IE83899B1 - Apparatus and containers for performing polymerase chain reaction - Google Patents

Description

APPARATUS AND CONTAINERS FOR PERFORMING POLYMERASE CHAIN REACTION PERKIN-ELMER CETUS INSTRUMENTS Background of the Invgntigg The invention pertains to the field of computer directed instruments for performing the polymerase chain (hereafter PCR). More particularly, the invention to automated instruments that can perform the reaction pertains polymerase chain reaction simultaneously’ on many samples with a very high degree of precision as to results obtained This the among other things, of performing so-called for each sample. high precision provides capability, "quantitative PCR".

To amplify DNA (Deoxyribose Nucleic Acid) using the PCR process, it is necessary to cycle a specially constituted liquid reaction mixture through a PCR protocol including The reaction mixture is comprised of various components such as several different temperature incubation periods. the DNA to be amplified and at least two primers selected in a predetermined way so as to be sufficiently complementary to the sample DNA as to be able to create extension products of the DNA to be amplified. various enzymes and/or other reagents, as well as several The reaction mixture includes deoxyribonucleoside triphosphates such as dATP, dCTP, dGTP and dTTP. Generally, the primers are oligonucleotides which are capable of acting as a point of initiation of synthesis when placed under conditions in which synthesis of a primer extension product which is complimentary to a nucleic acid strand is induced, i.e., in the presence of nucleotides and inducing agents such as thermostable DNA polymerase at a suitable temperature and pH.

The Polymerase Chain Reaction has (PCR) proven a phenomenally successful technology for genetic analysis, largely because it is so simple and requires relatively low cost instrumentation. A key to PCR is the concept of thermocycling: alternating steps of melting DNA, annealing short primers to the resulting single strands, and extending In thermocycling, the PCR reaction mixture is repeatedly cycled (>90° C) for melting the DNA, to lower temperatures (40°C to 70°C) for primer annealing and those primers to make new copies of double stranded DNA. from high temperatures extension. The first commercial system for performing the thermal cycling required in the polymerase chain reaction, the Perkin-Elmer Cetus DNA Thermal Cycler, was introduced in l987.

Applications of PCR technology are now moving from basic research to applications in which large numbers of similar amplifications are routinely run. These areas include diagnostic research, biopharmaceutical development, genetic analysis, and environmental testing. Users in these areas would benefit from a high performance PCR system that would provide the user with high throughput, rapid turn-around time, and reproducible results. Users in these areas must be assured of reproducibility from sample-to-sample, run-to- run, lab-to—lab, and instrument-to-instrument.

For example, the physical mapping process in the Human Genome Project may become greatly simplified by utilizing sequence tagged sites. An STS is a short, unique sequence easily amplified by PCR and which identifies a location on the chromosome. Checking for such sites to make genome maps requires amplifying large numbers of samples in a short time with protocols which can be reproducibly run throughout the world.

As the number of PCR samples increases, it becomes more important to integrate amplification with sample preparation and post-amplification analysis. The Sample vessels must not only allow rapid thermal cycling but also permit more automated for operations such solvent handling as extractions and centrifugation. The vessels should work consistently at low volumes, to reduce reagent costs.

Generally PCR temperature cycling involves at least two incubations at different temperatures. one of these incubations is for primer hybridization and a catalyzed The other incubation is for of the double extension products into single strand templates for use in the next hybridization and extension incubation interval.

The details of the reaction, the temperature cycling and reaction conditions necessary for PCR as well as the various reagents and enzymes necessary to perform the in U.S. patents 4,683,202, 4,683,195, EPO Publication 258,017 and 4,889,818 and all other PCR patents primer extension reaction. denaturation, i.e., separation stranded polymerase chain reaction are described (Taq polymerase enzyme patent) which are assigned to Cetus Corporation, which are hereby incorporated by reference.

The purpose of a polymerase chain reaction is to manufacture a large volume or DNA which is identical to an initially supplied small volume of "seed" DNA. The reaction involves copying the strands of the DNA and then using the copies to generate other copies in subsequent cycles. Under ideal conditions, each cycle will double the amount of DNA present thereby resulting in a geometric progression in the volume of copies of the "target" or "seed" DNA strands present in the reaction mixture.

A typical PCR temperature cycle requires that the reaction mixture be held accurately at each incubation temperature for a prescribed time and that the identical cycle or a similar cycle be repeated many times. A typical PCR program starts at a sample temperature of 94°C held for Then, the temperature of the reaction mixture is lowered to 37°C and Next, of the reaction mixture is raised to a seconds to denature the reaction mixture. held for one minute to permit primer hybridization. the temperture in the range from 50‘C to 72°C where it is held temperature for two minutes the synthesis of extension The next PCR cycle to promote products. This completes one cycle. then starts by raising the temperature of the reaction mixture to 94°C again for strand separation of the extension products .formed in the previous cycle (denaturation).

Typically, the cycle is repeated 25 to 30 times.

Generally, to the temperature to the next temperature in the cycle as rapidly it is desirable change sample as possible for several reasons. First, the chemical reaction has an optimum temperature for each of its stages.

Thus, better chemical result is achieved. less time spent at nonoptimum temperatures means a Another reason is that a minimum time for holding the reaction mixture at each incubation temperature is required after each said incubation temperature is reached. These minimum incubation "floor" Any time transitioning between sample times establish the or minimum time it takes to complete a cycle. incubation temperatures is time which is added to this Since the number of cycles is fairly this additional time unnecessarily lengthens the minimum cycle time. large, total time needed to complete the amplification.

In some prior automated PCR instruments, the reaction mixture was stored in a disposable plastic tube which is closed with a cap. A typical sample volume for such tubes was 100 Typically, instruments used many such tubes filled with sample DNA and approximately microliters. such reaction mixture inserted into holes called sample wells in a metal block. of the metal block was controlled according to prescribed To perform the PCR process, the temperature temperatures and times specified by the user in a PCR protocol file. A computer and associated electronics then controlled the temperature of the metal block in accordance with the user supplied data in the PCR protocol file defining the times, temperatures and number of cycles, etc.

As the metal block changed temperature, the samples in the various tubes followed with similar changes in temperature. in these prior art instruments not all samples In these However, experienced exactly the same temperature cycle. prior art PCR instruments, errors in sample temperature were generated by nonuniformity of temperature from place to place within the metal sample block, i.e., temperature gradients existed within the metal of the block thereby causing some samples to have different temperatures than Further, there were delays in transferring heat from the sample block other samples at particular times in the cycle. to the sample, but the delays were not the same for all samples. To perform the PCR process successfully and PCR, these time delays and temperature errors must be minimized efficiently, and to enable so called "quantitative" to a great extent.

The problems of minimizing time delays for heat transfer to and from the sample liquid and minimizing temperature errors due to temperature gradients or nonuniformity in temperature at various points on the metal block become particularly acute when the size of the region containing samples becomes large. It is a highly desirable attribute for a PCR instrument to have a metal block which is large enough to accommodate 96 sample tubes arranged in the format of an industry standard microtiter plate.

The microtiter plate is a widely used means for handling, processing and analyzing large numbers of small samples in the biochemistry and biotechnology fields.

Typically, a microtiter plate is a tray which is 3 5/8 inches wide and 5 inches long and contains 96 identical sample wells in an 8 well by 12 well rectangular array on 9 Although available in a wide variety of materials, shapes and volumes millimeter centers. microtiter plates are of the sample wells, which are optimized for many different uses, all microtiter plates have the same overall outside dimensions and the same 8 X 12 array of wells on 9 millimeter centers. A wide variety of equipment is available for automating the handling, processing and analyzing of samples in this standard microtiter plate format.

Generally microtiter plates are made of injection molded or vacuum formed plastic and are inexpensive and considered disposable. Disposability is a highly desirable characteristic because of the legal liability arising out of cross contamination and the difficulty of washing and drying microtiter plates after use.

It is therefore a highly desirable characteristic for a PCR instrument to be able to perform the PCR reaction on up to 96 samples simultaneously said samples being arranged in a microtiter plate format. the size of the metal block which is necessary to heat and cool 96 samples in an 8 x 12 well of course, array on 9 millimeter centers is fairly large. This large area block creates multiple challenging engineering problems for the design of a PCR instrument which is capable of heating and cooling such a block very rapidly in a temperature range generally from 0 to 100°C with very little These the large tolerance for temperature variations between samples. problems arise from several sources. First, thermal mass of the block makes it difficult to move the block temperature up and down in the operating range with Second, the need to attach the block to various external devices such as manifolds for supply and block support attachment great rapidity. withdrawal of cooling liquid, points, and associated other peripheral equipment creates the potential for temperature gradients to exist across the block which exceed tolerable limits.

There are also numerous other conflicts between the requirements in the design of a thermal cycling system for automated performance of the PCR reaction or other reactions requiring rapid, accurate temperature cycling of a large number of samples. For example, to change the temperature ‘ of a metal block rapidly, a large amount of heat must be added to, or removed from the sample block in a short period of time. Heat can be added from electrical resistance heaters or by flowing a heated fluid in contact with the block. fluid in contact with the block.

Heat can be removed rapidly by flowing a chilled However, it is seemingly impossible to add or remove large amounts of heat rapidly in’ block by these without differences in temperature from place to place in the block a metal means causing large thereby forming temperature gradients which can result in nonuniformity of temperature among the samples.

Even after the process of addition or removal of heat is terminated, temperature gradients can persist for a time roughly proportional to the square of the distance that the heat stored in various points in the block must travel to cooler regions to eliminate the temperature gradient. Thus, as a metal block is made larger to accommodate more samples, the time it takes for temperature gradients existing in the block to decay after a temperature change causes temperature gradients which extend across the largest dimensions of the block This it increasingly difficult to cycle the temperature of the can become markedly longer. makes sample block rapidly while maintaining accurate temperature uniformity among all the samples.

Because of the time required for temperature gradients to dissipate, an important need has arisen in the design of a high performance PCR instrument to prevent the creation of temperature gradients that extend over large distances in the block. the boundaries between metal parts or other peripheral equipment attached to the block. in a way that insures uniformly high thermal conductance Another need is to avoid, as much as possible, requirement for heat to travel across mechanical It is difficult to join metal parts everywhere across the joint. Nonuniformities of thermal conductance will generate unwanted temperature gradients.

Summary of Invention The present invention provides thermocycler apparatus suitable for performing the polymerase chain reaction comprising at least one sample well capable of receiving a capped sample tube containing a sample mixture, a heated platen with heating means being provided to heat said platen for contacting the top of a said sample tube, and heater control means for controlling the heating means so that the platen heats the upper part of a sample tube to a temperature above the condensation point such that condensation and refluxing of sample in a sample tube is avoided.

The at least one sample well of the thermocycler apparatus is preferably comprised in a sample block.

The thermocycler apparatus may further comprise means for forcing the heated platen against the top of a sample tube.

Preferably, the force of the heated platen in use against the tops of sample tubes is such that all sample tubes are pressed firmly into their respective sample wells and/or the force of the heated platen in use against the tops of the sample tubes is such that the caps of the sample tubes are deformed.

The sample block may be of metal and may have an array of spaced-apart sample wells each of which has an inside surface, said wells capable of receiving one or more capped sample tubes each containing a sample mixture placed in a microtiter plate having an uppermost edge, which plate is seated on said sample block.

The heated platen may be in the form of a cover to enclose said sample tubes, which cover comprises a flat, horizontal rectangular portion and downwardly projecting skirt portions along the periphery thereof and further comprises a device for heating at least the underside of said horizontal portion, said cover being dimensioned to contact said sample block and to enclose said microtiter plate and sample tubes on said sample block when the tops of the caps on said sample tubes deform, due to the application of heat and a downwardly directed force by said cover.

The skirt portions of the cover may be dimensioned such that they contact said sample block at substantially the same time as the underside of said cover contacts the uppermost edge of said microtiter plate as the cover encloses the plate, preferably the downwardly directed force is sufficient to ensure a snug contact between a lower portion of each sample tube and the inside surface of the well which contains said portion.

The thermocycler apparatus of the invention may further comprise knob and screw means for lowering said cover from one height to another, said knob and screw means including indication means for identifying a knob position corresponding to the cover height at which said cover contacts said uppermost edge.

According to the teachings of the invention, there is disclosed herein a thin walled sample tube for decreasing the delay between changes in sample temperature of the sample block and corresponding changes in temperature of the reaction mixture. Two different sample tube sizes are disclosed, but each has a thin walled conical section that fits into a matching conical recess in the sample block.

Typically, cones with 17° angles relative to the longitudinal axis are used to prevent jamming of the tubes into the sample block but to allow snug fit. other shapes and angles would also suffice for purposes of practicing the invention.

Also, other types of heat exchangers can also be used other than sample blocks such as liquid baths, ovens, etc.

However, the wall thickness of the section of the sample tube which is in contact with whatever heat exchange is being used should be as thin as possible so long as it is sufficiently strong to withstand the thermal stresses of PCR cycling and the stresses of normal use. Typically, the sample tubes are made of autoclavable polypropylene such as Himont PD701 with a wall thickness of the conical section in the range from 0.009 to 0.012 inches plus or minus 0.001 inches. Most preferably, the wall thickness is 0.012 inches.

In the preferred embodiment, the sample tube also has a thicker walled cylindrical section which joins with the conical section. This conical section provide containment for the original reaction mixture or reagents which may be added after PCR processing.

The sample tube shown in Figure 50 has industry standard configuration except for the thin walls for compatibility in other PCR systems. The sample tube of Figure 15 is a shorter tube which can be used with the system disclosed herein.

The other subject matter of the system environment in which use of the thin walled sample tubes is preferred are summarized below.

There is also described herein a novel method and apparatus for achieving very accurate temperature control number of microtiter plate format during the performance of very rapid for a very large samples arranged in the temperature cycling PCR protocols. The teachings of the invention contemplate a novel structure for a sample block, sample tubes and supporting mounting, heating and cooling apparatus, control electronics and software, a novel user interface and a novel method of using said apparatus to perform the PCR protocol.

The instrument described herein is designed to do PCR gene amplification on up to 96 samples with very tight tolerances of temperature control across the universe of samples. This means that all samples go up and down in temperature simultaneously with very little difference in temperature’ between different wells containing different samples, this being true throughout the polymerase chain reaction cycle. The instrument described herein is also capable of very tight control of the reaction mixture through of the condensation processes in each sample well. evaporation and Further, the instrument described herein is capable of processing up to concentration control samples of 100 microliters each from different donor sources with substantially no cross-contamination between sample wells.

The teachings of the invention herein includes a novel method of heating and cooling an aluminum sample block to thermally cycle samples in the standard 96-well microtiter plate format with the result that excellent sample—to-sample uniformity exists despite rapid thermal cycling rates, noncontrolled varying ambient temperatures and variations in other operating conditions such as power line voltage and coolant temperatures.

The teachings of the invention also contemplate a novel design for a disposable plastic 96-well microtiter plate for — V- accommodation of up to 96 individual sample tubes containing DNA for thermal cycling each sample tube having individual freedom of movement sufficient to find the best fit with the sample block under downward pressure from a heated cover.

The microtiter plate design, by allowing each tube to find the best fit, provides high and uniform thermal conductance from the sample block to each sample tube even if differing rates of thermal expansion and contraction between the metal of the block and the plastic microtiter plate structure cause the relative center-to- of the sample tube and center dimensions of the wells in the sample block to change relative to the center-to-center distance of the sample tubes in the disposable microtiter plate structure.

The teachings of the invention also contemplate a novel method and apparatus for controlling the PCR instrument which includes the ability to continuously calculate and display the temperature of the samples being processed without directly measuring these temperatures. These calculated temperatures are used to control the time that the samples are held within the given temperature tolerance band for each target temperature of incubation. The control system also controls a three-zone heater thermally coupled the sample block fluid flow directionally interlaced ramp cooling channels in the sample to and gates through block which, when combined with a constant bias cooling flow of coolant through the sample block provides a facility to achieve rapid temperature changes to and precise temperature The method and apparatus for controlling the three-zone heater control at target temperatures specified by the user. includes an apparatus for taking into account, among other the temperature and ambient temperature things, line voltage, block temperature, coolant in calculating the amount of electrical energy to be supplied to the various zones of the three-zone heater. This heater has zones which are separately controllable under the edges or "guard bands" of the sample block so that excess heat losses to the ambient through peripheral equipment attached to the edges of the sample block can be compensated. This helps prevent thermal gradients from forming.

The teachings of the invention also contemplate a novel method and apparatus for preventing loss of solvent from the reaction mixtures when the samples are being incubated at temperatures near their boiling point. A heated platen covers the tops of the sample tubes and is in contact with an individual cap which provides a gas-tight seal for each sample tube. The heat from the platen heats the upper parts pof each sample tube and the cap to a temperature above the condensation point such that no condensation and refluxing occurs within any sample tube. Condensation represents a relatively large heat transfer since an amount of heat equal to the heat of vaporization is given up when water vapor condenses. This could cause large temperature variations from sample to sample if the condensation does not occur uniformly. The heated platen prevents any condensation from occurring in any sample tube thereby minimizing this source The use of the heated platen also reduces reagent consumption. the heated platen provides a downward of potential temperature errors.

