a new conveyor calibration

Conveyor002 Air pressure low E/W Air pressure detected is below 1.6 bar Check air supply

Conveyor003 PCB version error E Yes Conveyor reports that the PCB version Contact local service engineer
is invalid for the soft ware

Conveyor004 Memory error E Yes A fault was detected in the memory Try to restart system
Contact local service engineer
Conveyor005 Rewind is not W Yes It is not possible for the conveyor to Try to restart system
possible. Error in make a rewind Contact local service engineer
system.

Conveyor006 Id communication E/W The bar code reader does not Check cables to the reader
error communicate with the conveyor PCB Try to restart system
Contact local service engineer

Conveyor007 No valid sensor E The Mechanical setup selected as Edit the mechanical setup.
calibration present. default does not include a valid sensor Make a valid conveyor calibration
calibration

Conveyor008 Temperature low W Tunnel temperature is to low Contact local service engineer
Conveyor009 Temperature high W Tunnel temperature is to high Switch off the conveyor heat
Contact local service engineer

Conveyor010 Fibre calibration E/W Yes The conveyor calibration is defect Make a new conveyor calibration
unstable

Conveyor011 Valve driver 1 error E Yes The driver for pipette stirrer stop pawls Try to restart system
is defect Contact local service engineer

Conveyor012 Valve driver 2 error E Yes The driver for rack stop pawl is defect Try to restart system
Contact local service engineer

Conveyor013 Valve driver 3 error E Yes The driver for bottle rotate is defect Try to restart system
Contact local service engineer

Conveyor014 Valve driver 4 error E Yes The driver for main air is defect Try to restart system
Contact local service engineer

Conveyor015 +12 volt error E Yes The +12 volt is out of range Contact local service engineer
Conveyor016 -12 volt error E Yes The -12 volt is out of range Contact local service engineer

Conveyor017 +24 volt error E Yes The +24 volt is out of range Contact local service engineer

Conveyor018 Rack in front of E Yes A rack was standing on the conveyor

sensors. Please in front of the sensors as auto was
Rewind Rack commanded
Conveyor019 24 volt ac error E Yes The 24 volt ac is out of range Contact local service engineer

Conveyor020 Thermistor is shorted. E Yes The conveyor temperature thermistor is Contact local service engineer
defect

Conveyor021 Thermistor is E Yes The conveyor temperature thermistor is Contact local service engineer
disconnected. defect

Conveyor022 Basis rack movement E Yes The stirrer/pipette sensors report Conveyor is full of racks
movement problems, the rack can not Check racks
move further to the left Check the adjust springs

Conveyor023 Decap rack movement

54
Unit Error Text Type Criti- Reset Description Corrective action
cal on I

Conveyor024 Sample output buffer E Yes Sample output buffer does not move Check if light is shining on the end
rack movement rack as commanded of conveyor sensor.
Contact local service engineer

Conveyor025 Sample output buffer Sample output buffer can not move Remove some racks from the tray
full rack as commanded because it is full

Conveyor026 Decap error 1

Conveyor027 Decap error 2

Conveyor028 Decap error 3

Conveyor029 (not used)

Conveyor030 Valve driver 1 error E Yes The driver for pipette stirrer stop pawls Try to restart system
is defect Contact local service engineer

Conveyor031 Valve driver 2 error E Yes The driver for rack stop pawl is defect Try to restart system
Contact local service engineer

Conveyor032 Valve driver 3 error E Yes The driver for bottle rotate is defect Try to restart system
Contact local service engineer

Conveyor033 Valve driver 4 error E Yes The driver for main air is defect Try to restart system
Contact local service engineer
Conveyor034 Valve driver 5 error E Yes

Conveyor035 Valve driver 6 error E Yes

Conveyor036 Valve driver 7 error E Yes

Conveyor037 Valve driver 8 error E Yes

Conveyor038 Valve driver 9 error E Yes

Conveyor039 Valve driver 10 error E Yes

Conveyor040 Valve driver 11 error E Yes

Conveyor041 Valve driver 12 error E Yes

Conveyor042 Valve driver 13 error E Yes The driver for the sample output buffer Try to restart system
is defect Contact local service engineer

Conveyor043 Valve driver 14 error E Yes The driver for the sample output buffer Try to restart system
is defect Contact local service engineer

Conveyor044 Valve driver 15 error E Yes

Conveyor045 Valve driver 16 error E Yes

Conveyor046 No bottle in first E Yes

position of rack

Conveyor047 Missing rack E Yes

descriptor. Please
rewind rack.

55
Unit Error Text Type Criti- Reset Description Corrective action
cal on I

PTU000 No error E Yes

PTU001 Unknown error - E Yes

HALT

PTU002 Power-up, Please wait E Yes

PTU003 Error in ROM-test - E Yes Start up test failed Try to restart system
HALT Contact local service engineer

PTU004 Error in RAM-test - E Yes Start up test failed Try to restart system
HALT Contact local service engineer

PTU005 Invalid HW/SW E Yes Start up test failed Try to restart system
version - HALT Contact local service engineer

PTU006 Need init E Yes Try to restart system

Contact local service engineer

PTU007 Need setup E Yes The mechanical setup used does not Select a other mechanical setup
include a valid pipette setup Make a new mechanical setup

PTU008 Invalid setup-value E Yes The pipette setup used is defect Try to restart system
Make a new setup
Contact local service engineer
PTU009 Communication error E Yes The pipette does not communicate with Try to restart system
the PCC Contact local service engineer

PTU010 Cover removed E/W The cover sensor reports that the Lower the cover and retry command
pipette cover is in its up position

PTU011 5011 not used ! E Yes

PTU012 Command impossible W Yes Invalid command detected Try to restart system
at current state Contact local service engineer

PTU013 Unknown error W Yes

PTU014 Invalid parameter E Yes The pipette setup used is defect Try to restart system
Make a new setup
Contact local service engineer
PTU015 Queue full E Yes Try to restart system
Contact local service engineer

PTU016 Queue fault E Yes Try to restart system

Contact local service engineer

PTU017 Movement error E Yes The pipette can not move according to Check if there is a lid on a sample
setup under the pipette/stirrer
Try to restart system
Contact local service engineer

PTU018 Volume sensor error The liquid sensor ( FM pipette in CF Check General Setup for pipette and
setup ) reports an error mechanical setup.
Try to restart system
Contact local service engineer

56
Unit Error Text Type Criti- Reset on Description Corrective action
cal I

PCC Bottle w. Alarm-Id E/W No Yes Bottle according to Measure setup Action according to agreements
000 detected alarm list was found

PCC Sample result is out E No Yes Sample has exceeded limit specified Action according to agreements
001 of limit in Measure setup

PCC Pilot result is out of E No Yes Pilot has exceeded limit specified in Action according to agreements
002 limit Measure setup

PCC Zero result is out of W No Yes Action according to agreements

003 limit

PCC Batch number does W No Yes Check batch list to find correct number
004 not exist in batchlist

PCC Batchlist is empty. W No Yes

005 Please insert new
batch data

PCC Batch stream number W No Yes Try to restart system

006 is invalid Contact local service engineer

PCC Dongle error W No Yes Try to restart system

007 Contact local service engineer

PCC PCIO is not E No Yes Try to restart system

008 responding Contact local service engineer

PCC Pause batch W No Yes System went to standby due to next Action according to agreements
009 batch specified as Pause batch

PCC Incomplete batch in W No Yes A batch in the list is invalid Check list ( defect batch can be
010 batchlist. marked with red )

PCC Error detected during W No Yes Try to restart system

011 Calibration. Contact local service engineer

PCC Pilot mean result is E No Yes Pilot has exceeded limit specified
012 out of limit. Measure setup

PCC Blind Mean is not W No Yes One or more samples in the test
013 calculated. was defect/missing

PCC Repeatability results W No Yes One or more samples in the test

014 is not calculated. was defect/missing

PCC Pilot Deviation is not W No Yes

015 calculated.

PCC Pilot Mean is not W No Yes

016 calculated.

PCC New Carry Over W No Yes

017 Factor is not
calculated.

PCC New Zero Setting is W No Yes

018 not calculated.

PCC Result File is too big. E/W No Yes The work session is to big with the Please make new work session
019 - Please change risk of loss of data before continuing
Work Session.

PCC Pilot Definition Mean W No Yes

020 is not calculated

57
Unit Error Text Type Criti- Reset Description Corrective action
cal on I

PCC021 Calibration not W No Yes

complete

PCC022 Please logon before E No Yes

Automode is selected.

PCC023 Pilot group size error. E No Yes

PCC024 Illegal pilot sample in E No Yes

batch.

PCC025 Incorrectly placed pilot E No Yes

sample.

PCC026 Missing pilot sample at E No Yes

end of batch.

PCC027 Batch already exists.- E No Yes

Substitute with a new
batch bottle.

PCC028 Please enter a new W No Yes

batch in batchlist.

PCC029 Id unit is not selected W No Yes

in autobatch mode.

PCC030 Prefix is not selected W No Yes

in autobatch mode.

PCC031 Autobatch: Id label W No Yes

size > batch name
size. Please change
setup.

PCC032 Critical error is E No Yes Try to restart system

detected Contact local service engineer

PCC033 Unable to set W No Yes

discriminator

PCC034 Id device is not active W No Yes The Measure Setup used has ID Check and correct Active units and
or selected included in the component setup, but the conveyor General Setup
system is not ready to read ID labels.

PCC035 Log-data from unit is W No Yes Try to restart system

missing Contact local service engineer

58
Unit Error Text Type Criti- Reset Description Corrective action
cal on I

PCC001 Dongle not valid E No No Try to restart system

Contact local service engineer

PCC002 Free disk space W No No Disk space is below 5 MB Remove old work sessions from
extremely low harddisk

PCC003 Free disk space low W No No Disk space is below 10 MB Remove old work sessions from
harddisk

PCC101 Wear-Log: Sample- W No Yes A specified counter indicating that a Action according to agreements
number exceeded unit needs service Contact local service engineer

PCC102 Wear-Log: Time-limit W No Yes A specified timer indicating that a unit Action according to agreements
exceeded needs service Contact local service engineer

59
 Unit Error Text Type Criti- Reset Description Corrective action
cal on I

PCIO000 Arcnet error E No Yes Switch off all instruments, wait 10

seconds and switch on again.
Try to restart system.
Contact local service engineer

PCIO001 Sync missing from E No Yes Switch off MSC, wait 10 seconds and
MSC switch on again.
Try to restart system
Contact local service engineer
PCIO002 Sync incorrect E No Yes Switch off all instruments, wait 10
seconds and switch on again.
Try to restart system
Contact local service engineer
PCIO003 Rack position E No Yes The rack counter did not match the Check racksCheck rack senso
mismatch. rack total specified in mechanical setup rCheck rack calibration
Please Rewind rack Try to restart system
Contact local service engineer

PCIO004 Sync missing from E No Yes Switch off all instruments, wait 10
PTU seconds and switch on again.
Try to restart system
Contact local service engineer

PCIO005 Sync missing from E No Yes Switch off conveyor, wait 10 seconds
Conveyor and switch on again. Try to restart
systemContact local service engineer

PCIO006 Sync missing from FM E No Yes Switch off FM, wait 10 seconds and
switch on again.
Try to restart system
Contact local service engineer
PCIO007 MSC no response E No Yes Switch off MSC, wait 10 seconds and
switch on again.
Try to restart system
Contact local service engineer

PCIO008 FM no response E No Yes Switch off FM, wait 10 seconds and

switch on again.
Try to restart system
Contact local service engineer
PCIO009 PTU no response E No Yes Switch off all instruments, wait 10
seconds and switch on again
Try to restart system
Contact local service engineer

PCIO010 Conveyor no response E No Yes Switch off conveyor, wait 10 seconds

and switch on again.
Try to restart system
Contact local service engineer

PCIO011 Mode time-out (MSC) E No Yes Switch off MSC, wait 10 seconds and
switch on again.
Try to restart system
Contact local service engineer

PCIO012 Mode time-out (FM) E No Yes Switch off FM, wait 10 seconds and
switch on again.
Try to restart system
Contact local service engineer

PCIO013 Mode time-out E No Yes Switch off conveyor, wait 10 seconds

(Conveyor) and switch on again.
Try to restart system
Contact local service engineer
60
Unit Error Text Type Criti- Reset Description Corrective action
cal on I

PCIO014 Mode time-out (PTU) E No Yes Switch off all instruments, wait 10
seconds and switch on again.
Try to restart system
Contact local service engineer

PCIO015 RD time-out E No Yes Try to restart system

Contact local service engineer
PCIO016 Batch time-out E No Yes Try to restart system
Contact local service engineer
PCIO017 Communication E No Yes Switch off MSC, wait 10 seconds and
(MSC) switch on again.
Try to restart system
Contact local service engineer
PCIO018 Communication (FM) E No Yes Switch off FM, wait 10 seconds and
switch on again.
Try to restart system
Contact local service engineer

PCIO019 Communication E No Yes Switch off conveyor, wait 10 seconds

(Conveyor) and switch on again.
Try to restart system
Contact local service engineer

PCIO020 Communication (PTU) E No Yes Switch off all instruments, wait 10

seconds and switch on again.
Try to restart system
Contact local service engineer

PCIO021 Illegal Mode-request W No Yes Try to restart system

from PCC Contact local service engineer

PCIO022 Missing Batch Info W No Yes The batch needs more information Insert the missing data in the batch
PCIO023 Host Transmitting W No Yes Contact local service engineer
while off

PCIO024 Empty bottle W No Yes Too little liquid in sample cup

PCIO025 PCC-PCIO E No Yes Try to restart system

communication Contact local service engineer

PCIO026 Serial board not W No Yes Contact local service engineer

installed

PCIO027 Unknown Serial W No Yes Try to restart system

board. Contact local service engineer

PCIO028 Unknown PCIO PCB. W No Yes Try to restart system

Contact local service engineer

PCIO029 Empty Pilot bottle. E No Yes Too little liquid in pilot sample cup
PCIO030 Host message lost. E No Yes

61
 Unit Error Text Type Criti- Reset Description Corrective action
cal on I

PCIO031 PCC communication E No Yes Try to restart system

count mismatch. Contact local service engineer
PCIO032 Stir answer missing. E No Yes Try to restart system
Contact local service engineer
PCIO033 Autobatch id-label W No Yes A sample is equipped with a Batch Action according to agreement
(prefix 63) is illegal in label, but the general batch setup
this mode requires manual input
PCIO034 Pilot sample with E No Yes A pilot sample is equipped with a
batch id-label Batch label.
(prefix 63)

PCIO035 Pilot sample with W No Yes A pilot sample is equipped with a

normal id-label sample label.
(prefix 69)
PCIO036 Normal sample with W No Yes A pilot sample has no metal tape.
pilot id-label
(prefix 79)
PCIO037 Communication E No Yes Switch off FM, wait 10 seconds and
(FM5000) switch on againTry to restart
systemContact local service engineer