Furthermore, force for each sample tube which exceeds an experimentally determined minimum downward force necessary to keep all sample tubes pressed firmly into the temperature controlled sample block so as to establish and maintain uniform block- to-tube thermal conductance for each tube. This uniformity of thermal conductance established of variations from tube to tube in length, diameter, angle or other dimensional errors which otherwise could cause some sample tubes to fit more snugly in their corresponding is regardless sample wells than other sample tubes.

The heated platen softens the plastic of each cap but does not totally destroy the caps elasticity. Thus, a minimum threshold downward forced is successfully applied to each tube despite differences in tube height from tube to tube.

The PCR instrument described herein reduces cycle times by a factor of 2 or more and lowers reagent cost by compatible with the industry standard 0.5 ml microcentrifuge tube.

Brie: Description 9f the Qrawings Figure l is a block diagram of the thermal cycler accommodating PCR volumes down to uh but remains according to the teachings of the invention.

Figure 2 is a plan view of a sample block according to »the teachings of the invention.

Figure 3 is a side, elevation View of the sample block showing the bias and ramp cooling channels.

Figures 4 and 5 are end, elevation views of the sample block.

Figure 6 is a sectional view of the sample block taken along section line Figure 7 along section -6' in Figure 2. is a sectional view of the sample block taken 2. of the sample block taken 8-8' in Figure 2.

Figure 9 is a cross-sectional, elevation view of the sample block structure after assembly with the three-zone film heater and block support. line 7-7' in Figure Figure 8 is a sectional view along section line Figure 10 is a graph or power line voltage illustrating the form of power control to the three-zone film heater.

Figure 11 is a temperature graph showing a typical three incubation temperature PCR protocol.

Figure 12 is a cross-sectional view of the sample block illustrating the local zone concept.

Figure 13 is a plan view of the three-zone heater.

Figure 14 is a graph of sample temperature versus time illustrating the effect of an r of a sample tube seating force F which is too low.

Figure 15 is a cross-sectional view of a sample tube and cap seated in the sample block.

Figure 16A is a graph of the impulse response of an RC circuit.

Figure 165 is a graph of an impulse excitation pulse.

Figure 16C is a graph illustrating how the convolution of the thermal impulse response and the temperature history of the block give the calculated sample temperature.

Figure 16D illustrates the electrical analog of the thermal response of the sample block/sample tube system.

Figure 17 illustrates how the calculated temperatures of different all temperature to within about 0.S°C of each other when the six samples converge on a target constants of proportionality for the equations used to control the three zone heater are properly set.

Figure 18 is a graph illustrating how the denaturation target temperature affects the amount of DNA generated.

Figure 19 is a cross-sectional view of the sliding cover and heated platen.

Figure 20 is perspective view of the sliding cover, sample block and the knob used to lower the heated platen.

Figure 21A is a cross-sectional View of the assembly of one embodiment of the frame, retainer, sample tube and cap when seated on a sample block.

Figure 215 is a cross-sectional view of the assembly of the preferred embodiment of the frame, retainer, sample tube and cap when seated on the sample block. disposable frame for the microtiter plate.

Figure 23 Figure 24 Figure 26 along section line 25-26' in Figure 22.

Figure is a top, plan view of the plastic, is a bottom, plan view of the frame. is an end, elevation view of the frame.

Figure is another end, elevation view of the frame. is a cross-sectional view of the frame taken Figure 27 is a cross-sectional View of the frame taken along section line 27—27' Figure 28 is an edge elevation view and partial section in Figure 22. of the frame.

Figure 29 is a sectional view of the preferred sample tube.

Figure 30 is a sectional view of the upper part of the sample tube.

Figure 31 is an elevation View of a portion of the cap strip.

Figure 32 is a top view of a portion of the cap strip.

Figure 33 is a top, plan view of the plastic, disposable retainer portion of the 96 well microtiter tray.

Figure 34 is a side, elevation view with a partial -section of the retainer.

Figure 35 is an end, elevation view of the retainer.

Figure 36 is a sectional view of the retainer taken along section line 36-36' in Figure 33.

Figure 37 is a sectional view of the retainer taken along section line 37-37‘ in Figure 33.

Figure 38 is a plan view of the plastic disposable support base of the 96 well microtiter tray.

Figure 39 is a bottom plan view of the base.

Figure 40 is a side elevation view of the base.

Figure 41 is an end elevation view of the base.

Figure 42 is a sectional view of the support base taken along section line 42-42' in Figure 38.

Figure 43 is a sectional view of the support base taken along section line 43-43' in Figure 38.

Figure 44 is a section view of the base taken along section line 44-44' in Figure 38.

Figure 45 is a perspective exploded view of the plastic disposable items that comprise the microtiter tray with some sample tubes and caps in place.

Figure 46 is a diagram of the coolant control system 24 in Figure 1.

Figures 47A and 47B are a block diagram of the control electronics according to the teachings of the invention.

Figure 48 is a schematic of a typical zener temperature sensor .

Iigure 49 is a time line diagram or a typical sample period.

Figure so is elevation sectional View of a tall thin walled sample tube marketed under the trademrax KAXIAHP. rigure 51 is a graph showing the difference in response time between the thin walled sasple tubes and the thick walled prior art tubes.

Figure 52 is a plan view of a sanple tube and cap.

Figures 5: and 54 are flow charts of the power up test sequence. mmnm Referring to rigure 1 there is shown a block diagram of the major syeten components or one enbodisent or a computer directed instrument for pertoreing PCR according to the teaching: or the invention. senple eixtures including the DNA or RNA to he amplitied are placed in the temperature- programed sample block l2 an are covered by heated cover 14.

A user supplies data detining time and temperature parameters of the desired PCR protocol via a terminal 16 including a keyboard and display. The keyboard and display are coupled via bs ll to a control conputer 20 (hereatter sonetines reterred to as a central processing unit or CPU).

This central processing unit 20 includes senory which stores the control proqran described below, the data detining the desired rcn protocol and certain calibration constants described below. The control proqrel causes the CPU 20 to control temperature cycling or the sample block 12 and ‘implements a user interface which provides certain displays to the user and which receives data entered by the user via the keyboard or the terminal 16.

In the preferred enbodinent, the central processing unit 20 is custom designed.

A block diagram of the electronics will be discussed in more detail below. In alternative embodiments, the central processing unit 20 and associated peripheral electronics to control the various heaters and other electro—mechanical systems of the instrument and read various sensors could be any general purpose computer such as a suitably programmed personal computer or microcomputer.

The samples 10 are stored in capped disposable tubes which are seated in the sample block 12 and are thermally isolated from the ambient air by a heated cover 14 which contacts a plastic disposable tray to be described below to form a heated, enclosed box in which the sample tubes reside. The heated cover serves, among other things, to reduce undesired heat transfers to and from the sample mixture by evaporation, condensation and refluxing inside the sample tubes. It also reduces the chance of cross contamination by keeping the insides of the caps dry thereby preventing aerosol formation when the tubes are uncapped.

The heated cover is in contact with the sample tube caps and keeps them heated to a temperature of approximately 104°C or above the condensation points of the various components of the reaction mixture.

The central processing unit 20 includes appropriate electronics to sense the temperature of the heated cover 14 and control electric resistance heaters therein to maintain the cover 14 at a predetermined temperature. Sensing of the temperature of the heated cover 14 and control of the resistance heaters therein is accomplished via a temperature sensor (not shown) and bus 22.

A coolant control system 24 continuously circulates a chilled liquid coolant such as a mixture of automobile antifreeze and water through bias cooling channels (not shown) in the sample block 12 via input tubes 26 and output tube 28. The coolant control system 24 also controls fluid flow through higher volume ramp cooling fluid flow paths in’ the sample block 12. (not shown) The ramp cooling -17.. channels are used to rapidly change the temperature of the sample block 12 by pumping large volumes of chilled liquid coolant through the block at a relatively high flow rate.

Ramp cooling liquid coolant enters the sample block 12 through tube 30 and exits the sample block through tube 32.

The details of the coolant control system are shown in Figure 46. The coolant control system will be discussed more fully below in the description of the electronics and software of the control system.

Typically, the liquid coolant used to chill the sample block 12 consists mainly of a mixture of water and ethylene glycol. The liquid coolant is chilled by a heat exchanger 34 which receives liquid coolant which has extracted heat from the sample block 12 via input tube 36. The heat exchanger 34 receives compressed liquid freon refrigerant This refrigeration unit 40 includes a compressor (not shown), a fan 42 and a fin tube heat radiator 44. 40 via input tube 38 from a refrigeration unit 40.

The refrigeration unit compresses freon gas received from the heat The gaseous freon is cooled and The pressure of the liquid freon is maintained above its vapor exchanger 34 via tube 46. condensed to a liquid in the fin tube condenser 44. pressure in the fin tube condenser by a flow restrictor capillary tube 47. The output of this capillary tube is coupled to the input of the heat exchanger 34 via tube 38.

In the heat exchanger, the pressure of the freon is allowed to and the freon drop below the freon vapor pressure, expands. In this process of expansion, heat is absorbed from the warmed liquid coolant circulating in the heat exchanger and this heat is transferred to the freon thereby causing the freon to boil. The warmed freon is then extracted from the heat exchanger via tube 46 and is again circulated through the fin tube The fan 42 blows air through the fin tube condensor 44 to cause heat in the freon from tube 46 to be As symbolized by arrows 48. compressed and condensor 44. exchanged with the ambient air.

The refrigeration unit 40 should be capable of extracting 400 watts of heat at 30°C and 100 watts of heat at 10°C from the liquid coolant to support the rapid temperature cycling according to the teachings of the invention.

In the preferred embodiment, the apparatus of Figure 1 is enclosed within a housing (not shown). The heat 48 expelled to the ambient air is kept within the housing to aid in evaporation of any condensation which occurs on the various tubes carrying chilled liquid coolant or freon from one place to another. This condensation can cause corrosion of metals used in the construction of the unit or the electronic circuitry and should be removed. Expelling the heat 48 inside the enclosure helps evaporate any condensation to prevent corrosion.

After exchanging its heat with the freon, the liquid coolant exits the heat exchanger 34 via tube 50 and reenters the coolant control system where it is gated as needed to the sample block during rapid cooling portions of the PCR cycle defined by data entered by the user via terminal 16.

As noted above, the PCR protocol involves incubations at at least two different temperatures and often three different temperatures. A typical PCR cycle is shown in Figure 11 with asdenaturation incubation 170 done at a temperature near 94°C, a hybridization incubation 122 done at a temperature near room temperature (25°C-37°C) and an extension incubation 174 done at a temperature near 50°C. substantially different, therefore means must be provided to move the temperature of These temperatures are and, the reaction mixture of all the samples rapidly from one temperature to another. The ramp cooling system is the means by which the temperature of the sample block 12 is brought down rapidly from the high temperature denaturation the extension incubation temperatures. incubation to lower temperature hybridization and Typically the coolant temperature is in the range from 10-20°C. when the coolant is at 20°C it can pump out about 400 watts of heat from the block. Typically the cooling channel coolant temperature and coolant flow rate are °-6°C per second can be sample ramp dimensions, set such that peak cooling of achieved near the high end of the operating range (100°C) and an average cooling rate of 2.5°C per second is achieved in bringing the sample block temperature down from 94°C to 37°C.

The ramp cooling system, in some embodiments, may also be used to maintain the sample block temperature at or near the target incubation temperature also. However, in the preferred embodiment, small temperature changes of the sample block 12 in the downward direction to maintain target incubation temperature are implemented by the bias cooling system. i As seen in Figure 46, a pump 41 constantly pumps coolant from a filter/reservoir 39 (130 milliliter capacity) via 1/2" pipe and pumps it via a 1/2' pipe to a branching The pump 41 supplies coolant to pipe 45 at a constant flow rate of 1-1.3 gallons per minute. At the intersection 47, a portion of the flow in tube 45 diverted as the constant flow through the bias cooling channels 49. Another portion of the flow in tube 45 is diverted through a flow restrictor 51 to output tube 38.

Flow restrictor 51 maintains sufficient pressure in the intersection 47. system such that a positive pressure exists at the input 53 of a two state solenoid operated valve 55 under the control of the CPU 20 via bus 54. when ramp cooling is desired to implement a rapid downward temperature change, the CPU 20 causes the solenoid operated valve 55 to open to allow flow of coolant through the ramp cooling channels 57. There are 8 ramp cooling channels so the flow rate through each ramp cooling channel is about 1/8 gallon per minute. The flow rate through the bias cooling channels is much less because of the greatly restricted cross-sectional area thereof.

The bias cooling system provides a small constant flow of chilled coolant through bias cooling channels 49 in the sample block 12. This causes a constant, small heat loss from the sample block 12 which is compensated by a multi- zone heater 156 which is thermally coupled to the sample block 12 for incubation segments where the temperature of the sample block is to maintained at a steady value. The constant small heat loss caused by the bias cooling flow allows the control system to implement proportional control both upward and downward in temperature for small temperatures. This means both heating and cooling at controlled, predictable, small rates is available to the temperature servo system to correct for block temperature errors to cause the block temperature to faithfully track a PCR temperature entered by the The alternative would be to cut off power to the film heater and allow the sample block to cool by giving up heat to the profile user. ambient by radiation and convection when the block temperature got too high. This would be too slow and too unpredictable to meet tight temperature control specifications for quantitative PCR cycling.

This multi-zone heater 156 is controlled by the CPU 20 via bus 52 in Figure 1 and is the means’ by which the temperature of the sample block 12 is raised rapidly to higher incubation temperatures from lower incubation temperatures and is the means by which bias cooling is compensated and temperature errors are corrected in the upward direction during temperature tracking and control during incubations.

In alternative embodiments, eliminated or may be supplied by other means such as by the use of a cooling fan and cooling fins formed in the metal of the block, peltier constantly circulating tap water. Care must be taken however in these alternative embodiments to insure that temperature gradients are not created in the sample block which would cause the bias cooling may be junctions or sample temperature of some samples to diverge from the temperature of other samples thereby possibly causing different PCR _ 21 _ amplification results in some sample tubes than in others.

In the embodiment, the proportional to the difference between the block temperature and the coolant temperature.

The CPU 20 controls the temperature of the sample block preferred bias cooling is by sensing the temperature of the metal of the sample block via temperature sensor 21 and bus 52 in Figure 1 and by sensing the temperature of the circulating coolant liquid via bus 54 and a temperature sensor in the coolant control system. The temperature sensor for the coolant is shown at The CPU also senses the internal ambient air temperature within the housing of the system via an ambient air temperature sensor 56 in Figure 1. Further, the CPU 20 senses the line voltage for the input power on line 58 via a sensor symbolized at 63. All these items of data together with items of data entered by the user to define the desired PCR protocol such as target temperatures and times for incubations are used by a control program to be described This control program calculates the amount of power to apply to the various zones of the multi-zone sample block film heater 156 via the bus 52 and generates a coolant control signal to open or close the solenoid operated valve 55 in the coolant control system 24 via bus 54 so as to cause the temperature of the sample block to follow the PCR protocol defined by data entered by the user.

Referring to Figure 2, there is shown a top view of the sample block 12. The purpose of the sample block 12 is to provide a mechanical support and heat exchange element for an array of thin walled sample tubes where heat may be exchanged between the sample liquid in each sample tube and liquid coolant flowing in the bias cooling and ramp cooling channels formed in the sample block 12. Further, it is the function of the sample block 12 to provide this heat function without gradients between various ones of the sample wells such that in Figure 46. in more detail below. exchange creating large temperature -"quantitative" PCR. all sample mixtures in the array experience the same PCR cycle even though they are spatially separated. It is an overall objective of the PCR instrument described herein to provide very tight temperature control over the temperature of the sample liquid for a plurality of samples such that the of appreciably (approximately plus or minus 0.5°C) temperature of any other sample liquid in another well at temperature any sample liquid does not vary from the any point in the PCR cycle.

There is an emerging branch of PCR technology called In this technology, the objective is to by causing the amount of target DNA to exactly double on every perform PCR amplification as precisely as possible cycle. Exact doubling on every cycle is difficult or impossible to achieve but tight temperature control helps.

There are many sources of errors which can cause a failure of a PCR cycle to exactly double the amount of target DNA referring to RNA) during a cycle. (hereafter DNA should be understood as also For example, in some PCR amplifications, the process starts with a single cell of target DNA. this single cell sticks to the wall of the sample tube and An error that can easily occur results when does not amplify in the first several cycles. is the entry of a foreign attacks the All cells have some nonspecific Another type of error into the "foreign" target DNA. nuclease that attacks foreign DNA that is loose in the cell. when this it interferes with the replication process. Thus, if a drop of saliva or a dandruff particle or material from another sample mixture nuclease reaction mixture which happens, or stops were inadvertently to enter a sample mixture, the nuclease materials in these cells could attack the target DNA and It is highly cause an error in the amplification process. desirable to eliminate all such sources cross- contamination.