PCIO038 Mode time-out (BSC) E No Yes Try to restart systemContact local

service engineer

PCIO039 Sync missing from E No Yes Try to restart systemContact local

BSC service engineer
PCIO040 Communication (BSC) E No Yes Try to restart systemContact local
service engineer

PCIO041 System information E No No Try to restart systemContact local

mismatch service engineer

62
8.2 Correcting Bar Code Read Errors Using Conveyor
4000
This section contains procedures for correcting errors in automatic identification (read
errors). The contents are common for all systems with a Conveyor 4000. However, the
examples of screen pictures are made with a MilkoScan 4000 only.
When bar code labels are used for automatic sample identification, a read error will occur
when the bar code reader is unable to retrieve the identification data. The reasons for read
errors can be:
- A dirty or damaged label
- A label wrongly positioned on the bottle
- A label not facing the bar code reader (when bottle rotate is not used)
- A label not rotating properly (when bottle rotate is used)
To correct the read error, there are three ways to enter sample identification:
1. Correcting errors before a rack is removed using a dialogue box that pops up
automatically when the rack is to be removed from the conveyor.
2. Correcting errors immediately as they occur using a dialogue box that pops up
immediately when the read error occurs.
3. Correcting errors when the sample rack has been removed from the conveyor
using a dialogue box that can be called on any sample line in the current work session.
This function can correct or edit any sample identification field, even sample identifi-
cations that have been identified automatically and correctly.
Which procedure to use depends on the system set-up. In the following, each of the
procedures is described separately, followed by additional information.
Note:
If you are in doubt which description applies to your present situation, try to
look at the screen pictures shown in each section. The last section, section 8.2.8,
Setup Parameters, may also help you, as it describes the Setup conditions.

Contents of this section:

- Correcting errors before a rack is removed.
- Correcting errors immediately as they occur.
- Correcting errors when the sample rack has been removed from the conveyor.
- Sample ID only on the first position in each rack.
- Label prefix
- Pilot samples
- Number of characters
- Setup parameters

63
 8.2.1 Correcting Read Errors on a Rack Ready for Removal
Every time a rack is finished, it is checked whether one or more of the samples have caused
a read error. If so, the dialogue box (Fig 8-1) pops up automatically, showing identification
data of all sample positions in the rack.

Procedure
- Enter sample identification in all the empty fields and exit the box with OK. Do not use
the Enter key to step from field to field, if there are more than one position to be
corrected, use the TAB-key or the trackball/cursor.
- If a prefix is used on the bar code labels, the complete label data, including prefix, must
be entered. When data have been entered, and you have exited with OK, the identifi-
cations are shown as seen in fig 8-2.
Note that samples with manually entered, or edited identifications, are automatically marked
using the Remark field.

64
Comments
This mode of operation is active when “Correct when removing rack” is chosen in Setup.
If “Read errors MUST be corrected” is not selected in the System Setup, you can exit the
dialogue box and continue analysis work without correcting any or all errors. In this case the
ID data fields are left empty. You can leave them so or use the third possibility later on, as
described in section 8.2.3, Correcting Read Errors anywhere in the Work Session.
If “Read errors MUST be corrected” is selected in Setup, you cannot exit the dialogue box
and continue analysis work until all read errors have been corrected.

8.2.2 Correcting Read Errors Immediately

When this option is selected, the system stops at every sample with read error. The sample
will be in the position before the pipette (to the right of the pipette), and the dialogue box
shown in fig. 8-3 is displayed.

Procedure
Enter a sample identification for the sample in question and exit by clicking OK. The analysis
process is then resumed automatically.
Comments
Fig. 8-7 shows the completed batch, the manually entered data is marked in the ‘Remark’
field.

65
 8.2.3 Correcting Read Errors anywhere in the Work Session
Procedure
- To select the sample to edit, place the tracking bar on the sample line in question, see
fig. 8-8. You may do this before or after the rack is removed from the conveyor.

- Call the dialogue box shown in fig. 8-9 by clicking at the sample line in question, or use
the Edit function on the menu line.
- Enter the correct sample identification, like “691234567890” in the example.
- Exit the dialogue box by selecting “Store”

66
Comments
When “No Correction” is selected in the System Setup, the system does not require any
action on read errors. The ID field is simply left empty. With this set-up, the above procedure
- is the only way to correct read errors when “No Correction” is selected
- can be used to correct identification data on all samples, regardless of set-up, and also
on those where no read error occurred.
The sample line is marked “Man. Corrected” in the remark field, see fig. 8-10.

67
 8.2.4 Identification on First Rack Position Only
The system can be set to require ID on the first rack position only. There are two possible
read error corrections, depending on set-up:
1) If “Correct when removing Rack” is chosen (see fig. 8-13 a and b), you get the dialogue
box shown in fig. 8-11.

2) If “Instant correction” is chosen (fig. 8-13 c), you get the picture in fig. 8-12.

8.2.5 Using Label Prefix

The bar code label can include a two-digit prefix, which identifies the type of sample.
A prefix is required, if Automatic Batch Identification is used, but can also be used without
Automatic Batch Identification.
If a prefix is used, then the set-up must be set to this mode of operation, see fig 8-13 f.
The prefix value is the two first digits on the bar code label, preceding the actual sample
identification data.
The following prefix values may be seen:
69XXXXX = Normal sample
79XXXXX = Pilot Sample
63XXXXX = Batch identification (only used if Automatic Batch Identification is used)

68
Procedure for Correcting Read Errors
You must always key in the complete bar code data, including prefix.

Examples: See fig 8-9 and 8-12, where prefix “69” is included.
Figure 13-a Figure 13-b

Figure 13-c Figure 13-d

69
 Figure 13-e Figure 13-f

8.2.6 Pilot Samples

Pilot samples are identified automatically by means of one or two metal collar(s) on the
sample.
A read error on a pilot sample is handled as other samples; you must enter data corresponding
to the label data.
Note:
If a prefix is used, it is very important to key in the prefix value.

8.2.7 Number of characters

Do not enter more digits than the bar code labels contain.

8.2.8 Setup Options for Mechanical Setup

The procedures for read error correction depend on the System set-up. You can see which
set-up is selected by entering Setup/Mechanical setup/ID labels (this requires a password).
You then get a screen picture as seen in fig. 8-13.
The figures above show the options in reference to the description of the different error
correction procedures.

70
 9. The Presentation Application
In this chapter you find a schematic description of how to operate the instrument. This
chapter is built up so that the menus used during daily operations are described systemati-
cally, rather than how they appear in the daily routines. This means that some functions are
described both in Chapter 5, Analysing Samples, and in this chapter, but for some of the more
detailed descriptions, there will only be a reference to Chapter 5.

9.1 Mode Symbols

These modes are controlled either by use of the Function Keys F1-F3, or by pointing and
clicking with the trackball at the symbols placed in the upper left corner of the Presentation
Application window. The symbols can only be selected when they are black (not when they
are grey), see fig. 9-1.
The modes are as follows:
- Auto mode (Key F1) is the mode in which samples will be automatically analysed, if
Batch Identification data have been keyed in, and samples have been placed in a rack
on the conveyor.
Auto mode is only available when the instrument is already in Standby mode.
- Standby mode (Key F2) is the mode in which short pauses may be made between
feeding new samples to the instrument.
- Stop mode (Key F3) is used whenever the instrument should not be used for a longer
period. When Stop mode is selected, the instrument will go through a rinsing program
before reaching Stop mode. When the instrument has stopped, it will perform no other
flow system operations until commanded to do so. A ‘Quick stop’ should not be used
during normal routine, as no rinsing of the system will take place before Stop mode is
reached. Quick stop requires the tick-off to be removed from the “Rinse” box in the
window that appears when you select Stop. Otherwise a lengthy Rinse procedure that
normally takes place at the end of the day will be activated.