Another source of error is nonprecise control over _ 23 _ sample mixture temperature as between various ones of a if all the samples are not precisely controlled to have the proper multiplicity of different samples. For example, annealing temperature (a user selected temperature usually in the range from 50 to 60°C) for the extension incubation certain forms of DNA will not extend properly. This happens because the primers used in the extension process anneal to the wrong DNA if the temperature is too low. If the annealing temperature is too high, the primers will not anneal to the target DNA at all. one can easily imagine the consequences of performing the PCR PCR amplification is part of diagnostic testing such as for the amplification process inaccurately when or the presence of A false positive or false negative result in such diagnostic testing presence HIV antibodies, hepatitis, genetic diseases such as sickle cell anemia, etc. can have disastrous and legal personal consequences.

Accordingly, it is an object for the design of the PCR instrument described herein to eliminate as many of these sources of possible errors as possible such as cross- contamination or poor temperature control while providing an instrument which is compatible with the industry standard 96-well microtiter plate The rapidly perform PCR in a flexible manner with a simple user format. instrument must interface.

In the preferred embodiment, the sample block 12 is machined out of a solid block of relatively pure but corrosion resistant aluminum such as the 6061 aluminum alloy. Machining the block structure out of a solid block of structure. thermally homogenous as is necessary to meet the very tight results in a more thermally homogenous Cast aluminum structures tend not to be as aluminum desired temperature control specifications.

Sample block 12 capable of rapid temperature because the thermal mass of the block is kept This is done by the formation in the block of many is changes in low. other some of these holes are used cooling passageways, sample and threaded and unthreaded holes. wells, grooves to attach the block to supports and to attach external devices such as manifolds and spillage trays thereto.

To best appreciate the "honeycomb" nature of the sample block structure, the reader should refer simultaneously to Figure 2 which shows the block in plan view as well as through 8 which strategically located sectional views of the sample block.

Figures 3 show elevation views and For example, Figure 3 is a side elevation view showing the cooling channel positions taken from the vantage point of the view line 3-3' in Figure 2. The elevation view of the sample block 12, looking at the opposite edge, is identical.

Figure 4 is an elevation view of the edge of the sample block 12 from the perspective of view line 4-4' in Figure 2.

Figure 5 is an elevation view of the end of the sample block 12 taken from the perspective of view line 5-5‘ in Figure 2.

Figure 6 is a sectional view of -ae sample block 12 taken along the section line 6-6' in Figure 2. Figure 7 is a sectional view of the sample block 12 taken along section line 7-7' in Figure 2. sample block 12 taken along section line 8-8' in Figure 2.

The top surface of the sample block 12 is drilled with Figure 8 is a sectional view of the an 8 x 12 array of conical sample wells of which wells 66 The conical configuration of each The walls of each to match the This is and 68 are typical. sample well is best seen if Figure 8. sample well are drilled at an angle of 17' angle of the conical section of each sample tube. done by drilling a pilot hole having the diameter D_ in Then a 17° conical walls 67.

The bottom of each sample well includes a sump 70 which Figure 8. countersink is used to form the has a depth which exceeds the depth of penetration of the tip of the sample tube. hole and provides a small open space beneath the sample tube The sump 70 is created by the pilot when the sample tube is seated in the corresponding sample - 25 _ well. This condensation that forms on the well walls to reside without interfering with the tight fit of each sample tube to the walls of the sample well. This tight fit is necessary to insure that the thermal conductance from the well wall to sump provides a space for liquid such as the sample liquid is uniform and high for each sample tube.

Any contamination in a well which causes a loose fit for one tube will destroy this uniformity of thermal conductance across the array. That is, because liquid is substantially uncompressible at the pressures involved in seating the sample tubes in the sample wells, if there were no sump 70, the presence of liquid in the bottom of the sample well could prevent a sample tube from fully seating in its sample well. gaseous phase of any liquid residing in the sump 70 can Furthermore, the sump 70 provides a space in which a expand during high temperature incubations such that large forces of such expansion which would be present if there were no sump 70 are not applied to the sample tube to push the tube out of flush contact with the sample well.

It has been found experimentally that it is important for each sample tube to be in flush contact with its corresponding sample well and that a threshold force be applied to each sample tube to keep the thermal conductivity between the walls of the sample well This certain minimum and the reaction mixture uniform throughout the array. minimum threshold seating force is shown as the force vector P in Figure 15 and is a key factor in preventing the thermal conductivity through the walls of one sample tube from being different than the thermal conductivity through the walls of The minimum threshold seating force F is 30 grams and the another sample tube located elsewhere in the block. preferred force level is between 50 and 100 grams.

The array of sample wells is substantially completely surrounded by a groove 78, best seen in Figures 2, 6 and 8, which has two functions. The main function is to reduce the thermal conductivity from the central area of the sample - 25 _ block to the edge of the block. The groove 78 extends about 2/3 through the thickness of the sample block. the effects caused by the necessary mechanical connections to the block This groove minimizes of unavoidable thermal gradients of the support pins, manifolds, etc. A secondary function is to remove thermal mass from the sample block 12 so as to allow the temperature of the sample block 12 to be altered more rapidly and to simulate a row of wells in the edge region called the "guard band". The amount of metal removed by the portion of the groove 78 between points 80 and 82 in Figure 2 is designed to be substantially equal to the amount of metal removed by the adjacent column of eight sample wells 83 through 90. thermal mass of the guard band to the thermal mass of the The purpose of this is to match the adjacent "local zone", a term which will be explained more fully below.

Referring specifically to Figures 3, 6 and 8, there is shown the number and relative positions of the various bias cooling and ramp cooling channels which are formed in the metal of the sample block 12. channels marked with reference numerals 91 through 99.

There are nine bias cooling Likewise, there are eight ramp cooling channels marked with reference numerals 100 through 107.

Each of these bias cooling and ramp cooling channels is gun drilled through the aluminum of the sample block. The gun drilling process is well known and provides the ability to drill a long, very straight hole which is as close as possible to the bottom surface 110 of the sample block 12. since the gun drilling process drills a straight hole, this process is preferred so as to prevent any of the bias cooling or ramp cooling channels from straying during the drilling process and penetrating the bottom surface 110 of the sample block or otherwise altering its position relative to the other cooling channels. Such mispositioning could cause undesirable temperature gradients by upsetting the and of the local zones. "local balance" "local symmetry" These concepts are explained below, but for now the reader should understand that these notions and the structures which implement them are key to achieving rapid temperature cycling of up to 96 samples without creating excessive temperature errors as between different sample wells.

The bias cooling channels 91 through 99 are lined with silicone rubber in the preferred embodiment to reduce the thermal conductivity across the wall of the bias cooling channel. Lowering of the thermal conductivity across the channel wall in the bias cooling channels is preferred so as to prevent too rapid of a change in temperature of the sample block 12 when the multi-zone heater 156 is turned off and heat loss from the sample block 12 is primarily through This is the situation during the control out the block temperature has strayed slightly above the desired target incubation temperature and the control system is attempting the bias cooling channels. process carried when sample to bring the sample block temperature back down to the user's specified incubation temperature. Too fast a cooling rate in this situation could cause overshoot of the desired incubation temperature before the control system's servo feedback loop can respond although a "controlled overshoot" algorithm is used as will be described below. since the block temperature servo feedback loop has a time constant for reacting to stimuli, it is desirable to control the amount of heating and cooling and the resulting rate of temperature change of the sample block such that overshoot is minimized by not changing the sample block temperature at a rate faster than the control system can respond to temperature errors.

In the preferred embodiment, the bias cooling channels are 4 millimeters in diameter, and the silicone rubber tube has a one millimeter inside diameter and a 1.5 millimeter wall thickness. This provides a bias cooling rate of approximately o.2°c per second when the block is at the high near 100°C, and a bias end of the operating range, i.e., V the sample block 12 with a gasket material cooling rate of approximately 0.l°C per second when the sample block 12 is at a temperature in the lower end of the operating range. The coolant control system 24 in Figure 1 causes a flow rate for coolant in the bias cooling channels of approximately 1/20th to 1/30th of the flow rate for coolant through the ramp cooling channels, 100 The bias cooling and ramp cooling channels are and extend liquid through 107. the same size, i.e., 4 millimeters in diameter, completely through the sample block 12.

The bias cooling channels are lined by inserting a -stiff wire with a hook at the end thereof through the bias cooling channel and hooking it through a hole in the end of a silicone rubber tube which has an outside diameter which is slightly greater than 4 millimeters. The hook in the ' wire is then placed through the hole in the silicone rubber tube, and the silicone tube is pulled through the bias cooling channel and cut off flush with the end surfaces of the sample block 12.

Threaded holes 108 through 114 are used to belt a coolant manifold to each side of the sample block 12.

There is a coolant manifold bolted to each end of the block.

These two coolant manifolds are coupled to the coolant 28, and are affixed to channels 25, 30 and 32 in Figure 1, (not shown) interposed between the manifold and the sample block metal.

This gasket prevents leaks of coolant and limits the thermal conductivity between the sample block 12 and the manifold which represents a heat sink.

Any gasket material which serves the above stated purposes will suffice for practicing the invention.

The positions of the bias cooling and ramp cooling channels relative to the position of the groove 78 are best seen in the sectional view of Figure 6. The the bias cooling and ramp cooling channels relative to the positions of The generally positions of the sample wells is best seen in Figure 8. bias and cooling channels are interposed between the positions of the tips of the sample Further, Figure 8 reveals that the bias cooling and cooling ramp wells. ramp cooling channels such as channels 106 and 97 cannot be moved in the positive z direction very far without risking penetration of the walls of one or more sample wells.

Likewise, the cooling channels cannot be moved in the negative 2 direction very far without creating the possibility of penetrating the bottom surface 116 of the sample block 12. For clarity, the positions of the bias and ramp cooling channels are not shown in hidden lines in Figure 2 relative to the positions of the sample wells and other structures. However, there is either a bias cooling channel or a ramp cooling channel between every column of sample wells.

Referring to Figure 2, the holes 118, 119, 120 and 121 are threaded and are used to attach the sample block 12 to machinery used to machine the various holes and grooves formed therein. In Figures 2, 4 and 5, the holes 124, 125, 126 and 127 are used to attach the sample block 12 to a support bracket shown in Figure 9 to be described in more detail below. Steel bolts extend through this support bracket into the threaded holes 124 through 127 to provide mechanical support of the sample block 12. These steel bolts also represent heat sinks or heat sources which tend to add thermal mass to the sample block 12 and provide additional pathways for transfer of thermal energy between These support pins and the manifolds are two important factors in creating the need for the guard bands to prevent the thermal the sample block 12 and the surrounding environment. energy transferred back and forth to these peripheral structures from affecting these sample temperatures.

Referring to Figure 5, the holes 128, 130 and 132 are mounting holes for an integrated circuit temperature sensor (not shown) which is inserted into the sample block through hole 128 and secured thereto by bolts which fasten to threaded holes 130 and 132. The extent of penetration of the hole 128 and the relative position of the temperature sensor to the groove 78 and the adjacent column of sample wells is best seen in Figure 2.

Referring to Figure 2, holes 134 through 143 are mounting holes which are used to mount a spill collar 147 (not shown). This spill collar 147 is shown in Figure 19 detailing the structure of the heated platen 14, sliding cover 316 and lead screw assembly 312. The purpose of the .spill collar is to prevent any liquid spilled from the sample tubes from getting inside the instrument casing where it could cause corrosion.

Referring to Figure 9, there is shown in cross-section a view of the support system and multi-zone heater 156 configuration ‘or the sample block 12. The sample block 12 is supported. by four bolts of which bolt 146 is typical.

These four bolts pass through upright members of a steel support bracket 148. Two large coil springs ..O and 152 are compressed between a horizontal portion of the support bracket 148 and a steel pressure plate 154. The springs 150 and 152 are compressed sufficiently to supply approximately 300 lbs. per direction acting to compress a film heater 156 to the bottom This three layer film square inch of force in the positive 2 surface 116 of the sample block 12. heater structure is comprised of a multi-zone film heater 156, a silicone rubber pad 158 and a layer of epoxy resin foam 160. In the preferred embodiment the film heater 156 has three separately controllable zones. film heater 156 is to supply heat to the sample block 12 under the control of the CPU 20 in Figure 1. The purpose of the rubber pad 158 lower the thermal conductivity from the film heater 156 to the These lower structures serve as heat The purpose of the silicone is to layer structures below. sinks and heat sources between which undesired heat energy may be transferred to and from the sample block 12. The ‘ temperature silicone rubber pad 158 has the additional function of compensating for surface irregularities in the film heater 156 since some film heaters embody nichrome wires and may not be not perfectly flat.

The purpose of the steel plate 154 and the epoxy resin foam 160 is to transfer the force from the springs 150 and 152 to the silicone rubber pad 158 and the multi-zone film heater 156 so as to compress the film heater to the bottom surface 116 of the sample block with as flush a fit as possible. The epoxy resin foam should be stiff so as to not be crushed under the force of the springs but it should also be a good insulator and should have low thermal mass, i.e., it In embodiment, manufactured should be a nondense structure. one the foam 160 is under the trademark ECKO foam. In alternative embodiments, other structures may be substituted for the silicone rubber layer 158 and/or the epoxy resin foam layer 160. For example, a stiff honeycomb structure such as is used in airplane construction could be placed between the pressure plate 154 and the film heater 156 with insulating layers therebetween.

Whatever structure is used for layers 158 and 160 should not absorb substantial amounts of heat from the sample block 12 while the block is being heated and should not transfer substantial amounts of heat to the sample block 12 when the block is being cooled. Perfect isolation of the block from its surrounding structures however, is virtually impossible. effort should be structures that will be in contact with the sample block 12 Every made in designing alternative so as to thermally isolate the sample block from environment as much as possible to minimize the thermal mass of the block and enable rapid temperature changes of the sample block and the sample mixtures stored therein. temperature control of the block achieved by the CPU 20 1 by controlling the amount of heat applied to the sample block Precise sample is in Figure The film heater is driven using a modified form of pulse width by the multi-zone film heater 156 in Figure 9.

First, the 120 volt waveform from the power line is rectified to preserve only half cycles of the same modulation. polarity. Then portions of each half cycle are gated to the appropriate zones of the foil heater, with the percentage of each half cycle which is applied to the various zones of the foil heater being controlled by the CPU 20.

Figure 10 illustrates one embodiment of a power control concept for the film heater 156. Figure 10 is a diagram of the of the supply Rectification to eliminate the negative half cycle 162 voltage waveform line voltage. occurs. Only positive half cycles remain of which half cycle 164 The CPU 20 and its associated peripheral electronic circuitry than controls the portion of each half cycle which is applied to the various zones of the is typical. film heater 156 by selecting a portion of each half cycle to apply according to a power level computed for each zone That is, the dividing line 166 is moved forward or backward along the based upon equations given below for each zone. time axis to control the amount of power to the film heater based upon a number of factors which are related in a special equation for each zone. The cross-hatched area under the positive half cycle 164 represents the amount of power applied to the film heater 156 for the illustrated position of the dividing line 166. As the dividing line 166 is moved to the right, more power is applied to the film heater, and the sample block 12 gets hotter. As the dividing line is moved to the left along the time axis, the cross-hatched area becomes smaller and less power is applied to the film heater. How the CPU 20 and software and peripheral circuitry control the temperature of its associated block 12 will be described in more detail below.

The amount of power supplied to the film heater is continuously variable from 0 to 600 watts. In alternative embodiments, the amount of power supplied to the film heater can be controlled using other schemes such as computer control over the current flow through or voltage applied to a DC film heater or by the zero crossing switching scheme described below.

In other embodiments, heating control of the sample block 12 may be performed by control over the flow rate and/or temperature of hot gases or hot liquid which is gated through heating control channels which are formed through the metal of the sample block 12. in such alternative embodiments, the number of sample wells in the block would have to be reduced since there is no room for Of course additional heating channels in the sample block 12 shown in Figures 2 through 8. Such alternative embodiments could still be compatible with the 96-well microtiter plate format if, for example, every other well were removed to make room for a heating channel in the sample block. This would provide compatibility only as to the dimensions of such microtiter plates and not as to the simultaneous processing of 96 different samples. Care must be taken to preserve local balance and local symmetry in these alternative embodiments.

In the embodiment described herein, the maximum power that can be delivered to the block via the film heater is watts. This limitation arises from the thermal conductivity of the block/heater interface. It has been found experimentally that the supply of more than approximately 1100 watts to the film heater 156 will frequently cause self-destruction of the device.

Typical power for heating or cooling when controlling block temperatures at or near target incubation temperatures is in the range of plus or minus so watts.

Referring to Figure 11, temperature plot of a typical PCR protocol. there is shown a time versus Large downward changes in block temperature are accomplished by gating chilled liquid coolant through the ramp cooling channels while monitoring the sample block temperature by the Typically these rapid downward temperature changes are carried out during the ramp following the denaturation incubation 170 to the temperature Typically, the user must temperature sensor 21 in Figure 1. of hybridization incubation 172. specify the protocol by defining the temperatures and times in one fashion or another so as to describe to the CPU 20 the positions on the temperature/time plane of the checkpoints symbolized by the circled intersections between the ramp legs and the incubation legs. Generally, the incubation legs are marked with reference numerals 170, 172 ‘and 174 and the ramps are marked with reference numerals , Generally the incubation intervals are conducted but embodiments, they may be stepped or continuously ramped to different temperatures within a range of temperatures which is acceptable for performing the particular portion of the PCR cycle involved. That is, the denaturation incubation 170 need not be carried out at one temperature as shown in and l80. at a in alternative single temperature, Figure 11, but may be carried out at any of a plurality of different temperatures within the range of temperatures acceptable for denaturation. In some embodiments, the user may specify the length of the ramp segments 176, 178 and 180. In other embodiments, the user may only specify the temperature or temperatures and duration of each incubation interval, and the instrument will then move the temperature of the block rapidly as possible between incubation temperatures the of incubation and the start of another. In the preferred the user can also have temperatures and/or sample as upon completion one embodiment, incubation times which are different for each cycle or which automatically increment on every cycle.

The average power of ramp cooling during a transition from a 95°C denaturation incubation to a 35'C hybridization incubation is more than one kilowatt typically. This results in a temperature change for the sample block of approximately 4-6°C per second when the block temperature is at the high end of the operating range, and approximately 2°C per second when the block temperature is at the low end of the operating range. Generally it is desirable to have as high a cooling rate as possible for ramp cooling.

Because so much heat is being removed from the sample block during ramp cooling, temperature gradients across the sample block from one end of a ramp cooling channel to the To prevent this and minimize these types the ramp cooling channels are That in Figure 3, the other could occur. of temperature gradients, is, directionally interlaced. -direction of coolant flow through ramp cooling channels 100, l02, 104, and 106 is into the page as symbolized by the x's inside these ramp cooling channel holes. Ramp cooling liquid flow in interlaced ramp cooling channels 101, 103, 105, and 107 is out of the page as symbolized by the single points in the center of these ramp cooling channel holes.

This interlacing plus the high flow rate through the ramp cooling channels minimizes any temperature gradients which might otherwise occur using noninterlaced flow patterns or lower flow rates because the distances between the hot and cold ends of the channels is made smaller. A slower flow rate results in most or all of the heat being taken from the block in the first inch or so of travel which means that the input side of the block will be at a lower temperature than the output side of the block. A high flow rate minimizes the temperature gradient along the channel. means the hot end of the channels running in one direction Interlacing are "sandwiched" between the cold ends of channels wherein flow is in the opposite direction. This is a smaller distance than the length of the channel. gradients are reduced because the distances heat must travel This Thus, temperature to eliminate the temperature gradient are reduced. causes any temperature gradients that form because of cooling in the ramp channels to be quickly eliminated before they have time to differentially heat some samples and not others. without interlacing, one side of the sample block -36.. would be approximately 1°C hotter than the other side.

Interlacing results in dissipation of any temperature gradients that result in less than approximately 15 seconds.

In order to accurately estimate the amount heat added to or removed from the block, the CPU 20 measures the block temperature using temperature sensor 21 in Figure 1 and measures the coolant temperature by way of temperature sensor 61 in Figure 46 coupled to bus 54 in Figure 1. The ambient measured by way of and the air temperature is also temperature sensor 56 in Figure 1, power line which controls the power applied to the film heaters on 52, is The thermal conductance from the sample block to ambient and from the sample block to the coolant are known to the CPU 20 as a result of measurements made during an initialization process voltage, bus also measured. to set control parameters of the system.

For the population, the block, at constant temperature, can have no good temperature uniformity of sample net heat flow in or out. However, temperature gradients can occur within the sample block arising from local flows of heat from hot spots to cold spots which have zero net heat transfer relative to the block borders. For instance, a slab of material which is heated at one end and cooled at the other is at a constant average temperature if the net in this zero. However, heat flow into the‘ block is situation a significant temperature nonuniformity, i.e., a temperature gradient, can be established within the slab due to the flow of heat from the hot edge to the cold edge.

When heating and cooling of the edges of the block are stopped, the flow of heat from the hot edge to the cold edge eventually dissipates this temperature gradient and the block reaches a uniform temperature throughout which is the average between the hot temperature and cool temperature at the beginning of heat flow.

If a slab of cross sectional area A in length L has a held at uniform thermal conductivity K, and the slab is -37.. constant average temperature because heat influx from a heat source Q” is matched by heat outflow to a heat sink Qwt the steady state temperature profile which results from the heat flow is: (1) Delta T Where, , Delta T L = the A = the K = the In general, the temperature gradient thermal path length area of the thermal path thermal conductance through the path within any material of uniform thermal conductance, the temperature gradient will be established in Heat flow and intimately linked. proportion to the heat flow per unit area. temperature nonuniformity are thus Practically speaking, it is not possible to control the temperature of a sample block without some heat flow in and out. The cold bias control cooling requires some heat flow in from the strip heaters to balance the heat removed by the cooling channels to The key to a uniform sample block temperature under these conditions coolant flowing through the bias maintain the block temperature at a stable value. is a geometry which has "local balance" and "local symmetry" of heat and heat sinks both dynamically, and which is arranged such that any heat flow sources statically and from hot spots to cold spots occurs only over a short distance.

Stated briefly, the concept of "static local balance" means that in a block at constant temperature where the the heat sources and heat sinks are arranged such that within a total heat input equals the total heat output, distinct local region, all heat sources are completely balanced by heat sinks in terms of heat flows in and heat flows out of the block. if isolated, would be maintained at a constant temperature.

Therefore, each local region, ’ means that, the The concept of "static local symmetry" within a local region and for a constant temperature, center of mass of heat sources is coincident with the center of mass of heat sinks. If this were not the case, within each local region, a temperature gradient across each local region can exist which can add to a temperature gradient in an adjacent local region thereby causing a gradient across the sample block which is twice as large as the size of a single local region because of lack of local symmetry even though local balance within each local region exists. The -concepts of local balance and local symmetry are important to the achievement of a static temperature balance where the temperature of the sample block is being maintained at a constant level during, for example, an incubation interval.

For the dynamic case where rapid temperature changes in or heat the sample block are occurring, the thermal mass, capacity of each local region becomes important. This is because the amount of heat that must flow into each local region to change its temperature is proportional to the thermal mass of that region.

Therefore, the concept of static local balance can be expanded to the dynamic case by requiring that if a local region includes x percent of the total dynamic heat source and heat sink, it must also include x percent of the thermal mass for "dynamic local balance" to exist. Likewise, "dynamic local symmetry" requires that the center of mass of heat capacity be coincident with the center of mass of dynamic heat sources and sinks. Vhat this means in simple terms is that the thermal mass of the sample block is the metal thereof, and the machining of the sample block must be symmetrical and balanced such that the total mass of metal Further, the center of mass of the metal in each local zone should be coincident within each local zone is the same. with the center of mass of the dynamic heat sources and sinks. Thus, 156, i.e., its geometric center, and the geometric center of the center of mass of the multi-zone heater the bias and ramp cooling channels must coincide. From a study of Figures 2-9, it will be seen from the detailed discussion below that both static and dynamic local balance and local symmetry exist in sample block 12.

Figure 12 illustrates two local regions side by side for the design of the sample block 12 according to the teachings of the invention. In Figure 12, the boundaries of 200 and 202, Figure 12 shows that each local region two columns two local regions, are marked by dashed lines 204, 206 and 208. which is not in the guard band is comprised of: of sample wells; a portion of the foil heater 156 which turns out to be 1/8th of the total area of the heater; one ramp cooling channel such as ramp cooling channels 210 and 212; symmetry, each local region is centered on its ramp cooling and, one bias cooling channel. To preserve local channel and has one-half on a bias cooling channel at each boundary. Fo; example, local region 200 has a center over the ramp cooling channel 210 and bias cooling channels 214 and 216 are dissected by the local region boundaries 204 and 206, Thus the center of mass of the ramp cooling (the middle thereof), (horizontally) with the center of mass of the bias cooling channels and with the center of mass of the film heater portion coupled to each local region. static local balance will exist in each local region when the CPU 20 is driving the film heater 156 to input an amount of heat energy that is equal to the amount of heat energy that is being removed by the ramp cooling and Dynamic local balance for each local respectively. channel coincides (the center of the local region) bias cooling channels. region exists because each local region in the center portion of the block where the 96 sample mixtures reside contains approximately 1/Bth the total thermal mass of the entire sample block, contains 1/8th of the total number of ramp cooling channels and contains 1/8th of the total number of bias cooling channels. Dynamic local symmetry exists for each local region, because the center of mass of the metal -40.. of each local region is horizontally coincident with: the center of film heater portion underlying the local region; the center of the ramp cooling channel; and, the center of mass of the two half bias cooling channels.

By virtue of these physical properties characterized as static and dynamic local balance and local symmetry, the sample block heats and cools all samples in the population much more uniformly than prior art thermal cyclers.

Referring to Figure 2, the plan view of the boundaries of the local regions are illustrated by dashed lines 217 through 225. central region of the 96 sample wells are divided into six Inspection of Figure 2 reveals that the adjacent local regions bounded by boundaries 218 through 224. are added at each edge.

In addition, two guard band local regions The edge local region (local regions are sometimes herein also called local zones) having the most negative x :oordinate is bounded by boundary lines 217 and 218. coordinate is bounded by boundary lines 224 and 225.

The edge local region having the most positive x Note that the edge local regions contain no sample well columns but do contain the groove 78 simulating a column of wells.

The depth and width of the groove 78 is designed to remove the same metal mass as a column of wells thereby somewhat The edge local zones are different in thermal mass (they have additional thermal by of the connections such as manifolds and support pins) than the six This difference is accounted for by heating the edge local zones preserving dynamic local symmetry. therefore also mass virtue external local zones in the central part of the sample block. or guard bands with separately controllable zones of said multizone heater so that more energy may be put into the guard band than the central zone of the block.

The local at of the block approximate, but do not exactly match the thermal properties The edge local they regions each edge of the six centrally located local regions. regions are called “guard band" regions because -41... complete a guard band which runs around the periphery of the sample block 12. The purpose of this guard band is to provide some thermal isolation of the central portion of the block the 96 wells uncontrolled heat sinks and sources inherently embodied in to the block by such things sample containing sample from mechanical connections as support pins, manifolds, drip collars and other devices which must be mechanically affixed to the sample block 12.

For example in Figure 2, the edge surfaces 228 and 230 of the sample block have plastic manifolds attached thereto which carry coolant to and from the ramp and bias cooling passages. The guard band along edges 228 and 230 consists of portions of the slot 78 which are parallel to and closest to the edges 228 and 230. The depth of the groove 78 is such that the bottom of the groove is as close to the perimeters of the bias and ramp cooling channels as is possible without actually intersecting them. The width of the groove 78 coupled with this depth is such that the volume of metal removed by the slot 78 between points 82 and 232 in Figure 2 approximately equals the volume of metal removed by the adjacent row of sample wells starting with Also, the slot 78 all around the perimeter of the block is located sample well 234 and ending with sample well 83. approximately where such an additional row of wells would be if the periodic pattern of sample wells were extended by one row or column of wells in each direction.

Along the 250 252 connections are made to the sample block, local regions contain, in addition to a portion of the slot Referring where the the guard band edges and support , the full length of several cooling channels. to Figure 3, these include: 1/2 of a bias cooling channel (e.g., 92) which merges with the adjacent 1/2 bias cooling channel of the adjacent local region to form a whole bias cooling channel; a ramp cooling channel (e.g., 100); and a 91). For the edge local region at edge 250, these cooling channels are 107, 198 and whole bias cooling channel (e.g., 99.

The whole bias cooling channels in the guard bands are The reason that these whole bias cooling channels are used is slightly displaced inward from the edge of the block. because a "half" cooling channel is impractical to build.

Since the bias cooling channels require such a thick walled rubber lining, it would be difficult to keep a hole through "half" This asymmetry in the edge local regions causes a small a lining of a bias cooling channel reliably open. excess loss of heat to the coolant from the edge guard band local regions, but it is sufficiently remote from the central region of the sample block containing the sample that to nonuniformities is small. contribution Also, affects of this small asymmetry are predictable, the effect wells its sample temperature since the temperature can be further minimized by the use of a separately controllable zone of the multi-zone heater system under each guard band. there shown three Referring to 13, separately controlled zones within the film heater layer 156 Figure are in Figure 9. These separately controlled zones include edge heater zones which are situated under the guard bands at the exposed edges of the sample block 12 which are coupled to the controlled manifold heater zones situated under the guard bands for the edges 228 and 230 which are attached to the support bracket. 148. There are also separately coolant manifolds. Finally, there is a central heater zone that underlies the sample wells. The power applied to each of these zones is separately controlled by the CPU 20 and the control software.

The film heater 156 electrical conductors formed by etching a thin sheet of is composed of a pattern of metal alloy such as Inconel'. The metal alloy selected should have high electrical resistance and good resistance to heat. The pattern of conductors so etched is bonded between thin sheets of an electrically insulating polymeric _ 43 - Whatever material is used to the material such as Kapton'. insulate the electrical resistance heating element, material must be resistant to high temperatures, have a high dielectric strength and good mechanical stability.

The 254 of the film heater approximately the same dimensions as the central portion of Central region 254 central has zone the sample block inside the guard bands. delivers a uniform power density to the sample well area.

Edge heater regions 256 and 258 are about as wide as the edge guard bands but are not quite as long.

Manifold heater regions 260 and 262 underlie the guard bands for edges 228 and 230 in Figure 2.

The manifold heater zones 260 and 262 are electrically connected together to form one separately controllable heater zone. Also, the edge heater sections 256 and 258 are electrically coupled together to form a second separately The third separately controllable Each of these three separately controllable heater zones has separate electrical controllable heater zone. heater zone is the central section 254. leads, and each zone is controlled by a separate control algorithm which may be run on separate microprocessors or a shared CPU as is done in the preferred embodiment. zones 256 and 258 are driven to compensate for heat lost to the support brackets. This heat loss is proportional to the temperature difference between the sample block 12 and the ambient air surrounding it. The edge heater zones 256 and 258 also compensate for the excess loss of heat from the sample block to the full bias cooling This heat loss is The edge heater channels at each edge of the block. proportional to the temperature difference between the sample block 12 and the coolant flowing through these bias cooling channels.

The manifold heater sections 260 and 262 are also driven so as to compensate for heat lost to the plastic coolant manifolds 266 and 268 attached to the edges of the sample block 12. in Figure 13 which are The power for - 44 _ the manifold heater sections 260 and 262 compensates for heat loss which is proportional mainly to the temperature difference between the sample block and the coolant, and to a lesser degree, between the sample block and the ambient air.

For practical reasons, it is not possible to match the thermal mass of the guard band local regions with the thermal masses of the local regions which include the sample wells overlying central heater section 254. For example, the plastic coolant manifolds 266 and 268 not only conduct _heat away from the guard band, but they also add a certain amount of thermal mass to the guard band local regions to which they are attached. The result of this is that during rapid block temperature changes, the rates of rise and fall of guard band temperature do not exactly match that of the This temperature gradient between the guard bands and sample sample well local regions. generates a dynamic wells, which if allowed to become large, could persist for a time which is longer than is tolerable. This temperature gradient effect is roughly proportional to the rate of change of block temperature and is minimized by adding or deleting heat from each guard band local zone at a rate which temperature.

The coefficients of proportionality for the guard band is proportional to the rate of change of block zone heaters are relatively stable properties of the design of the system, and are determined by engineering measurements on prototypes. The values for these coefficients of proportionality are given below in connection with the definitions of the terms of Equations (3) through (5). These equations define the amounts of power to be applied to the manifold heater zone, the edge heater zone and the central zone, respectively in an alternative embodiment. The equations used in the preferred embodiment are in the description of the software (Equations (46)-(48), power distributed by area). given below where, P *».

BL! AH! L dtm/dt PE = ATP + 3%1VTu: P. = Am P + Kl\1(TlLK K112 (TILK - Tue) ' Team) + Kfl(dt|LK/dt) power supplied to the manifold heater zones 260 and 262. area of the manifold heater zone. power needed to cause the block temperature to stay at or move to the desired temperature at any particular time in a PCR thermal cycle protocol. of proportionality to compensate for excess heat loss to ambient through the manifolds, equal to 0 watts/ degree Kelvin. an experimentally determined constant of proportionality to compensate for excess heat to the equal to 0.4 watts/degree Kelvin. an experimentally determined constant loss coolant, of proportionality to provide extra power to an experimentally determined constant compensate for additional thermal mass of the manifold edge guard bands caused by the attachment of the plastic manifolds etc., equal to 66.6 watt-seconds/degree Kelvin. the the the the unit time. temperature of the sample block 12. temperature of the ambient air. temperature of the coolant. change in sample block temperature per ' Tm) + K52 (TILK ' Tcaou) * Ks: (dtm/‘-‘"5’ power to be applied to the edge heater zones the area of the edge heater zones an experimentally determined constant of proportionality to compensate for excess heat loss to ambient through the manifolds, equal to 0.5 watts/degree Kelvin.

Kn = an experimentally determined constant of proportionality to compensate for excess heat loss to the coolant, equal to 0.15 watts/degree Kelvin.

Kn = an experimentally determined constant of proportionality to provide extra power to compensate for additional thermal mass of the exposed edge guard bands caused by the attachment of the sample block 12 to the support pins and bracket, the temperature sensor etc., equal to 15.4 watt-sec/degree Kelvin. (5) PC = A: P where PC = the power to be applied to the central zone 254 of the multi-zone heater.

A = the area of the central zone 254.