71
 The Auto-key (same as F1) used to start automatic analysis of samples placed
on the conveyor in a rack. Automatic analysis can only be initiated when the
instrument is in Standby mode.

The Standby-key (same as F2) is used to make a pause in the analysis sequence.

The Stop-key (same as F3) is used to stop the instrument for a longer period.
Standby must be pressed before the instrument may enter Auto mode again.

The Manual-key (same as F4) is used whenever samples that are not placed in
a rack must be tested.
Manual analysis can only be initiated when the instrument is in Standby mode.

The Rack-Reverse-key (same as F5) is used whenever samples standing on the

left side of the conveyor must be transported to the right side of the conveyor.
This can only be done when in Standby mode (available only with Conveyor
4000).
An alternative way to select ‘Auto’, ‘Standby’ and ‘Stop’ is to select ‘Commands’, and then
select the desired function.

9.2 Manual Mode

Manual Mode (F4) is only available when the instrument is in Standby mode.
In Manual mode, samples need not be placed in racks, but may simply be placed directly
under the pipette. When the sample is placed in a rack directly under the pipette, it will be
analysed, but no rack advance movement will be made for the following samples.
Results from analysis in Manual Mode are not transmitted to the Host Computer (if
applicable), or exported to a floppy disk when using the File/Export-function in the
Presentation Application.
Press F4 or click the ‘Manual’ key (to the left in presentation mode), to see the window in
fig. 9-2. The following actions may then be selected:

Measure
Samples that are not placed in racks may be analysed using this function.
Settings
These are described in the following section.
72
9.2.1 Settings
Activate the ‘Settings’ key in fig. 9-2 to see the window in fig. 9-3. In this window, the
following options are displayed:

Program
The Measure Program to be used for analysis of the samples is selected here. Once selected,
the same Measure Program is used for the following samples, until this setting is changed
again.
Sample Type
The ‘Sample Type’ identifies to the System 4000 how the sample is to be analysed. Select
‘Normal’ for all typical milk samples.
To select other Sample Types, activate the key by the ‘Sample Type’ input box. The types
of Batches to be analysed are then displayed.
Point at the desired type of sample to select it, and finally activate ‘Store’.
Total
The number of samples to be measured is entered here.
Same bottle
If several samplings are to be made from the same bottle (i.e. ‘Total’ is higher than 1), then
System 4000 will do so without further operator action, provided the ‘Same bottle’ box has
been clicked [X].
If several samplings are to be made (i.e. the ‘Total’ is higher than 1), but from different
bottles, then the ‘Same bottle’ box should be clicked off [ ]. System 4000 will then prompt
for activation of the ‘Measure’ key for each new sample to be measured.
73
 9.3 Result and Batch Lists
When running samples, two lists are displayed:
- One is ‘Batches’, where the name of the batch (i.e. route number of the tanker) and the
number of samples (i.e. number of farms on the route) are displayed.
- The other is ‘Results’, where all results of analysed samples are displayed.
To shift between these two lists, click with the trackball in the Menu Bar (Batches or
Results), or simply press function key F11.
To be able to type in batch information, press F11 to be in ‘Batches’.

9.4 Entering Batch Name and Number of Samples

Before samples can be analysed, they must be identified; e.g. the name of the dairy and the
number of samples (farmers). This is done as described in section 5.3.2, Identifying Batches
and Samples. Please refer to this section for further information.

9.5 The Information Window

Under the Results/Batches display, an area is found where information concerning the
running batch and possibly occurred errors and warnings can be seen.

74
9.5.1 Batch Information Fields
The three Information Fields in the lower part of the Batch display in fig. 9-5, in this Program,
Batch Type and Time (of analysis), show information about the batch currently analysed.
All kinds of data concerning a batch can be seen by repeatedly clicking at the information
field itself with the trackball. This will present the data-type one by one, including Batch
(name), Total (number of samples in batch), measuring program, Batch type, batch date,
extension 1, 2, and 3, laboratory date, laboratory 1 and 2, first ID, sample number in batch,
position number, time of analysis, sample ID, remark and operator’s remark.

9.5.2 The Information Window (Errors and Warnings)

A large key as illustrated here is found in the lower right hand part of the Results-display in
fig. 9-5. Activate this key to get the window seen in fig. 9-7.

When an error or warning occurs, this key should be activated to see the list of errors and/
or warnings. This will also switch off the flashing orange lamp, if this has been activated.
The complete list of errors/warnings is presented in section 8, Errors and Error Correction.
Here you may find and correct the cause of the error or warning.
The ‘System Reset’ key will have the effect of re-starting the System 4000.
Note:
Pressing the ‘System Reset’ key may result in the loss of data from a single or
a few samples, and should only be used if the error condition cannot be cor-
rected in any other way.

Pressing the ‘View Log’ key displays all system messages.

75
 9.5.3 Sample Rack Graphics
When running samples, this is illustrated on the monitor as bottles passing from right to left.
As they are being analysed, they change colour when they pass the pipette. The new colour
depends on the status of the analyses, see fig. 9-8.
The colour marking their status is also displayed to the left of the analysis results as dots.
Before analysis the bottles are white.
- If analysis was OK the bottle becomes green
- If some error/warning occurs, or a sample limit is exceeded, the bottle may turn red
depending on the Setup. When limits are exceeded, a red bottle only occurs if this has
been selected in “Setup”, “Limits” (see the IMT Reference Manual).
- A yellow bottle is seen when a sample is to be re-tested, either automatically or
manually.
- A half-green bottle marks insufficient sample volume.

- A transparent bottle marks an empty bottle.

If no Bar Code Reading is used, all labels on the bottles are white.
When Bar Code Reading option is used:
- White labels turn green when identification was OK.
- If identification was not possible, the white label turns red.
In the far left side of the screen picture in Results or Batch mode, just above the information
picture, the number of sample ID errors are marked. To delete this number, click when
pointing at the area. The number of errors is displayed to give an overview, in case the
operator is not beside the instrument all the time.

76
9.6 The Menu Bar
9.6.1 The ‘Window’ Menu
When selecting Window on the Menu Bar in top of the display, a list of functions are
displayed, see fig. 9-9.

Upper Section
The functions are divided in three parts where the functions in the upper square are general
Windows functions that can be used for arranging the information from different parts of the
program so that it can be displayed at the same time.
For further explanation see your Windows Manual.
Middle Section (Inactive)
Selecting ‘Inactive’ and ‘File manager’ is a convenient way to reach the Windows File
Manager (Fig. 9-10).

To get back in presentation mode, click on the square in the left corner and select ‘Close’.
77
 Lower Section
In the last section, System 4000 applications may be selected.
To use any of these applications, a password has to be defined. This is done by selecting
‘Commands’ and ‘Logon’, entering your password, and clicking ‘Logon’.
The PHA Application
When selecting ‘PHA’, a large-scale PHA diagram is displayed instead of the small-scale
diagram, which can be selected in ‘View’.
The large-scale PHA picture may also be selected by pointing and clicking in the grey area
in the small PHA diagram.
To go back to presentation mode, select ‘Window’ and ‘Presentation’ (or point and click in

the grey area under ‘Values’).