In each of Equations (3) through (5), P is a variable which is calculated by the portion of the the power term, control algorithm run by the CPU 20 in Figure 1 which reads the user defined setpoints and determines what to do next to cause the sample block temperature to stay at or become the proper temperature to implement the PCR temperature protocol defined by the time and temperature setpoints stored in memory by the user. The manner in which the setpoints are read and the power density is calculated will be described in more detail below.

The control algorithm run by CPU 20 of Figure 1 senses the temperature of the sample block via temperature sensor 21 in Figure 1 and Figure 9 and bus 52 in Figure 1. This temperature is differentiated to derive the rate of change of temperature of the sample block 12. The CPU then measures the temperature of the ambient air via temperature sensor 56 in Figure 1 and measures the temperature of the coolant via the temperature sensor 61 in the coolant control system 24 shown in Figure 46. The CPU 20 then computes the power factor corresponding to the particular segment of the PCR protocol being implemented and makes three calculations in accordance with Equations (3), (4) and (5) by plugging in all the the constants of proportionality (which are stored in nonvolatile memory), the power factor P for that particular iteration of the measured temperatures , control program and the areas of the various heater zones (which are stored in nonvolatile memory). The power factor is the total power needed to move the block temperature from its current level to the temperature level specified by the user via a setpoint. More details on the calculations performed by the CPU to control heating and cooling are given below in the description of the control software "PID task".

After the required power to be applied to each of the three of the heater 156 calculation is made regarding the proportion of each half zones is calculated, another cycle of input power which is to be applied to each zone in some embodiments. In the preferred embodiment described below, the calculation mode is how many half cycles of the total number of half cycles which occur during a 200 millisecond sample period are to be applied to each zone.

This process is described below in connection with the discussion of Figures 47A and 47B (hereafter referred to as Figure 47) and the 'PID Task" of the control software. In the alternative embodiment symbolized by Figure 10, the computer calculates for each zone, the position of the dividing line 166 in Figure 10. After this calculation is performed, appropriate control signals are generated to cause the power supplies for the multi-zone heater 156 to do the appropriate switching to cause the calculated amount of _ 43 _ power for each zone to be applied thereto.

In alternative embodiments, the multi-zone heater can be implemented using a single film heater which delivers uniform power density to the entire sample block, plus one or two additional film heaters with only one zone apiece for the guard bands. These additional heaters are superimposed over the single film heater that covers the entire sample block. make up the guard band losses is delivered to the additional In such an embodiment, only the power necessary to heater zones. (3) through (5) is calculated by the CPU 20 for various points on the PCR temperature protocol based upon the set points and ramp a limitation is The power factor P in Equations times specified by the user. However, imposed based upon the maximum power delivery capability of the zone heater mentioned above.

The of proportionality in Equations (3) through (5) must be properly set to adequately compensate heat in the guard band for temperature uniformity. constants for excess losses good Referring to Figure 17, there is shown a graph of the differences between calculated sample temperatures for a plurality of different sample in response to a step change in block temperature to raise the temperature of the sample block toward a denaturation incubation target temperature of approximately 94°C from a substantially lower temperature.

Figure 17 illustrates the calculated sample liquid temperatures when the multi-zone heater 156 is properly managed using the constants of proportionality given above in the definitions of the terms for Equations (3) through (5). of Figure 17 are indicated thereon by a single letter and The various wells which were used to derive the graph number combination. The 8 x 12 well array showing Figure 2 Thus, example, sample well 90 is also designated sample well A12, is coded by lettered columns and numbered rows. for while sample well 89 is also designated sample well B12.

Likewise, sample well 68 is also designated sample well D6, Note that the well temperatures settle in asymptotically at approximately O.5°C of each other because of the overall and so on. temperatures which are within thermal design described herein to eliminate temperature gradients.

The foregoing description illustrates how the sample block temperature may be controlled to be uniform and to be quickly changeable. in the PCR process, it is the temperature of the sample reaction mixture and not the block In the preferred However, temperature that is to be programmed. embodiment according to the teachings of the invention, the user specifies a sequence of target temperatures fig;_;ng sample liquid itself and specifies the ingypgtign time: for for each stage in the PCR process. The CPU 20 then manages the sample 919;; temperature so as to get the sample reaction mixtures to the specified target incubation temperatures and to hold the sample mixtures at these target temperatures for the specified incubation times. The user interface code run by the CPU 20 displays, at all stages of this process, the current calculated sample liquid temperature on the display of terminal 16.

The difficulty with displaying an actual measured sample temperature is that to measure the actual temperature of the reaction mixture requires insertion of a temperature measuring probe therein. The thermal mass of the probe can significantly alter the temperature of any well in which it placed the reaction mixture in particular well is often only 100 microliters in volume.

Thus, reaction mixture can cause a temperature gradient to exist is since sample any the mere insertion of a temperature probe into a between that reaction mixture and neighboring mixtures.

Since the extra thermal mass of the temperature sensor would cause the reaction mixture in which it is immersed to lag behind in temperature from the temperatures of the reaction mixtures in other wells that have less thermal mass, errors can result in the amplification simply by attempting to measure the temperature.

Accordingly, the instrument described herein calculates the sample temperature from known factors such as the block temperature history and the thermal time constant of the system and displays this sample temperature on the display.

It has been found experimentally for the system described herein that if the sample tubes are pressed down into the sample wells with at least a minimum threshold force F, then for the size and shape of the sample tubes used in the preferred embodiment and the sample volumes of approximately 100 microliters, thermally driven convection occurs within the sample reaction mixture and the system acts thermally like a single time constant, linear system. Experiments have shown that each sample tube must be pushed down with approximately 50 grams of force for good well-wall-to-liquid thermal conductivity from well to well. The heated platen design described below is designed to push down on each sample tube with about 100 grams of force. This minimum symbolized by force vector F in Figure 15, necessary to insure that regardless of slight differences in force, is external dimensions as between various sample tubes and various sample wells in the sample block, they all will be pushed down with sufficient force to guarantee the snug and flush fit for each tube to guarantee uniform thermal conductivity. Any design which has some sample tubes with loose tits in their corresponding sample wells and some tubes with tight fits will not be able to achieve tight temperature control for all tubes because of non-uniform thermal conductivity. An insufficient level of force F results in a temperature response of the sample liquid to a step change in block temperature as shown at 286 in Figure . An adequate level of force F results in the temperature response shown at 282.

The result achieved by the apparatus constructed according to the teachings of the invention is that the tempezature at each saaple mixture behaves as it the sasple is being well lixsd physically during transitions to new temperatures. In fact, because of the convection currents caused in each sample mixture, the sample reaction mixture in each sample tube 11 being well nixed.

The surprising result is that the thersal behavior of the entire system is like an electrical no circuit with a single tine constant of 9 seconds which is about 1.‘; tines the halt-lite or the decay ot the difference between the black tenpersturs and the laupll tenperture. A GenaAnp' sample tube filled with 50 sillileters of seals has a tile constant of about 23 seconds. In other words, during an upward change in temperature of the sample block, the temperature of the reaction sixtuxe acts like the rise in voltage on the capacitor C in a series RC electrical circuit like that shown in Figure 16D in response to a step change in the voltage output or the voltage source V.

To illustrate these concepts, refer to rigure 14 which shows dizterent temperature responses or the sasple liquid to a step change in block tenperature and to Figure is which shows a cross section through a senple well/sample tube combination. It has been found experiaentally that when the volune or sasple liquid 276 is epproxisataly 100 sicroliters and the dimensions at the tube are such that the seniscus 278 is locate below the top surface 200 of the sanple block 12, and the force I pushing the sample tube into the saaple well is at least 30 grass, the thernsl tise constant 7 (tau) oi! the systes shown in riqure 15 is approximately nine seconds for a sample tube wall thickness in the conical section or 0.009 inches (dinension A). It has also been found exporissntally that tor these conditions, the thermal tine constant 7 varies by about 1 second for every 0.001 inch change in wall thickness to: the sasple tube trustun (cone). The thin-walled sample tubes described herein have been found to have thermal time constants of from about 5 to about 14 seconds when containing from 20 to 100 microliters of sample. Thicker tube walls result . in longer time constants and more lag between a change in sample block temperaturo and the resulting change in sample liquid temperature.

Mathematically, the expression for the thermal response of the sample liquid temperature to a change in temperature of the sample block is: (6) raw = A'I‘(l-e“’” where _ Tuuuu 2 the temperature of the sample liquid AT - the temperature difference between the temperature of the sample block 12 and the temperature of the sample liquid t 2 elapsed time = thermal time constant of the system, or the heat capacity of sample divided by the thermal conductance from sample well wall to the sample liquid In Figure 14, the curve 282 represents this exponential temperature response to a theoretical step change in sample block temperature when the force F pushing down on the sample tube is sufficiently high. The step change in temperature of the sample block is shown as function 284, with rapid rise in temperature starting at time T1. Note how the temperature of the sample liquid exponentially increases in response to the step change and asymptotically approaches the final sample block temperature. As mentioned briefly above, the curve 286 represents the thermal response when the downward seating force F in Figure 15 is insufficient to cause a snug, flush fit between the cone of the sample tube and the wall 290 of the sample well. Generally, the thermal response of curve 286 will result if the force F is less than 30 grams. Note that although Figure 15 shows a small layer of air between the cone of the sample tube and the sample well wall for clarity, this is exactly the opposite of the desired situation since air is a good insulator and would substantially increase the thermal time constant of the system. _ 53 - The thermal time constant 1 is analogous to the RC time constant in a series RC circuit where R corresponds to the thermal resistance between the wall of the sample well and the sample liquid and C is the heat capacity of the sample liquid. Thermal resistance is equal to the inverse of thermal conductance which is expressed in units watts- seconds per degree Kelvin.

Because of the convection currents 292 shown in the sample liquid in Figure 15, everywhere in the reaction mixture the sample liquid and the flow of heat between the block and the sample is very nearly proportional to the difference in temperature, temperature between the sample block and the sample reaction mixture. The constant of proportionality is the thermal conductance between the wall of the sample well in the For different different wall thicknesses or materials, the thermal time constant will be different. the user can as part of his specification of the PCR protocol enter the sample volume or sample block 12 and the reaction mixture. sample volumes or different tubes, i.e., In such a case, tube type and the machine will automatically look up the correct thermal time constant for use in calculating the sample temperature. In some embodiments, the user may enter the actual time constant, and the machine will use it for sample temperature temperature calculation.

To keep the thermal time constant as small as possible, the conical walls of the sample tubes should be as thin as possible. In the preferred embodiment, these conical walls are 0.009 inches thick whereas the walls of the cylindrical of the sample tube are 0.030 inches thick. The shape of the sample tube provides a relatively large portion conical surface area of contact with the metal of the sample well wall in relation to the volume of the sample mixture.

Molding of the sample tubes is done using a "cold runner" system and a four cavity mold such that four sample tubes are molded at each injection. The molten plastic is is at very nearly the same injected at the tip of the sample tube cone so that any remnant of plastic will project into the cavity 291 between the tip of the sample tube and the tip of the sample well.

This prevents any remnant from interfering with the flush fit between the tube and the well. A maximum limit of 0.030 .inches is placed on the size of any remnant plastic.

In different grades of polypropylene each with different advantages can be used.

The preferred polypropylene is PD701 from Himont because it However this plastic is difficult to mold This plastic has a melt PD701 tends to leave flash and creates somewhat spotty quality parts but would work better if it was injected into the thick walled part of the mold instead of at the tip of the conical various embodiments, 3 is autoclavable. because it has a low melt index. index of 35 and a molecular density of 9. section as is currently done. Generally, it is desirable to have a high melt index for ease of molding but also a high molecular density to maintain good strength and to prevent the thermal of the autoclaving process at 260°F. Another plastic, PPW 1780 from American Hoescht has a melt index of 75 and a molecular Another plastic which may crazing or cracks under stress density of 9 and is autoclavable. be used in some embodiments is Himont 444. This plastic is not autoclavable and needs to be sterilized in another manner. the tubes may be molded system where the In alternative embodiments, using a "hot runner" or "hot nozzle" temperature of the molten plastic is controlled right up to the gate of the mold. Also, in some embodiments, multiple gates may be used. However, neither of these techniques has been experimentally proven at the time of filing to be better than the currently used "cold runner“ system.

The fact that the system acts thermally like a single time constant RC circuit is an important result, because it means that if the thermal conductance from the sample block to the sample reaction mixture is known and uniform, the — 54A —A thermal response of the sample mixtures will be known and uniform. Since the heat capacity of the sample reaction mixture is known and constant, the temperature of the sample reaction mixture can be computed accurately using only the measured history of the block temperature over time. This eliminates the the sample temperature thereby eliminating the errors and mechanical difficulty of need to measure putting a probe with nonnegligible thermal mass into a sample well to measure the sample temperature directly thereby changing the thermal mass of the sample in the probed well.

‘ The algorithm which makes this calculation models the thermal behavior of the system after a single time constant series R—C electrical circuit. This model uses the ratio of the heat capacity of the liquid sample divided by the thermal conductance from the sa_ple block to the sample reaction mixture. The heat capacity of the sample reaction mixture is equal to the specific heat of the liquid times the mass of the liquid. The thermal resistance is equal to one over the thermal conductance from the sample block to the liquid‘reaction mixture through the sample tube walls. when this conductance is expressed in consistent units, ratio of heat capacity divided by thermal it has the dimension of time. For a fixed sample volume and a fixed sample composition both of which are the same in every sample well and a fixed thermal conductance, the ratio is and is called the It is the time required for the sample temperature to come within 36.8% of also a constant for every sample well, thermal time constant of the system. the block temperature after a sudden step change in the block temperature.

There is a mathematical theorem used in the analysis of electronic circuits that holds that it is possible to calculate the output response of a filter or other linear system if one knows the impulse response of the system.

This impulse response is also known as the transfer - 543 — function. In the case of a series RC circuit, the impulse response is an exponential function as shown in Figure 16A.

The impulse stimulus resulting in the response of Figure 16A is as shown in Figure 168. The mathematical theorem referred to above holds that the output response of such a linear be determined by calculating the convolution of the input signal and a weighting function where the weighting function is the impulse response of the The convolution is otherwise known system can system reversed in time. as a running weighted average although a convolution is a concept in calculus with infinitely small step sizes whereas a running weighted average has discreet step sizes, i.e., multiple samples. The impulse response of the series RC circuit shown in Figure 160 as such that when the voltage of the voltage generator V suddenly rises and falls with a spike of voltage as shown in Figure 163, the voltage on the capacitor C suddenly rises to a peak at 294 in Figure 16A which is equal to the peak voltage of the impulse shown in Figure 158 and then exponentially decays back to the steady state voltage V,. The resulting weighting function is the impulse response of Figure 16A turned around in time as shown in Figure 16C at 385.

Superimposed upon Figure 16C is a hypothetical curve 387 illustrating a typical temperature history for the temperature of the sample block 12 for an approximate step change in temperature. Also shown superimposed upon Figure 16C are the times of five temperature sample periods labelled T1 through T5. According to the teachings of the invention, the calculated by multiplying the temperature at each one of these times T, through T5 by the value of the weighting function at that sample temperature is particular time and then summing all these products and dividing by 5. The fact that the thermal system acts like a single time constant linear circuit is a surprising result based of thermal heat transfer upon the complexities considerations for this complicated thermal system.

In embodiment, the calculation of the sample temperature is adjusted by a short delay to account for transport lag caused by different thermal path lengths to the block temperature sensor and the sample liquid. The calculated sample temperature is displayed for the user's information on the terminal 16 shown in Figure 1.

Figure 17 shows the temperature response results for six different wells spread throughout the 96 well sample block for a step change in sample block temperature from a relatively lower temperature in the hybridization/extension »temperature range to the relatively higher temperature of approximately 94°C used for denaturation. The graph of 17 exponential rise in sample temperature if the system were perfectly analogous to the series RC circuit shown in Figure 16D, and also shows excellent uniformity of temperature response in that the temperatures of the six sample wells used for this study asymptotically settle in at temperatures very close to each other and in a denaturation temperature Figure shows good agreement between the predicted "tolerance" band which is approximately 0.5'C wide.

In one embodiment, the ten most recent block temperature samples are used for the running weighted average, but in other embodiments a "different number of tempersature history samples may be used. The good agreement with theoretically predicted results stems from the fact that the thermal convection currents make the sample liquids well mixed thereby causing the system to act in a linear fashion.

The uniformity between sample temperatures in various sample wells spread throughout the 96 well array results from dynamic and static local balance and local symmetry in the sample block structure as well as all the other thermal design factors detailed herein. Note however that during rapid temperature changes all the sample wells will have temperatures within 0.5°C of each other only if the user has carefully loaded each sample well with the same mass of sample liquid. Inequality of mass in different wells does not cause unequal temperatures in steady state, unchanging only during rapid changes. The mass of the in each well is the dominant factor conditions, sample liquid in determining the heat capacity of each sample and, therefore, is the dominant factor in the thermal time constant for that particular sample well.