Settings
Having selected the large-scale PHA diagram, ‘Settings’ can be selected in the upper menu
bar. Doing this displays the following functions:
- Manual control
Activating this field causes the PHA-display to switch between two display-modes:
‘Follow Track Bar’ and ‘Manual Control’.
‘Follow Track Bar’ mode means that the PHA-display follows samples as they are
analysed. ‘Manual Control’ gives you the possibility to view previous samples. When
‘Manual Control’ is selected, arrow symbols will be presented on the display. Activate
the left arrow to go back in the result list, the right arrow to move forward.
- Best-fit curve and Grid
These are described in the IMT Reference Manual.
- String Quality
Activating this field opens a second window with DC values:
Samplings and Bad samplings indicate how many samplings have been made, and how
many that are discarded as bad.
- Show first 64 channels
Activating this field will remove the first 64 channels, which contain the noise counts.

78
Presentation
When selecting ‘Presentation’ under Window, you go back to the main picture, displaying
Results or Batches. Most of the daily operations are carried out in Presentation mode.

9.6.2 The ‘View’ Menu

Results
The list of sample results is displayed.
Batches
The list of batches is displayed. (The same function, i.e. changing between viewing results/
batches may be obtained by clicking with the trackball directly at the grey field underneath
the Menu Bar or simply by pressing key F11).
PHA
Switches a small PHA-display on/off. ‘PHA’ is an abbreviation of Pulse Height Analysis.
When the display appears it will look as seen in fig. 9-12
The small PHA-display may be moved to a convenient place by use of the trackball: Point
with the trackball at the area where ‘PHA’ is written, then press the left key on the trackball
and keep it depressed while moving the picture to a suitable place.
During analysis of samples, you may want to look at a full-size PHA-display. To do so,
simply click at the PHA-display with the trackball.
To see the PHA curve of a sample analysed earlier, simply select the sample in the ‘Result’
window, and then select ‘PHA’ under ‘Windows’.
Samples in Progress
Activating this feature opens an extra window where you can see data on which samples have
been taken in by the analyser, but are not yet completed and therefore not present on the result
list.
Rack Bottles
A graphical representation of the sample rack may be shown at the bottom of the screen. It
may be switched on/off by activating this selection with the trackball.
79
 Label error counter (Conveyor 4000 only)
Here the label error counter can be switched on and off.
Alarm label counter (Conveyor 4000 only)
Certain samples may be marked as alarm samples (e.g. a certain route number). This function
switches this alarm counter on and off.
Font size
The character size used on the screen may be selected here. The ‘Large’ size may well be
convenient. You may well experiment with this: 13 is small, 16 normal and 20 large.
Emphasise
Various information may be selected to appear more visible than other information such that
the sample-types may be found faster when scrolling through the display. The ‘Everything’
setting is the normal setting.
Welcome text
Activate this field with the trackball.
Whenever a new work session is started, a text will appear on the screen according to what
is written in this window. Suggested uses include: Laboratory name, operator name, etc. The
text typed in and stored here will only be displayed when the display is otherwise cleared,
i.e. when a new work session is started.

9.6.3 The ‘Commands’ Menu

Auto, Standby, Quick Standby, Stop
Identical to the Function Keys listed to the right.
Rack reverse, manual (Conveyor 4000 only)
The function of this menu item is identical to the Rack Reverse Key to the left.
Manual
The function of this menu item is identical to the Manual Key to the left.
80
Status
Here errors and warnings are listed. The same information is displayed when clicking on the
information window in the bottom left side in Presentation mode.
Active units
Here information is found concerning which units are connected in the system (not grey), and
which units are defined as active at the moment [X].
If for instance the conveyor is not needed, it can be put in Stop mode here.
Logon
The function of this menu item is identical to the function key F8 as listed to the right in the
sub-menu.
Mechanical Setup
The Mechanical Program stores data for Rack Size, Bottle Size, etc. Like the Measure
Program, it is necessary in order to analyse samples.
The Mechanical Program is displayed as follows:
- Select ‘Mechanical Setup’.
- Click in the grey area to the left, highlighting the Setup to be displayed.
- Click on ‘View’
The default program is automatically selected, unless the operator decides to actively select
a different program (F12).
Default Program
The Measure Program stores data for calibration used, components displayed etc.
The Measure Program displayed here is the default program, which is automatically selected
when starting up a work session, unless the operator selects a different program (F12).

9.6.4 File

Print
All sample results in the current work session file may be printed.
The printout is sorted so that results from samples, which have been re-tested, replace any
previous results from the same sample in the same batch.
Samples are only printed once, even though they have been re-tested.
Export
The purpose of the Data Export facility is to send data stored during the current work session
to the floppy disk, to a printer, or to a host computer.
81
 The Data Export application includes sorting as described above for the Print function. It
may be activated when the system is in Standby or Stop mode.
Note:
Samples analysed in Manual mode will not be exported.

9.6.5 Edit
The available functions are shown in fig. 9-17.

Copy, Cut, Insert, Edit

These functions apply only to batches that are listed, when the batch list is displayed in the
Presentation Application.
Copy: Used to copy a batch-identification. Point with the trackball at the batch to be
copied, then press Ctrl+C.
To Insert the copied batch: point with the trackball at the place where the copied
batch is to be inserted, then press the Ctrl+Ins keys.
Since batch-identifications cannot be the same, you must now point at the copy
and click to edit the batch-identification in such a way that it is different from
the one from which the copy was made.
Cut: Moves a batch-identification to another place in the list of batches. It is used like
the above Copy function. Point with the trackball at the batch to cut, then press
Ctrl+Del keys.
Edit: Move the sample pointer with the trackball to the batch to be edited, then press
‘Enter’ to get the window as seen in fig. 9-18. You can perform editing as
follows:

82
 - Editing of a Batch for which analysis has not yet started:
All data entered for the batch may be corrected. Enter the data and press
‘Store’.
- Editing of a batch for which analysis has started:
Only the name of the batch may be changed.
- Editing of a batch for which analysis has been completed:
Only the name of the batch may be changed.
Block mark
This function applies for both the Results and Batch list screens.
The ‘Block’ function is used to select one or more sample results or batch identities for which
a certain function should be performed.
To select a block, point with the trackball at the line where the block should start, then select
‘Block’ in the Menu Bar or press Shift+F12. Repeat this where the block should end.
(If you click with the right hand key on the trackball, this will have the same effect as
Shift+F12).
If a block of sample results is selected, the functions available will automatically appear as

seen on fig. 9-19 (the ‘Re-test’ function is only available with Conveyor 4000).
The sample results selected may be either printed, re-tested, or deleted, or statistics may be
performed (see the IMT Reference Manual).
If a block of batch identities was selected, then the selected batches may be stored as a ‘Batch
Sequence’. Please see the IMT Reference Manual for details.
Insert sequence / Delete sequence
This function applies to the batch list screen. This function inserts (press Ctrl+s) or deletes
(press Ctrl+d) a pre-programmed sequence of batches (see the IMT Reference Manual for
details).

83
 9.7 BCS Monitor
The BactoScan Control Sample Monitor can be found in the File drop-down menu.

In addition to the warnings given at once if the results measured on BCS samples are outside
limits, the BCS Monitor allows you to monitor performance over time, observe any tendency
or sudden jumps in result levels, and take action before a potential problem results in faulty
milk sample results.
The software includes the most recent 100 BCS sample results. When 100 BCS sample
results are stored, the oldest is automatically discarded as new data becomes available.
The following parameters are available in the View Graph drop-down menu:
Signal Mean
BCS Counts
Repeatability
Signal Width
Noise level
PHA

84
The upper left hand window shows the Lot number for the sample in question. The curves
(except the PHA picture) are made up of a number of connected points, each representing
a BCS sample result. When the cursor covers a point, the corresponding data for three
measurements on the same sample are shown in the window to the left of the graph, and since
the 100 samples can easily be from different lots, the lot number above will change when
samples from different lots are encountered. Sample number 1 (to the left on the x-axis) is
the oldest sample stored, the further to the right a sample is plotted, the newer the
measurement is.

9.7.1 Signal Mean

The window to the left shows the channels in which the peak of the three measurements on
each sample is found, the mean peak channel value and the channel limits for the lot in
question. The graph shows the deviation in channels from the target value, which is indicated
by the 0.0 line. The exact target value can be seen in the Lot Edit program.

The limits are ± 10% of the target channel value, i.e. the limit levels may well vary from
sample lot to sample lot.
In the illustration above, the lot data allow a ± 4 channel limit, but here the variation is only
0 to -2, well within limits.

85
 9.7.2 Count
The window to the left shows a. o. the results of the three measurements on each sample, the
mean value and the limits for the Lot in question. The graph shows the deviation in x 1000
counts from the target value, indicated by the 0.0 line.

On the graph above, the values are generally below target values and slightly decreasing over
time, but not yet enough to cause alarm. The fluctuations are acceptable.

86
9.7.3 Repeatablity

Shows data similar to the count picture in the window to the left, but includes calculated Cv,
which is the value displayed in the graph.
Here the average is well below 2.0 and the fluctuations normal. A continuous rise in value
would indicate a worsening repeatability, which should be investigated.

87
 9.7.4 Signal Width
Signal width is an indicator of correct alignment of the optical system. An abnormally large
signal width indicates poor alignment of the detector. Be aware of sudden or gradual changes
in level.

88
9.7.5 Noise Level
The noise level indicates the channel number where noise is cut off. A sudden shift in noise
level may indicate flow disturbances due to a poor adjustment of the instrument.

89
 9.7.6 PHA
The graph allows you to examine each of the three measurements that make up each of the
sample points on the other BCS Monitor graphs. This is quite similar to the PHA Application
described earlier in this chapter. The < and > buttons below the graph step one measurement
backwards/forwards, while the << and >> buttons move three measurement to the previous
or next BCS sample. The +y and -y buttons are used to alter the y-axis scale.

90
 10. Preparation of Reagents
This section is divided into 4 parts:
1. General information
2. Preparation of stock solutions
3. Preparation of ready-for-use solutions
4. Storage times and conditions

10.1 General Information

Reagents required are supplied as individual packs, providing the amounts necessary for
preparation of stock- and ready-for-use solutions for approx. 25.000 samples at a capacity
of 150 samples per hour.
Enzyme is available in two package sizes, allowing for preparation of smaller or larger
amounts of incubation liquid, depending on sample throughput.
All reagents are coded with functional names and safety precautions according to regula-
tions.
You will require:
Buffer Powder
Enzyme
Staining Medium
Rinse Concentrate
Detergent
You will also require: 0.25 l of ammonia per week, approx. 25% (analytical grade)
Furthermore, a Bacterial Control Sample and a Particle Control Sample are available for
performance checks during the day.
Caution
The Bacterial Standard must be stored in a freezer at below -15 °C.
The Enzyme, Staining Medium and Particle Control Sample must all be stored in
a refrigerator at 2 - 8 °C.
Cold storage is not required during shipment.
The expiry date is stated on each bottle.

10.1.1 Standard procedure

The procedure described later includes preparation of a few stock solutions. You then use
a small portion of each stock solution per working day to prepare ready-for-use solutions.
This procedure speeds up daily routines, leaving more time for actually measuring samples.

10.1.2 Daily Consumption

The prescribed volumes of ready-for-use solutions are sufficient for a working period of
approx. 7½ - 8 hours, depending on sample throughput.
91
 All ready-for-use solutions are easily made during the start-up period.
Remaining volumes of Sheath Liquid and Rinsing Liquid can be re-used the next day. The
Incubation Reagent must not be re-used because the active ingredients deteriorate signifi-
cantly overnight.
If the BactoScan is in operation only part-time, you can prepare smaller portions of
Incubation Reagent by using the small size bottles of Enzyme.
Remaining Rinse Solution may be stored in the Rinse container for up to one week.
Remaining Sheath Liquid may be stored up to a week in the Sheath Liquid container.

10.1.3 Water Quality

Important
The water used for all BactoScan liquids must be purified water, i.e. water that
has passed through a properly working ion exchanger and then through a bacte-
rial filter (0.2 µm filter).
The conductivity must be less than 5 µS/cm.
Proper water quality is essential for correct instrument performance.
Please refer to installation procedure if in doubt.

10.1.4 Clean Flasks

All flasks used for preparation of reagents must be carefully cleaned, either manually or in
a dishwasher. They must then be thoroughly flushed at least 3 times with purified water just
before preparation of reagents.
If liquids are contaminated, the instrument will count too high on blank solution, and the
correct bacterial content in the samples will be “blurred”. Also, if the liquids are contami-
nated when work is begun, bacteria will grow during the day, giving increasing blank values.

10.1.5 Waste
Waste amounts to 7 litres per hour when running 150 samples per hour. Dispose of waste
according to local regulations.
Description of waste composition is available from Foss upon request.

10.2 Preparation of Stock Solutions

* Sheath Liquid
* Staining Reagent
* Preservation Stock Solution
* Re-hydration Solution

10.2.1 Sheath Liquid Stock Solution, (for approx. 6 days normal

operation)
Pour approximately 8 litres of purified water into a 10-litre bottle and carefully add one
Buffer Powder package.
Stir the mixture until the powder is dissolved, you can speed up the process by heating to

92
40°C while stirring. When the powder is dissolved, add 500 ml Detergent (one bottle), and
slowly fill up to the 10-litre mark ± 2 % with purified water to avoid foaming.
May be stored for up to 6 weeks at room temperature, do not refrigerate.

10.2.2 Staining Reagent Stock Solution, for approx. 7.000 sam-

ples
Pour approximately 8 litres of purified water into a 10-litre bottle and carefully add one
Buffer Powder package.
Stir the mixture until the powder is dissolved. When the powder is dissolved, add one Bottle
of Staining Medium, 500 ml Detergent (one bottle), and slowly fill up to the 10-litre
mark ± 2 % with purified water to avoid foaming.
Store in darkness for up to 6 weeks at room temperature, do not refrigerate.
DANGER!
Be careful that Staining Medium does not come into contact with your skin!
Wear gloves!

Note
The Staining Medium has a limited shelf life; the expiring date is stated on the
bottle.

10.2.3 Preservation Stock Solution for Bacterial Control Sample

Requires: Boric Acid, analysis grade, e.g. Merck art. no. 165
Potassium Sorbate, analysis grade, e.g. Merck art. no. 5119
Glycerol 87%, analysis grade, e.g. Merck art. no. 4094
Pour 53 g Boric Acid, 0.8 g Potassium Sorbate and 10 g Glycerol in a 2 litre bottle. Fill
up to the 2000 ml mark with purified water. Stir until mixed, you can speed up the process
by heating to 40°C while stirring.
Store at room temperature (<25 °C) for up to 10 weeks.

10.2.4 Re-hydration Solution for Bacterial Control Sample

Requires: Ringer tablets, 1/4 strength, e.g. Oxoid Unipath
Drop one Ringer tablet into a 1-litre bottle, add 300 ml purified water and 200 ml
Preservation Stock Solution.
Shake the mixture until the tablet is dissolved.
Store at room temperature (<25 °C) for up to 1 week.