Note that the ability to cause the sample liquid in all the sample wells to cycle up and down in temperature in unison and to stabilize at target temperatures very near each other, in tolerance bands that are only o.5°c wide, also depends upon the force F in Figure-15. This force must exceed a minimum threshold force before the thermal time constants of all sample wells loaded with i.e., similar masses of sample liquid will have the same time constant. This minimum threshold experimentally determined to be 30 grams for the sample tube force has been and sample well configuration described herein. For higher levels of accuracy, the minimum threshold force F in Figure should be established at at least 50 grams and preferably 100 grams for an additional margin of safety as noted above.

The importance of thermal uniformity in sample well temperature can be appreciated by reference to Figure 18.

This figure shows the relationship between the amount of DNA generated in a PCR cycle and the actual sample temperature during the denaturation interval for one instance of amplification of a certain segment of DNA. The slope of function 298 between temperatures 93 and 95 degrees centigrade is approximately 8% per degree centigrade for this particular segment of DNA and primers. Figure 18 shows the general shape of the curve which relates the amount of DNA generated by amplification, but the details of the shape of the curve vary with every different case of primers and DNA target. Temperatures for denaturation above 97 degrees centigrade are generally too hot and result in decreasing increasing denaturation temperature. amplification for Temperatures between 95 and 97 degrees centigrade are generally just right.

Figure 18 illustrates that any sample well containing this particular DNA target and primer combination which stabilizes at a denaturation temperature of approximately 93°C is likely to have 8% less DNA generated over the course of a typical PCR protocol than wells denatured at 94°C.

Likewise, sample liquids of this mixture that stabilize at denaturation temperatures of 95°C are likely to have 8% more DNA generated therein than is generated in sample wells which of 94°C. stabilize at denaturation temperatures "Because all curves of this nature have the same general it is have uniformity in sample temperature. shape, important to The sample temperatures calculated as described above are used by the control algorithm for controlling the heaters and flow through the ramp cooling channels and to determine how long the samples have been held at various target temperatures. The control algorithm uses these times for comparison with the desired times for each incubation period as entered by the user. When the times match, the control algorithm takes the appropriate steps to heat or cool the sample block toward the target temperature defined by the user for the next incubation. when the calculated sample temperature is within one i.e., the incubation temperature programmed by the user, the control program This timer may be preset to count degree centigrade of the setpoint, causes a timer to start. down from a number set so as to time out the interval specified by the user for the incubation being performed.

The timer starts to count down from the preset count when the calculated sample temperature is within one degree centigrade. when the timer reaches a zero count, a signal is activated which causes the CPU to take actions to implement the next segment of the PCR protocol. Any way to time the specified interval will suffice for purposes of practicing the invention.

Typically, the tolerance band around any particular target temperature is plus or minus 0.5°C. Once the target temperature is reached, the computer holds the sample block at the target temperature using the bias cooling channels and the film heater such that all the samples remain close to the target temperature for the specified interval.

For the thermal system described herein to work well, the thermal conductance from the sample block to each sample must be known and uniform to within a very close tolerance.

Qtherwise, not all samples will be held within the specified tolerance band of the target temperature when the timer starts and, not all the samples will experience the same incubation intervals at the target temperature.

Also, for this thermal system to work well, all sample tubes must be isolated from variables in the ambient environment. That is, it is undesirable for some sample tubes to be cooled by drafts while other sample tubes in different physical positions do not experience the same cooling effects. For good uniformity it is highly desirable that the temperatures of all the samples be determined by the temperature of the sample block and by nothing else.

Isolation of the from the ambient, and application of the minimum threshold force F pushing down on the sample tubes is achieved by a heated cover over the tubes sample tubes and sample block.

Even though the sample liquid is in a sample tube pressed tightly into a temperature-controlled metal block, tightly capped, with a meniscus well below the surface of the temperature-controlled metal block, the samples still lose their heat upward by convection. Significantly, when the sample is very hot (the denaturation temperature is typically near the boiling point of the sample liquid), the sample liquid can lose a very significant amount of heat by refluxing of water vapor. In this process, water evaporates from the surface of the hot sample liquid and condenses on -59.- the inner walls of the cap and the cooler upper parts of the sample tube above the top surface of the sample block. If there is a relatively large volume of sample, condensation continues, and condensate builds up and runs back down the walls of the sample tube into the reaction mixture. This "refluxing" process carries about 2300 joules of heat per This process can cause a drop of of a 100 large gram of water refluxed. the mixture several degrees in surface temperature microliter reaction thereby causing a reduction of efficiency of the reaction.

If the reaction mixture is small, say 20 microliters, and the sample tube has a relatively large surface area above the top surface of the sample block, a significant fraction of the water in the reaction mixture may evaporate.

This water may then condense inside the upper part of the sample tube and remain there by surface tension during the remainder of the high temperature part of the cycle. This can so concentrate the remaining reaction mixture that the reaction is impaired or fails completely.

In the prior art PCR thermal cyclers, this refluxing problem was dealt with by overlaying the reaction mixture with a layer of oil or melted wax. This immiscible layer of oil or wax floated on the aqueous reaction mixture and However, labor was required to Further, the presence of oil interfered with later steps of processing prevented rapid evaporation. add the oil which raised processing costs. and analysis and created a possibility of contamination of In fact, mineral oils have in the past contaminated samples by the the sample. it.is known that industrial grade unknown presence of contaminating factors in the oil which were unknown to the users. and the problems of heat loss and concentration of the reaction The need for an oil overlay is eliminated, mixture by evaporation and unpredictable thermal effects caused by refluxing are avoided according to the teachings of the invention by enclosing the volume above the sample -60.. block into which the upper parts of the sample tubes project and by heating this volume from above by a heated cover sometimes hereafter also called the platen.

Figure 19, sectional view of the structure which is used to enclose the Referring to there is shown a cross sample tubes and apply downward force thereto so as to supply the minimum threshold force F in Figure 15. A heated platen 14 is coupled to a lead screw 312 so as to move up and down along the axis symbolized by arrow 314 with rotation of the lead screw 312. The lead screw is threaded through an opening in a sliding cover 316 and is turned by a knob 318. The platen 314 is heated to a temperature above the boiling point of water by resistance heaters (not shown) controlled by computer 20.

The sliding cover 316 slides back and forth along the Y axis on rails 320 and 322. The cover 316 includes vertical sides 317 and 319 and also includes vertical sides parallel to the X-Z plane (not shown) which enclose the sample block 12 tubes. This substantially prevent drafts from acting on the sample tubes and sample structure of which tubes 324 and 326 are typical.

Figure 20 is a perspective view of the sliding cover 316 and sample block 12 with the sliding cover in retracted position to allow access to the sample block. The sliding cover 316 resembles the lid of a rectangular box with vertical wall 328 having a portion 330 removed to allow the sliding cover 316 to slide over the sample block 12. The sliding cover is moved along the Y axis in Figure 20 until the cover is centered over the sample block 12. The user then turns the knob 318 in a direction to lower the heated platen 14 until a mark 332 on the knob 318 lines up with a mark 334 on an escutcheon plate 336. In some embodiments, the top the escutcheon plate 336 may be permanently affixed to the surface of the sliding cover 316. In other embodiments, escutcheon 336 may be rotatable such that the index mark may be placed in different positions when different size sample tubes are used. In other words, if taller sample tubes are used, the heated platen 14 need not be lowered as much to apply the minimum threshold force F in Figure 15.

In use, the user screws the screw 318 to lower the platen 14 until the index marks line up. The user then knows that the minimum threshold force F will have been applied to each sample tube.

Referring jointly to Figures 15 and 19, prior to lowering the heated platen 14 in Figure 19, the plastic cap 338 for each sample tube sticks up about 0.5 millimeters above the level of the top of the walls of a plastic tray 340 (Figure 19) which holds all the sample tubes in a loose 8x12 array on 9 millimeter centers. The array of sample wells can hold up to 96 HicroAmp' PCR tubes of 100 pL capacity or 48 larger GeneAmp' tubes of 0.5 ml capacity.

The details of this tray will be discussed in greater detail below. The tray 340 has a planar surface having an 8x12 array of holes for sample tubes. This planar surface is shown in Figures 15 and 19 as a horizontal line which intersects the sample tubes 324 and 326 in Figure 19. Tray 340 also has four vertical walls two of which are shown at 342 and 344 in Figure 19. The top level of these vertical walls, shown at 346 in Figure 15, establishes a rectangular box which defines a reference plane.

As best seen in Figure 15, the caps 338 for all the sample tubes project above this reference plane 346 by some small amount which is designed to allow the caps 338 to be softened and deformed by the heated platen 14 and "squashed" down to the level of the reference plane 346. In the preferred embodiment, the heated platen 14 is kept at a temperature of 105°C by the CPU 20 in Figure 1 and the bus 22 coupled to resistance heaters (not shown) in the platen 14. In the preferred embodiment, the knob 318 in Figure 19 and the lead screw 312 are turned until the heated platen 14 descends to and makes contact with the tops of the caps 338.

In the preferred embodiment, the caps 338 for the sample - 52 _ These caps soften shortly after they come into contact with the heated platen 14. As but they do not lose all of the heated platen is lowered further until it rests upon the reference This further lowering deforms the caps 338 and tubes are made of polypropylene the caps soften, they deform, their elasticity. After contacting the caps, plane 346. causes a minimum threshold force F of at least 50 grams to push down on each sample tube to keep each tube well seated firmly in its sample well. The amount by which the caps 338 project above the reference plane 346, and the amount of deformation and residual elasticity when the heated platen A14 rests upon the reference plane 346 is designed such that a minimum threshold force F of at least 50 grams and preferably 100 grams will have been achieved for all sample tubes then present after the heated platen 14 has descended to the level of the reference plane 346.

The heated platen 14 and the four vertical walls and planar surface of the tray 340 form a heated, sealed compartment when the platen 14 is in contact with the top edge 346 of the tray. The plastic of the tray 340 has a relatively poor thermal conductivity property. It has been found experimentally that contacting the heated platen 14 with the caps 338 and the isolation of the portion of the sample tubes 288 which project above the top level 280 of the sample block 12 by a wall of material which has relatively poor thermal conductivity has a beneficial result. with this structure, the entire upper part of the tube and cap are brought to a temperature which is high enough that little or no condensation forms on the inside surfaces of the tube and cap since the heated platen is kept at a temperature above the boiling point of water. This is true even when the sample liquid 276 in Figure 15 is heated to a temperature near its boiling point. This eliminates the need for a layer of immiscible material such as oil or wax floating on top of the sample mixture 276 thereby reducing the amount of labor involved in a PCR reaction and ‘ eliminating one source of possible contamination of the sample.

It has been found experimentally that in spite of the very high temperature of the heated cover and its close proximity to the sample block 12, there is little affect on the ability of the sample block 12 to cycle accurately and rapidly between highland low temperatures.

The heated platen 14 prevents cooling of the samples by the refluxing process noted earlier because it keeps the temperature of the caps above the condensation point of water thereby keeping the insides of the caps dry. This ‘also prevents the formation of aerosols when the caps are removed from the tubes.

In alternative embodiments, any means by which the acceptable downward force F in Figure 15 can be to each individual sample tube regardless of the minimum applied number of sample tubes present and which will prevent refluxing and convection cooling will application of this downward force F and the use of heat to condensation and suffice for purposes of practicing the invention. prevent refluxing and undesired sample liquid concentration need not be both implemented by the same system as is done in the preferred embodiment.

The sample tubes may vary by a few thousandths of an inch in their overall height. Further, the caps for the sample tubes may also vary in height by a few thousandths of Also, each conical sample well in the sample block and each an inch. 12 may not be drilled to exactly the same depth, conical sample well in the sample block may be drilled to a slightly different diameter and angle. Thus, population of capped tubes is placed in the sample block so when a as to be seated in the corresponding sample well, the tops of the caps will not all necessarily be at the same height.

The worst case discrepancy for this height could be as much as 0.5 millimeters from the highest to the lowest tubes.

If a perfectly flat unheated platen 14 mounted so that it is free to find its own position were to be pressed down on such an array of caps, it would first touch the three tallest tubes. As further pressure was applied and the tallest tubes were compressed somewhat, the platen would begin to touch some caps of lower tubes. There is a distinct possibility that unless the tube and cap assemblies the tallest tubes would be damaged before the shortest tubes were contacted at all. Alternatively, the force necessary to all the tall tubes sufficiently so as to contact the shortest tube could be too were compliant, compress large for the device to apply. In either case, one or more short tubes might not be pressed down at all or might be pressed down with an insufficient amount of force to guarantee that the thermal time constant for that tube was equal to the thermal time constants for all the other tubes.

This would result in the failure to achieve the same PCR cycle for all tubes in the sample block since some tubes with different thermal time constants woulc not be in step with the other tubes. Beating the platen and softening the caps eliminates these risks by eliminating the manufacturing tolerance errors which lead to differing tube heights as a factor.

In an alternative embodiment, the entire heated platen i4 is covered with a compliant rubber layer. A compliant rubber layer on the heated platen would solve the height problem, but would thermal insulation layer which would delay the flow of heat from the heated platen to the tube caps. Further, with long use at most rubber materials deteriorate or tolerance also act as a high temperatures, become hard. It is therefore desirable that the heated platen surface be a metal and a good conductor of heat.

In another alternative embodiment, 96 individual springs could be mounted on the platen so that each spring individually presses down on a single sample tube. This is a complex and costly solution, however, and it requires that the platen be aligned over the tube array with a mechanical precision which would be difficult or bothersome to achieve.

The necessary individual compliance for each sample tube in the preferred embodiment is supplied by the use of plastic caps which collapse in a predictable way under the force from the platen but which, even when collapsed, still exert a downward force F on the sample tubes which is adequate to keep each sample tube seated firmly in its well.

In the sample tube cap 338 shown in Figure 15, the surface 350 should be free of nicks, flash and cuts so that it can provide a hermetic seal with the inner walls 352 of the sample tube 288. the material for the cap is polypropylene. A suitable material might be Valtec Hm-444 or PD701 polypropylene manufactured by Himont as described above or PPW 1780 by American Hoescht. the wall thickness for the domed portion of the cap is 0.130 + .000 - 0.005 inches. The thickness of the shoulder portion 356 is 0.025 inches and the width of the domed shaped portion of the cap In the preferred embodiment, In the preferred embodiment, is 0.203 inches in the preferred embodiment.

Any material and configuration for the caps which will cause the minimum threshold force F in Figure 15 to be applied to all the sample tubes and which will allow the cap and upper portions of the sample tubes to be heated to a V high to refluxing will suffice The dome shaped cap 338 has a thin wall to aid in deformation of the cap. Because the heated platen is kept at a high temperature, the wall thickness of the domed temperature enough prevent condensation and for purposes of practicing the invention. shaped cap can be thick enough to be easily manufactured by injection molding since the necessary compliance to account for differences in tube height is not necessary at room temperature.

The platen can be kept at a temperature anywhere from 94°C to 110°C according to the teachings of the invention although the range from 100°C to 110°C is preferred to prevent refluxing since the boiling point of water is 100°C.

. In this temperature range, it has been experimentally found that the caps soften just enough to collapse easily by as much as 1 millimeter. Studies have shown that the elastic properties of the polypropylene used are such that even at these temperatures, the collapse is not entirely inelastic.

That is, even though the heated platen causes permanent the material of the caps still enough of their temperature elastic modulus that the minimum threshold force F is applied to each sample tube. Further, the heated all the that it contacts without excessive force regardless of how many tubes are present in the sample block because of the softening of the cap.

Because the cap temperature is above the boiling point deformation of the caps, retain a significant fraction room platen levels caps of water during the entire PCR cycle, the inside surfaces of Thus, at the end of a PCR are cooled to room temperature each cap remain completely dry. process, if the samples before being removed from the sample block, if the caps on each sample tube are opened, there is no possibility of creating an aerosol spray of the sample tube contents which could result in cross contamination. This is because there is no liquid at the cap to tube seal when the seal is broken.

This is extremely advantageous, because tiny particles of aerosol containing amplified product DNA can contaminate a laboratory and get into sample tubes containing samples from other sources, e.g., other patients, thereby possibly causing false positive or negative diagnostic results which can be very troublesome. Users of the PCR amplification process are extremely concerned that no aerosols that can contaminate other samples be created.

A system of disposable plastic items is used to convert the compatible with microtiter plate format lab equipment but individual sample tubes to an 8x12 array which is ‘ which maintains sufficient individual freedom of movement to compensate for differences in the various rates of thermal .on the surface of the sample block 12. — expansion of the system components. The relationship of the thermally compliant cap to the rest of this system is best seen in Figure 21A which is a cross sectional view of the sample block, and two sample tubes with caps in place with the sample tubes being held in place by the combination of one embodiment of a plastic 96 well microtiter tray and a 218 preferred embodiment showing the structure and interaction of most of The rectangular plastic 96 well microtiter plate tray 342 rests The top edge 346 of the frame 342 has a height which is approximately 0.5 millimeters shorter than the height of the caps of which cap 364 is exemplary. All of the capped tubes will project higher than the edge 346 of the frame 342. The frame 342 is configured such that a downward extending ridge 366 extends The which retainer. Figure is an alternative, the various plastic disposable items of the system. into the guardband groove 78 through its entire length. 342 gap corresponds to the gap in the groove 78 for the temperature frame does however have a (not shown) sensor shown in Figure 2 in plan view and in Figure 7 in cross-sectional view.