93
 10.3 Preparation of Ready-for-Use Solutions
*Sheath Liquid
*Blank
*End of Day
*Rinse
*Incubation Reagent
*Bacterial Control Sample
*Particle Control Sample

10.3.1 Ready-for-use Sheath Liquid

Pour 8 litres ± 10% of purified water and 2 litres ± 10% of Sheath Liquid Stock Solution
into a 10-litre container. Put on the lid and mix using a magnetic stirrer. When in use, the
liquids temperature must be above 15 °C.

10.3.2 Ready-for-use Blank Solution

Mix 1 litre ± 10% of purified water and 50 ml ± 10% of Sheath Liquid Stock Solution
in a clean 1 litre bottle and shake well. Use on the day of preparation.

10.3.3 Ready-for-use End of Day Solution for approx. 1 week

Tap 10 litres ± 10% of purified water and pour in 50 ml ± 10% of 25% Ammonia. Shake
well. Can be kept at room temperature (< 25 °C) for maximum one week. Then discard
remains and make new solution. When in use, the liquids temperature must be above 15 °C.

10.3.4 Ready-for-use Rinse for 1 - 2 days

Start by pouring 100ml of Rinse Concentrate into a 50 litre container, then add 50 litres
of purified water to ensure complete mixing of the Rinse Concentrate into the water. Stir
thoroughly. Must be kept at room temperature (15 - 25 °C) for maximum one week.

10.3.5 Ready-for-use Incubation Reagent

• For 150 samples/h, 8 hours
Mix 1600 ml ± 2% of Staining Reagent with 1 bottle of Enzyme 150. Turn bottle upside
down 10 times before using. Must be used on day of preparation.
• For 100 samples/h, 8 hours
Mix 1100 ml ± 2% of Staining Reagent with 2 bottles of Enzyme 50. Turn bottle upside
down 10 times before using. Must be used on day of preparation.
• For 50 samples/h, 8 hours
Mix 550 ml ± 2% of Staining Reagent with 1 bottle of Enzyme 50. Turn bottle upside
down 10 times before using. Must be used on day of preparation.
Note
The best results are obtained if the volume of Incubation Reagent is as specified.
Use high accuracy measuring equipment.

94
 Note
All reagents used for the BactoScan FC must have a temperature above 15 °C
during measurements in order to ensure a sufficiently high temperature when
cleaning between samples.
If your water supply is much colder, we suggest preparing the Sheath Liquid and
End of Day Solution the day before so they can warm up overnight.

10.3.6 Ready-for-use Bacterial Control Sample

Note:
The Bacterial Control Sample is a viable, certified and controlled non-patho-
genic microorganism. It is safe to use, and can be disposed of in the same way as
raw milk samples.

Measure 100 ml ± 2% of Re-hydration Solution using a measuring cylinder and transfer it

to a suitable container with lid. Take a Bacterial Control sample vial from the freezer, remove
the metal cap and loosen the lid.
Use a small disposable 5 ml pipette to transfer 4 - 5 ml out of the 100 ml Re-hydration Solution
to the vial. Close the vial and turn it upside down 3 times.
Fill the pipette once more with Re-hydration Solution.
When the control sample material is dissolved, pour the contents of the vial into the container
and use the contents of the pipette to rinse the vial, pour the liquid into the container with
the Control Sample. Put on the lid and shake well.
Store in a refrigerator at 2 - 5 °C except when filling sample beakers. The preserved Bacterial
Control Sample can be stored for up to 10 hours when kept in the refrigerator.
Note:
It is important that exact volumes are measured for this liquid, otherwise you
cannot expect to obtain the same counts for each vial. Heating of the re-hydrated
Bacterial Control Sample will affect mean value and counts. Keep sample as
cold as possible until measuring.

10.3.7 Particle Control Sample

Place the bottle containing Particle Control Sample Concentrate on a magnetic stirrer for 10
minutes.
After mixing, dispense 5 drops of concentrate into 20 ml of blank solution in a suitable con-
tainer, for example a sample bottle with lid. Replace the lid on the concentrate bottle. If a
larger volume is required, then dispense the same ratio of particle concentrate and blank
solution liquid in larger amounts, for example 10 drops in 40 ml or 1.4 ml concentrate in 100
ml blank solution.
Place lid(s) on sample bottle(s) and turn upside down a few times.
Diluted Particle Control Sample should be used within one hour.

95
 10.4 Storage Time and Conditions
Here are the prescribed storage times for stock solutions and ready-for-use solutions.
NOTE: Prescribed maximum storage times require clean bottles and containers.

10.4.1 Storage Time and Conditions before Mixing

Sheath Liquid Stock Solution:
Must be stored at 10 - 35 °C.
Recommended maximum storage time is 6 weeks.
Staining Medium Stock Solution:
Must be stored in the dark and at 10 - 35 °C.
Recommended maximum storage time is 6 weeks.
Preservation Stock Solution for Bacterial Control Sample:
Store at room temperature (<25 °C) for up to 10 weeks.
Re-hydration Solution for Bacterial Control Sample:
Store at room temperature (< 25 °C) for up to 1 week.

10.4.2 Storage Time and Conditions for Ready-for-use Solutions

Sheath Liquid:
Can be kept at room temperature (<25°C) for maximum one week.
Can be kept at temperatures 25 - 35 °C for 2 days.
Incubation Reagent:
Must be used on the day of preparation.
Must be kept at temperatures above 10 °C. Maximum recommended temperature is 35 °C.
Rinse:
Can be kept at room temperature (<25 °C) for maximum one week.
End of Day Solution:
Can be kept at room temperature (<25 °C) for maximum one week.
Bacterial Control Sample:
The suspension must be stored at 2 - 5 °C when not in use. Can be stored for up to 10 hours.
Particle Control Sample:
Must be stored in darkness at 2 - 8 °C. Do not freeze. When diluted, use within one hour.

96
 11. Maintenance
11.1 Regular Maintenance
11.1.1 Cleaning the incubation wheel and pipettes

1. Activate the Service Menu

2. Place the incubation wheel in upper posi-
tion.
3. Remove the perspex cover (a) and the steel
cover (b)
4. Place the incubation wheel in lower posi-
tion
5. Switch off power to the incubation wheel
6. Loosen the three screws (c). The incubation
wheel will not fall down because it is se-
cured by three locks.
7. Pull the incubation wheel free of the locks.
8. Wash the incubation wheel by brushing it
with a detergent/water solution and flush it
with deionized water. (Do not clean the
incubation wheel in a dishwasher ma-
chine).
9. Pipettes without flushing unit are easy to
clean while the incubation wheel is dis-
mounted.
Use only precision fluff-free paper to avoid
introduction of paper fibres in the flow
system.
Be aware not to bend the pipettes, as they
need to be fixed precisely in the wells.
It is not necessary to clean pipettes fitted
with a flushing unit ring as they are cleaned
automatically.
10. Re-assemble in the reverse order of the
above steps. Be careful not to tighten the
screws too much in order to avoid damage.

Note
Due to the risk of contamination of the flow system with dust and other small
particles, it is important to always run the incubation unit with the steel and
plastic covers mounted.
97
 11.1.2 Cleaning Reagent and Waste Containers
Daily Cleaning:
Wash the Incubation Reagent Container thoroughly by brushing it with washing-up liquid/
water. Then rinse it with purified water and dry it. The container can also be cleaned in a
dishwashing machine.
Weekly Cleaning:
All containers and pipettes must be washed by brushing them with washing-up liquid/water.
Then rinse them with purified water and dry them.
Inspect the pipette filters for contamination, and clean them if required:
- remove the O-ring and take out the filter, see figure
- clean the filter by brushing it with purified water
If the filter is damaged, replace it with a new filter from the accessories box.

Note:
When re-installing the filter, remember always to place the filter in
the same way as it was before cleaning. This will prevent the few
remaining particles from entering the instrument.

98
11.2 Other Maintenance
These procedures are to be carried out as and when required. Fixed intervals cannot be given,
but must be decided upon, based on local conditions and experience.

11.2.1 Cleaning the Air Filters

There are three air filters in the cabinet:
- one on each side of the counting module, built into the cabinet walls
to remove these, unlock the rear panel and release the filter plates
- one below the electronics cabinet
to remove this filter, open the door under the right hand side of the instrument
and release the filter plate
The air filters should be inspected regularly for blockage and cleaned if necessary, with a
vacuum cleaner or by washing them in soap water. Pay special attention to the filters in the
counting module. The cleaning interval depends on the ambient air quality.

11.2.2 Cleaning the Inline Filter

The inline filter prevents dirt from being
transferred from the incubation unit to the
counting module.
In regular use it should not be necessary to
clean the inline filter, but if heavy contami-
nation occurs, or if error 49 is displayed, it
can be necessary to clean the filter.
The inline filter is located in the optical
sensor housing, “OS8”, at the lower tube
fitting.
1. Remove the lower tube fitting.
2. Remove the filter. If it does not drop
out by itself, it can be necessary to
gently remove the filter with a needle.
Be careful not to damage the filter.
3. Clean the filter by flushing it with
deionized water and/or alcohol.
4. Re-assemble in the reverse order of the
above steps.

99
 11.2.3 Cleaning the Throttles
In the units INU, INC and DVU, there are several throttles used to reduce the flow rate of
the Rinse liquid. These throttles consist of a cannulla pipe with a small orifice pressed into
a union.
The following procedure should only be taken into consideration if the pressure on the Rinse
Chamber is correct and you have a suspicion that the flow from the throttle is too low.
Remove only one throttle at a time (they are not all alike).
1. The BSC FC should be in Stop-mode
2. Remove the tube from the throttle in question
3. Unscrew the union with the suspected throttle
4. Use a syringe to flush the throttle with water in the opposite direction of the normal
flow.
5. It may be necessary to use a thin tread (e.g. a core from an electrical wire ) to remove
possible dirt.
6. Re-assemble using the reverse order of the above steps.
Note
Be aware of the small O-ring at the end of the union.

11.3 Replacements
11.3.1 Replacing Tubes
It should not be necessary to replace any of the tubes in the BactoScan FC during normal
service intervals.
However, should any damage occur to a tube, or it becomes extremely dirty (e.g. intake) it
is very important that the tube is replaced with a similar tube of the correct material, length
and dimensions.

11.3.2 Replacing a Damaged Stirrer

The stirring and flushing ability of the BactoScan FC stirrer is very sensitive to physical
damage of the stirrer.
Replacement of a damaged stirrer will therefore be necessary. Use the following procedure,
the numbers refer to the figure.
1. Place the stirrer in the upper position
2. Use the tool to loosen the finger screw (a) that holds the stirrer
3. Unscrew the three screws (b) holding the upper and lower part of the flushing unit
together
4. Separate the two parts of the flushing unit and remove the damaged stirrer
5. Gently insert a new stirrer from the box of accessories
6. Re-assemble the two parts of the flushing unit with the three screws
7. With the pipette in the correct upper position, fix the stirrer in a position 0.5 - 1.0 mm
from the physical top position in the flushing unit.
100
 Caution
When the flushing unit has been re-assembled, make sure that the unit can move
freely horizontally.

11.3.3 Replacing a Damaged Pipette

The BactoScan FC pipette is made of two concentric cannula pipes, insulated from each
other.
The inner pipe functions as pipette and both make up a liquid sensor.
If the pipette is bent or otherwise damaged, it can be necessary to replace it.
Use the following procedure to replace the pipette, the numbers refer to fig.
1. Place the pipette in the upper position and remove the protection tube (c)
2. Remove the milk tube
3. Unscrew the small upper nuts (d)
4. Remove the cable connector with the grey cable
5. Unscrew the large nut (e) above the bracket and lower the pipette out of the bracket.
6. Lift the pipette out of the flushing unit.
7. Install a new pipette from the box of accessories, mount in the reverse order of the above
steps.

101
 11.3.4 Replacing the Intake Filter
Use the following procedure to replace the intake filter in the intake manifold. The numbers
refer to the figure

1. Unscrew the two screws (c) and re-

move the transparent part that holds
the intake filter.
d
2. Carefully remove the O-ring (b) (e.g.
with a needle) and then remove the
filter (a) from the intake manifold.
a
3. Insert a new intake filter from the box e
b
of accessories, mount using the above c
steps in reverse order.

11.3.5 Replacing O-rings at the ends of the Incubation Reagent Filter

The Incubation Reagent Filter is replaced every morning, so it is possible that damage could
occur to the O-ring at either of the two ends.
Use the following procedure to replace O-rings,
the numbers refer to the figure.
1. Remove the Incubation Reagent Filter.
2 a. Remove gently with a needle the O-ring (d)
(upper seal) from the spring loaded Filter
Adapter without making scratches on the
surface of the unit.
d 2 b. Remove gently with a needle the O-ring (e)
(lower seal) from the mounting hole on the
Intake Manifold, without making any
scratches on the surrounding surfaces on the
manifold.
3 a. Mount a new O-ring P/N 349407 from the
e box of accessories as upper seal (d).
3 b. Mount a new O-ring P/N 198499 from the
box of accessories as lower seal (e).

You may need to use the bottom end of an Incubation Reagent Filter to check that the O-ring
is in the correct position. Mount a new Incubation Reagent Filter.
When the Incubation Reagent Filter has been removed and replaced, a Start-up shall take
place to fill tubes with liquids and remove any air.
102
11.3.6 Replacing Rinse and Sheath Liquid Filters
These filters must be replaced at least once a year, but it can be necessary to exchange the
filters more often, due to contamination of the liquids.
If high blank counts occur, this can be due to heavy contamination or damaging of the filter.
If the instrument has problems filling the rinse and/or sheath liquid unit during start up, this
can be due to clogging of the filter or to air trapped in the filters.
How to replace a filter:
- The instrument must be in Stop Mode.
- The pressure must be released before removing the filters. This is done by activating two
valves.
- Activate the Service Menu
- Select Simple I/O
- Select Output
- Activate valve SLU_V2 for the Sheath Liquid Filter and/or RIN_V2 for the Rinse Filter,
to open the position(s) for a few seconds.
Remember to close the valves again before leaving the service menu.

- Remove the old filter by pulling off the silicon tubes.

- When mounting the new filter it can be helpful to use a Kleenex to increase the friction
on the silicon tube.
- Please observe the flow indication arrow on the housing. Correct flow direction is
upwards.
- Write the date of the filter replacement on the filter.
- In case of damage to the silicon tubes, there are extra tubes to be found in the accessories
kit.

The filters must be filled with liquid during the mode shift from Stop to Stand-by.
To facilitate this filling, any air trapped in the filter must be released by twisting the upper
valve 1/4 turn counter-clockwise. The lower valve must always be closed. Close the upper
valve after liquid begins to pass through the vent.

103
104