The reference plane 346 mentioned above is established by the top of the frame 342. interacts with the heated platen is as follows.

How this reference plane Prior to screwing down the knob 318 in Figure 20 to line up the index marks 332 334 to calibration process will have been performed to locate the and start an amplification run, a position of the index mark on the escutcheon platen 336 in Figure 20. This calibration is started by placing the frame 342 in Figure 21 in position on the sample block. The frame 342 will be empty however or any sample tubes therein will Then, the knob 318 is screwed down until the heated platen 14 is firmly in contact with the 346 of the frame parameter. when the knob 318 sufficiently to allow the heated platen to reast on the not have any caps in place. top edge 342 around its’ entire has been screwed down L.) Ul - 68 reference plane 346 and to press the frame 342 firmly the rotatable escutcheon 336 of the preferred embodiment will be against the top surface 280 of the sample block, rotated until the index mark 334 on the escutcheon lines up with the index mark 332 on the knob 318. Then, the knob 318 is rotated counterclockwise to raise the platen 14 and the cover 316 in Figure 19 is slid in the negative Y direction to uncover the frame 342 and the sample block 12. sample tubes with caps loaded with a sample mixture may then be placed in position in the frame 342. The heated cover 316 is then placed back over the sample block, and the knob 318 is turned clockwise to lower the heated platen 14 until the index mark 332 on the knob lines up with the index mark 334 as previously positioned. This guarantees that all tubes ' have been firmly seated with the minimum force F applied.

The use of the index marks gives the user a simple, verifiable task to perform.

If there are only a few sample tubes in place, it will take only a small amount of torque to line up the index marks 332 and 334. If there are many tubes, it will take more torque on the knob 318 to line up the index however, marks. This is because each tube is resisting the downward movement of the heated platen 14 However, the user is assured that when the index marks 332 as the caps deform. and 334 are aligned, the heated platen will once again be tightly placed against the top edge 346 of the frame 342 and all tubes will have the minimum threshold force F applied thereto. This virtually guarantees that the thermal time constant for all the tubes will be substantially the same.

In alternative embodiments, the index marks 332 and 334 may be dispensed with, and the knob 318 may simply be turned clockwise until it will not turn any more. This condition will occur when the heated platen 314 has reached the top edge or reference plane 346 and the plastic frame 342 has stopped further downward movement of the heated platen 14. obviously in this alternative embodiment, and preferably in -69.. the index mark embodiment described above, the plastic of the frame 342 will have a melting temperature which is sufficiently high to prevent deformation of the plastic of the frame 342 when it is in contact with the heated platen 14. In the preferred embodiment, the plastic of the frame 342 is celanese nylon 1503 with a wall thickness of 0.05 inches.

An advantage of the above described system is that sample tubes of different heights may be used simply by The frame 342 should have a height which is approximately 0.5 millimeters using frames 342 having different heights. shorter than the plane of the tips of the capped tubes when both are seated in the sample block. In the preferred embodiment, two different tube heights are used. The range of motion of the lead screw 312 which drives the heated platen 14 in Figure 19 must be sufficient for all the different sizes of sample tubes to be used. Of course, during any particular PCR processing cycle, all tubes must be the same height. temperatures above uniform block, and isolation of the described provides the conductance from block to sample, system in sample uniform thermal sample tubes from the vagaries of the ambient environment.

Any number of sample tubes up to 96 may be arrayed in the microtiter plate The temperature control for a very large number of samples and format. system allows accurate a visual indication of the sample temperatures for all samples without actually measuring the temperature of any sample.

As the container for PCR reactions, it has been common in the prior art to use polypropylene tubes which were originally designed for microcentrifuges. This prior art tube had a cylindrical cross~section closed at the top by a snap-on cap which makes a gas-tight seal. This prior art tube had a bottom section which comprised the frustrum of a cone with an included angle of approximately 17 degrees.

When such a conical sample tube is pressed down into a sample well of a sample block with a conical cavity with the same included angle, and when the sample mixture in the tube lies entirely within the conical volume and below the top surface of the sample block, the thermal conductance between the block and the liquid can be made adequately predictable for good uniformity of sample temperature throughout the array. To of the conductance between the sample block and the sample mixture, achieve adequate control thermal the included angles of the conical tube and the sample well _must match closely, and the conical surfaces of the tube and well must be smooth and held together in flush relation.

Further, the minimum threshold force F must be applied to each sample tube to press each tube tightly into the sample well so that it does not rise up or loosen in the well for any reason during thermal cycling, such as steam formation from trapped liquid in space 291 in Figure 15. Finally, each tube must be loaded with the same amount of sample liquid. If the above listed conditions are met, the thermal conductance between the sample block and the sample liquid in each tube will be predominantly determined by the conductance of the conical plastic wall 368 in Figure 15 and a boundary layer, (not shown) of the sample liquid at the inside surface 370 of the conical sample tube wall.

The thermal conductance of the plastic tube walls is thickness, be controlled by the injection molding method of manufacture of the tubes. The sample liquid in all the sample tubes has virtually identical thermal properties. determined by their which can closely It has been found by experiment and by calculation that a molded, 96-well microtiter plate is only marginally feasible for PCR because the differences in the one—piece, thermal expansion coefficients between aluminum and plastic lead to dimensional changes which can destroy the uniformity of thermal conductance to the sample liquid across the array. That is, since each well in such a one-piece plate is connected to each other well through the surface of the plate, the distances between the wells are determined at the time of initial manufacture of the plate but change with changing temperature since the plastic of the plate has a of Also, distances between the sample wells in the metal sample block significant coefficient thermal expansion. 12 are dependent upon the temperature of the sample block since aluminum also has a significant coefficient of thermal expansion which is different than that of plastic. good thermal conductance, each sample well in a one-piece -well microtiter plate would have to fit almost perfectly in the corresponding well in the sample block at all temperatures. since the temperature of the sample block changes over a very wide range of temperatures, the distances between the sample wells in the sample block vary cyclically during the PCR cycle. Because the coefficients of substantially thermal for plastic and aluminum are the of the well separation in the sample block would vary differently over expansion different, distances changing temperatures than would the distances between the sample wells of a plastic, one-piece, 96-well microtiter plate.

Thus, between a sample tube and the corresponding sample well over as an important criteria for a perfect fit the PCR temperature range, it is necessary that each sample tube in the 96-well array be individually free to move laterally and each tube must be individually free to be pressed down vertically by whatever amount is necessary to make flush contact with the walls of the sample well.

The sample tubes used in the invention are different from the prior art microcentrifuge tubes in that the wall thickness of the conical frustrum position of the sample tube is much thinner to allow faster heat transfer to and The upper part of these tubes has In Figure from the sample liquid. a thicker wall thickness than the conical part. , the wall thickness in the cylindrical part 288 in Figure To have is generally 0.030 inches while the wall thickness for the conical wall 368 is 0.009 inches. Because thin parts cool faster than thick parts in the injection molding process, it is important to get the mold full before the thin parts cool off.

The material of the sample tubes must be compatible chemically with the PCR reaction. Glass is not a PCR compatible material, because DNA sticks to glass and will not come off which would interfere with PCR amplification.

Preferably an autoclavable polypropylene is used. Three »types of suitable polypropylene were identified earlier herein. some plastics are not compatible with the PCR process because of outgassing of materials from the plastic or because DNA sticks to the plastic walls. Polypropylene is the best known class of plastics at this time.

Conventional injection molding techniques and mold manufacture techniques for the injection mold will suffice for purposes of practicing the invention.

The of tubes substantially all manufacturing tolerance errors to height use cone shaped sample translates errors, i.e., a variance from tube to tube in the height of the tip of the cap to the top of the sample block when the sample tube is seated For example, in the sample well. an angle error for the angle of the sample tube walls is converted to a height error when the tube is placed in the sample block because of the mismatch between the tube wall angle and the sample well wall angle. Likewise, a diameter error in the dimensions of the cone would also translate into a height error since the conical part of the tube would either penetrate deeper or not as much as a properly dimensional tube.

For good uniformity of thermal conductance across the array, a good fit between the sample tubes and the sample well must exist for all 96-wells over the full temperature range of 0 to 100°C regardless of differences in thermal Also, expansion rates. each of the 96 sample tubes must _ 73 - have walls with dimensions and wall thicknesses which are Each sample tube in which should be fitted with a uniform to a very high degree. to be held removable ‘gas-tight cap that makes a gas-tight seal to sample mixture is prevent loss of water vapor from the reaction mixture when this mixture is at or near its boiling point such that the All these factors combine to make a one-piece microtiter plate with 96 volume of the sample mixture does not decrease. individual sample wells extremely difficult to manufacture in a manner so as to achieve uniform thermal conductance for all 96 wells.

Any structure which provides the necessary individual lateral and vertical degrees of freedom for each sample tube will suffice for purposes of practicing the invention.

According to the teachings of the preferred embodiment of the invention, all the above noted requirements have been met by using a 4 piece disposable plastic system. This system gives each sample tube sufficient freedom of motion in all necessary directions to compensate for differing rates of thermal expansion and yet retains up to 96 sample tubes in a 96 well microtiter plate format for user with equipment which is sized to work with the industry standard The plastic system is very tolerant of manufacturing tolerance convenience and compatibility other laboratory -well microtiter’ plate. multi-piece disposable errors and the differing thermal expansion rates over the wide temperature range encountered during PCR thermal cycling.

Figures 21A and 215 show alternative embodiments of most of the four piece plastic system components in cross- section as assembled to hold a plurality of sample tubes in their sample wells with sufficient freedom of motion to account for differing rates of thermal expansion. Figure 45 shows all the parts of the disposable plastic microtiter plate emulation system in an exploded view. This figure illustrates how the parts fit together to form a microtiter -74.- plate with all the sample tubes loosely retained in an 8x12 microtiter plate format 96 well array. Figure 22 shows a plan view of a microtiter plate frame 342 according to the teachings of the invention which is partially shown in cross-section in Figures 21A and 21B. Figure 23 shows a bottom view plan view of the frame 342. Figure 24 is an end view of the frame 342 taken from view line 24-24' in Figure 22. Figure 25 is an end View of the frame 342 taken from view line 25-25' in Figure 22. Figure 26 is a cross section through the frame 342 at section line 26-26' in Figure 22.

Figure 27 is a cross sectional view through the frame 342 taken along section line 27-27' in Figure 22. Figure 28 is a side view of the frame 342 taken along view line 28-28' in Figure 22 with a partial cut away to show in more detail the location where a retainer to be described below clips to the frame 342.

Referring jointly to Figures 21A, 213 and 22 through 28, the frame 342 is comprised of a horizontal plastic plate 372 96 holes millimeter centers in the standard microtiter plate format. in which there are formed spaced on 9 There are 8 rows labeled A through H and 12 columns labeled 1 through 12. Hole 374 at row D, these holes. In each hole in the frame 342 there is placed column 7 is typical of a conical sample tube such as the sample tube 376 shown in Figure 15. Each sample tube is smaller in diameter than the hole in which it is placed by about 0.7 millimeters, so that there is a loose fit in the hole. This is best seen in Figures 21A and 218 by observing the distance between the inside edge 378 of a typical hole and the side wall 380 of the sample tube placed therein. Reference numeral 382 in Figures 21A and 213 shows the opposite edge of the hole which is also spaced away from the outside wall of the cylindrical portion of the sample tube 376.

Each sample tube has a shoulder shown at 384 in Figures , 21A and 21B. circumference of the cylindrical portion 288 of each sample This shoulder is molded around the entire ” Normally, tube. The diameter of this shoulder 384 is large enough that it will not pass through the holes in the frame 342, yet not so large as to touch the shoulders of the adjacent tubes in neighboring holes.

Once all the tubes are placed in their holes in the frame 342, a plastic retainer 386 (best seen in Figures 21A and 21B and Figure 45) is snapped into apertures in the frame 342. The purpose of this retainer is to keep all the tubes in place such that they cannot fall out or be knocked out of the frame 342 while not interfering with their looseness of fit in the frame 342. The retainer 386 is sized and fitted to the frame 342 such that each sample tube has freedom to move vertically up and down to some extent before the shoulder 384 of the tube encounters either the retainer 386 or the frame 342. Thus, the when coupled, provide a microtiter plate format frame and retainer, for up to 96 sample tubes but provide sufficient horizontal and vertical freedom such that each tube is free to find its best fit at all temperatures under the influence of the minimum threshold force F in Figure 15.

A more clear view of the sample tube and shoulder may be had by reference to Figures 29 and 30. Figures 29 and 30 are an elevation sectional view and a partial upper section of the shoulder portion, respectively, of a typical sample tube. A plastic dome-shaped cap such as will be described in more detail below is inserted into the sample tube shown in Figure 29 and forms a hermetic seal with the inside wall 390 of the top at the sample tube. A ridge 392 formed in the inside wall of the sample tube acts as a stop for the dome-shaped cap to prevent further penetration. Normally, the dome-shaped caps come in strips connected by web.

Figure 31 shows three caps in elevation view connected by a web 394 and terminated in a tab 396. The tab aids the user in removing an entire row of caps by a single pull. the web 394 rests on the top surface 398 of the sample tube and prevents further penetration of the cap into the sample tube. Each cap includes a ridge 400 which forms the hermetic seal between the cap and the inside wall of the sample tube. Figure 32 shows a top view of three caps in a typical strip of 12 connected caps.

For a more detailed understanding of the retainer, refer to Figures 33 through 37. Figure 33 is a top view of the plastic retainer. Figure 34 is an elevation view of the retainer taken along view line 34-34' in Figure 33. Figure is an end elevation view of the retainer taken along View line 35-35‘ taken along section line 36-36' in Figure 33. in Figure 33. Figure 36 is a sectional view Figure 37 is a sectional view through the retainer taken along section line 37-37' in Figure 33.

Referring jointly to Figures 33-37, the retainer 386 is plastic plane 402 The plane 402 has an 8 x 12 array of 96 holes formed therein divided into 24 groups comprised of a single horizontal surrounded by a vertical wall 404. of four holes per group. These groups are set off by ridges Each of which hole 410 is typical, has a diameter D which formed in the plane 402 such as ridges 406 and 408. hole, is larger than the diameter D, in Fig. 29 and smaller than the diameter Dr This allows the retainer to he slipped over the sample tubes after they have been placed in the frame 342 but prevents the sample tubes from falling out of the frame since the shoulder 384 is too large to pass through the hole 410.

The retainer snaps into the frame 342 by means of plastic tabs 414 shown in Figures 34 and 36. These plastic tabs are pushed through the slots 416 and 418 in the frame as shown in Figure 23. There are two plastic tabs 414, one on each long edge of the retainer. These two plastic tabs are shown as 414A and 4148 in Figure 33.

The frame 342 of Figures 22-28, with up to 96 sample tubes placed therein and with the retainer 386 snapped into place, forms a single unit such as is shown in Figures 21A and 215 which can be placed in the sample block 12 for PCR elevation view of the base taken from view line 40-40' processing.

After all the simultaneously by lifting the frame 342 out of the sample block. the frame 342 with sample tubes and retainer in place can be inserted into The base has the processing, tubes may be removed For convenience and storage, another plastic component called the base. outside dimensions and footprint of a standard 96-well microtiter plate and is shown in Figures 38 through 44.

Figure 38 is a top plan view of the base 420, while Figure 39 is a bottom plan view of the base. Figure 40 is an in Figure 38. Figure 41 is an end elevation view taken from Figure 42 is a sectional in Figure 43 is a sectional view through the base view line 41-41' in Figure 38. view taken through the base along section line 42-42' Figure 38. taken along section line 43-43' in Figure 38. Figure 44 is a sectional view taken along section line 44-44' in Figure 38.

The base 420 includes a flat plane 422 of plastic in which an 8 x 12 array of holes with sloped edges is formed. holes have dimensions and spacing such that when the 342 is seated in the base, the bottoms of the sample tubes fit into the conical holes in the base such that the sample tubes are held in the same relationship to the frame These frame as the sample tubes are held when the frame 342 is mounted on the sample block. Hole 424 is typical of the 96 holes formed in the base and is shown in Figures 38, 44 and 43. between the tray and retainer, immobile when the frame is inserted in the base.

The individual sample tubes, though loosely captured become firmly seated and The manner in which a typical sample tube 424 fits in the base is shown in Figure 44.

In other words, retainer are seated in the base 420 the entire assembly when the frame, sample tubes and becomes the exact functional equivalent of an industry standard 96-well microtiter plate, and can be placed in -78.. virtually any automated pipetting or sampling system for 96- well industry standard microtiter plates for further processing.

After the sample tubes have been filled with the necessary reagents and DNA sample to be amplified, the sample tubes can be capped. In an alternative embodiment of the cap strip shwon in Figures 31 and 32, an entire mat of 96 caps with a compliant web connecting them in an 8 x 12 array may be used. This web, shown at 394 in Figure 31 must be sufficiently compliant so that the caps do not restrain ’the sample tubes from making the small motions these sample tubes must make to fit perfectly in the conical wells of the sample block at all temperatures.

The assembly of tubes, caps frames, retainer and base is brought after filling the tubes to the thermal cycler.

There, the frame, capped tubes and retainer plate are removed from the base as a unit. This unit is then placed in the sample block 12 to make the assembly shown in Figure 21A or 21B with the tubes loosely held in the conical wells in the sample block. As shown in Figure 21, the frame 342 is seated on the top surface 280 of the guardband. In the preferred embodiment, the ridge 366 extends down into the groove 78 of the guardband, but this is not essential.

Next, the heated cover is slid over the samples, and the heated platen is screwed down as previously described until it contacts the top edge 346 of the frame 342.

Within seconds after the heated platen 14 in Figure 19 touches the caps, the caps begin to soften and yield under the downward pressure from the lead screw 312 in Figure 19.

The user then continues to turn to knob 318 until the index marks 332 and 334 in Figure 20 line up which indicates that every sample tube has been tightly pressed into the sample block with at least the minimum threshold force F and all air gaps between the heated platen 14, the sample block and the top edge 346 of the frame 342 have been tightly closed.

The sample tubes are now in a completely closed and controlled environment, and precision cycling of temperature can begin.

At the end of the PCR protocol, the heated platen 14 is moved upward and away from the sample tubes, and the heated cover 316 is slid out of the way to expose the frame 342 and sample tubes. The frame, sample tubes and retainer are then removed and replaced into an empty base, and the caps can be removed. As each cap or string of caps is pulled off, the retainer keeps the tube from coming out of the tray. Ribs formed in the base (not shown in Figures 38-44) contact the retainer tabs 414A and 4148 shown in Figure 33 to keep the retainer snapped in place such that the force exerted on the tubes by removing the caps does not dislodge the retainer 386.

Obviously, the frame 342 may be used with fewer than 96 Also, the retainer 386 can be removed if desired by unsnapping it. tubes if desired.

A user who wishes to run only a few tubes at a time and handle these tubes individually can place an empty frame 342 without retainer on the sample block. The user may then use the base as a "test tube rack" and set up a small number of tubes therein. These tubes can then be-filled manually and capped with individual caps. The user may then transfer the tubes individually into wells in the sample block, close the heated cover and screw down the heated platen 14 until the marks line up. when the cycling is complete, the cover 316 is removed and the sample PCR cycling may then commence. tubes are individually placed in an available base. retainer is not necessary in this type of usage.

Referring to Figures 47A and 473 (hereafter Figure 47), there is shown a block diagram for the electronics of a preferred embodiment of a control system in a class of control systems represented by CPU block 10 in Figure 1.

The purpose of the control electronics of Figure 47 is, inter alia, to receive and store user input data defining the desired PCR protocol, read the various temperature sensors, calculate the temperature, the calculated sample temperature to the desired temperature as sample compare defined by the user defined PCR protocol, monitor the power line voltage and control the film heater zones and the ramp cooling valves to carry out the desired temperature profile of the user defined PCR protocol. (hereafter CPU) the control program described below and given in Appendix C in In the preferred embodiment, the CPU 450 The CPU drives an address bus 452 by A microprocessor 450 executes source code form. is an OKI CMOS 8085. which various ones of the other circuit elements in Figure 47 are addressed. The CPU also drives a data bus 454 by which data is transmitted to various of the other circuit elements in Figure 47.

The control program of Appendix C and some system constants are stored in EPROM 456. User entered data and other system constants and characteristics measured during the install process (install program execution described below) are stored in battery backed up RAM 458. clock/calendar 460 supplies the CPU 450 with date and time information for purposes of recording a history of events A system during PCR runs and the duration of power failures as described below in the description of the control software.

An address decoder 462 receives and decodes addresses from the address bus 452 and activates the appropriate chip select lines on a chip select bus 464.

The user enters PCR protocol data via a keyboard 466 in response to information displayed by CPU on display 468.

The two way communication between the user and the CPU 450 is described in more detail below in the user interface section of the description of the control software. A keyboard interface circuit 470 converts user keystrokes to data which is read by the CPU via the data bus 454. 472 and 474 contain counters which are loaded with counts calculated by Two programmable interval timers each the CPU 450 to control the intervals during which power is applied to the various film heater zones.

An interrupt controller 476 sends interrupt requests to the CPU 450 every 200 milliseconds causing the CPU 450 to run the PID task described below in the description of the control software. This task reads the temperature sensors and calculates the heating or cooling power necessary to move the sample temperature from its current level to the level desired by the user for that point in time in the PCR protocol being executed.

A UART 478 services an RS232 interface circuit 480 such that data stored in the RAM 480 may be output to a printer.

The control software maintains a record of each PCR run which is performed with respect to the actual temperatures which existed at various times during the run for purposes of user validation that the PCR protocol actually executed In addition, user entered data defining the specific times and corresponded to the PCR protocol desired by the user. temperatures desired during a particular PCR protocol is All this data and other data as well may be read by the CPU 450 and output to a printer coupled to the RS232 port via the UART 478. The RS232 interface also allows an external computer to take control of the address also stored. and data buses for purposes of testing.

A peripheral interface chip (hereafter PIC) 482 serves as a programmable set of 4 input/output registers. At power-up, the CPU 450 selects the PIC 482 via the address decoder 462 and the chip select bus 464. The CPU then writes a data word to the PIC via data bus 454 to program the PIC 482 regarding which registers are to be output ports Subsequently, the CPU 450 the output registers to store data words written therein by the CPU via the data bus 454 to control the internal logic state of a programmable array logic chip (PAL) 484.

The PAL 484 is a state machine which has a plurality of PAL's in and which are to be input ports.

USES input signals and a plurality of output signals. _ 32 - general contain an array of logic which has a number of different states. Each state is defined by the array or vector of logic states at the inputs and each state results in a different array or vector of logic states on the The CPU 450, PIC 482, PAL 484 and several other circuits to be defined below cooperate to generate different outputs. states of the various output signals from the PAL 484.

These different states and associated output signals are what control the operation of the electronics shown in Figure 47 as will be described below. A A 12 bit analog-to-digital converter (A/D) 486 converts analog voltages on lines 488 and 490 to digital signals on data bus 454. address for the A/D converter such that a chip select signal These are read by the CPU by generating an on bus 464 coupled to the chip select input of the A/D The analog signals on lines 488 and 490 are the output lines of two multiplexers 492 and 494. Multiplexer 492 has four inputs ports, each having two signal lines. Each of these ports is coupled to one of the four temperature sensors in The first port is coupled to the sample block converter goes active and activates the converter. the system. temperature sensor. The second and third ports are coupled to the coolant and ambient temperature sensors, respectively and the fourth port heated temperature sensor. A typical circuit for each one of these temperature sensors is shown in Figure 48. A 20,000 ohm resistor 496 receives at a node 497 a regulated +15 volt regulated power supply 498 in Figure 47 via a bus connection is coupled to the cover line which is not shown. This +15 volts D.C. signal reverse biases a zener diode 500. The reverse bias current and the voltage drop across the zener diode are functions of the temperature. The voltage drop across the diode is input to the multiplexer 292 via lines 502 and 504. sensor has a similar connection to the multiplexer 292.

Each temperature Multiplexer 494 also has 4 input ports but only three are connected. The first input port is coupled to a ‘stored during the install process, calibration voltage generator 506. This voltage generator outputs two precisely controlled voltage levels to the multiplexer inputs and is very thermally stable. That is, the reference voltage output by voltage source 506 drifts very little if at all with temperature. This voltage is read from time to time by the CPU 450 and compared to a stored constant which represents the level this reference voltage had at a known temperature as measured during execution of the install process described below. If the reference voltage has drifted from the level measured and the CPU 450 knows that the other electronic circuitry used for sensing the various temperatures and line voltages has also drifted and adjusts their outputs accordingly to maintain very accurate control over the temperature measuring process.

The other input to the multiplexer 494 is coupled via line 510 to an RMS-to-DC converter circuit 512. This circuit has an input 514 coupled to a step-down transformer 516 and receives an A.C. voltage at input 514 which is proportional to the then existing line voltage at A.C. power input 518. The RHS-to-DC converter 512 rectifies the A.C. voltage and averages it to develop a D.C; voltage on line 510 which also is proportional to the A.C. input voltage on line 518. _ ’ Four optically coupled triac drivers 530, 532, 534 and 536 receive input control signals via control bus 538 from PAL logic 484. Each of the triac drivers 530, 532 and 534 controls power to one of the three film heater zones. These 250/252 and (the same reference numerals used in Figure 13). heater zones are represented by blocks 254, 256/258 The triac driver 536 controls power to the heated cover, represented by block 544 via a thermal cut-out switch 546.

The heater zones of the film heater are protected by a block thermal cutout switch 548. The purpose of the thermal cutout to of the film heater/sample block on the heated cover in case of a failure switches is prevent meltdown ‘voltages at sis less than 150 volts RHS. leading to the triac drivers being left on tor an unsafe interval. If such an event happens, the thersal ¢ut~out switches detect an overly hot condition. and shut down the triacs via signals on lines 552 or 554.

The saih heater zone or the tile heater is rated at 360 watts while the manifold and edge heater zones are rated at 180 watts and 170 watts respectively. The triac drivers are Motorola HAC lsaio is sup triacs. Each heater zone is split into 2 electrically isolated sections each dissipating 1/2 The 2 halves are connected in parallel tor line For line voltages greater than this, the two halves are connected in series.

These alternate connections are accomplished through a 'perscnality' plug 550.

The ac power supply for the till heater zones is line 559, and the ac supply to: the heated cover is via line 560.

A zero crossing detector 566 provides basic system timing by emitting a pulse on line 568 at each zero crossing of the AC power on line 513. a National Lu 3llN rszerenced to analog ground and has 25 av of hysteresis. The zero crossing detector takes its input tron tranatoruer 516 which outputs a.c. signal from 0 to .52 volts for an A.C. input signal or fro o to 240 volts A.C.

A power transformer 570 supplies a.c. power to the pump 41 that pumps coolant through the ranp and bias cooling channels. The refrigeration unit 40 also receives its A.c. power tron the transferee: 570 via another portion or the personality plug 550. The transformer 550 also supplies power to three regulated power supplies 572, 498 and 574 and one unregulated power supply 576.

For accuracy purposes in seasuring the teaperaturee, thfl calibration voltage generator :06 uses a series or very precise, thin-fill, ultralov temperature drift 20K ohn resistors (not shown in Figure 47 ). 7 These same ultrelou drift the power.

The zero crossing detector is resistors are used to set the gain of an analog amplifier 578 which amplifies the output voltage from the selected temperature sensor prior to conversion to a digital value.

These resistors drift only 5 ppm/C°.

All the temperature sensors are calibrated by placing them (separated from the structures whose temperatures they measure) first stable, controlled bath at 40°C and measuring the actual output at the to the multiplexer 492. The temperature sensors then bath at a temperature of 95°C and their output voltages are again The output voltage of the in a stirred-oil, temperature voltages inputs are placed in a measured at the same points. calibration voltage generator 506 is also measured at the input of the multiplexer 494. the digital output difference from the A/D converter 486 between each of the temperature sensor outputs and the digital For each temperature, from the voltage generated by the 506 The each temperature to output that results calibration voltage generator is measured. calibration constants for sensor calibrate each for changes in temperature may then be calculated.

The sample block temperature sensor is then subjected to a further calibration procedure. This procedure involves driving the sample block to two different temperatures. At each temperature level, the actual temperature of the block in 16 different sample wells is measured using 16 RTD thermocouple probes accurate to within 0.02-c. An average profile for the temperature of the block is then generated and the output of the A/D converter 464 is measured with the block temperature sensor in its place in the sample block.

This is done at both temperature levels. From the actual block temperature as measured by the RTD probes and the A/D the further calibration factor can be calculated. The temperature output for block temperature sensor, a calibration factors backed up RAM 458. so generated are stored in battery Once these calibration factors are - an determined for the eyeten, it is important that the system not drirt appreciably from the electrical characteristics that existed at the time o: calibration. It is important therefore that low drift circuits be selected and that ultralov drift resistors he used.

The aanner in which the CPU 450 controls the sample block temperature can be best understood by reference to the section below describing the control program. However, to illustrate how the electronic circuitry of rigure 47 cooperates with the control software to carry out a PCR protocol consider the tolloving.

The zero crossing detector 566 has two outputs in output bus 568. one or these outputs emits a negative going pulse for every positive going transition of the A.c. signal across the zero voltage reference. The other nits a negative pulse upon every negative—going transition at ‘the A.c. signal across the zero reference voltage level. These two pulses, shown typically at 580 detine one complete cycle or two half cycles. It is the pulse trains on hue 568 which define the 200 lillieecond eanple periods. For 60 cycle/sec A.C_. as found in the U.s., 200 nilliseconds contains 24 half cycles. 1 ' A typical eanple period is shown in Figure 49. Each "tick" mark in Figure 49 represents one halt cycle. During each 200 uec sample period, the C90 450 is calculating the amount or heating or cooling power needed to naintain the sample block tenperature at a user defined setpoint or incubation temperature or to IOVO the bloclc temperature to a new temperature depending upon where in the PCR protocol time line the particular aanple period lies. The amount of power needed in each til: heater zone is converted into a number at half cycle: each heater zone is to retain or: during the next 200 Mac sample period. Just before the end of the current sample period in which these calculations are the CPU 450 addresses each of the 4 timers in the programmable interval timer (PIT) 472. the CPU writes data constituting a "present" count representing the number of half cycles the heater zone associated with that timer is to remain off in the next sample period. In Figure 49, this data is written to the timers during interval 590 just preceding the starting time 592 of the next sample period. Assume that a rapid ramp up to the denaturation temperature of 94°C is called for by the user setpoint data for an interval which includes the sample made, To each timer, Accordingly, the film heaters will be on for most of the period. Assume that the central zone heater is to be on for all but three of the half cycles during the sample period. In this case, the CPU 450 writes a three into the counter in PIT 472 associated with the central zone heater during interval 590. This write operation automatically causes the timer to issue a interval between times 592 and 594. "shut off" signal on the particular control line of bus 592 which controls the central zone heater. This “shut off" signal causes the PAL 484 to issue a "shut off" signal on the particular one of the signal lines in bus 538 associated The triac driver 530 then shuts off at time 592. The PIT receives a pulse train of positive-going pulses on line 594 from the PAL 484. zero-crossing pulses on 2-line bus 568 by PAL 484 into positive going pulses at all zero crossing pulses on 2-line bus 568 by PAL 484 into positive going pulses at all zero crossings on a single line, line 594. The timer in PIT 472 associated with the central film heater zone starts counting down from its present count of 3 using the half At the end of the third half cycle, this timer reaches 0 and causes its This with the central zone. at the next zero crossing, i.e.,‘ These pulses are translations of the i.e., cycle marking pulses on line 594 as its clock. output signal line on bus 592 to change states. transition from the off to on state is shown at 596 in Figure 49. This transition is communicated to PAL 484 and causes it to change the state of the appropriate output signal on bus 538 to switch the triac driver 530 on at the third zero-crossing. Note that by switching the triacs on at the in the embodiment, switching off of a high current flowing through This zero crossings as is done preferred an inductor (the film heater conductor) is avoided. minimizes the generation of radio frequency interference or other noise. Note that the technique of switching a portion of gagh half cycle to the film heater in accordance with the calculated amount of power needed will also work as an alternative embodiment, but is not preferred because of the noise generated by this technique.

The other timers of PIT 472 and 474 work in a similar manner to manage the power applied to the other heater zones and to the heated cover in accordance with power calculated by the CPU.

Ramp cooling is controlled by CPU 450 directly through the peripheral interface 482. when the heating/cooling power calculations performed during each sample period the CPU 450 addresses the peripheral interface controller (PIC) 482. A data word is then written into the appropriate register to This output line triggers a indicate that ramp cooling power is needed, drive output line 600 high. pair of monostable multivibrators 602 and 604 and causes each to emit a single pulse, 606 and 608, These pulses each have peak currents just on lines respectively. under 1 ampere and a pulse duration of approximately 100 milliseconds. The purpose of these pulses is to drive the solenoid valve coils that control flow through the ramp cooling channels very hard to turn on ramp cooling flow quickly. The pulse on line 606 causes a driver 610 to ground a line 612 coupled to one side of the solenoid coil The other terminal of the coil 614 is coupled to a power supply "rail" 616 at +24 volts DC from power supply 576. The one shot 602 controls the ramp cooling solenoid operted valve for flow in of one of the solenoid operated valves. - 39 _. one direction, and the one shot 604 controls the solenoid operated valve for flow in the opposite direction.

Sinultaneously, the activation or the RCOOL signal on line 600 causes a driver 618 to be activated. This driver grounds the line 612 through a current liniting resistor 620. The value of this current limiting resistor is such that the current flowing through line 622 is at least equal to the hold current necessary to keep the solenoid valve 614 open. solenoid coils have transient characteristics that require large currents to turn on a solenoid operated valve but substantially less current to keep the valve open. when the 100 nsec pulse on line 606 subsides, the driver 612 ceases directly grounding the line 612 leaving only the ground connection through the resistor 620 and driver 618 for holding current.

The solenoid valve 614 controls the flow or ramp cooling coolant through the sample block in only 1/2 the ramp cooling tubes, i.e., the tubes carrying the coolant in one direction through the sample block. Another solenoid operated valve 624 controls the coolant flow at coolant through the senle block in the opposite direction. This valve 624 is driven in exactly the same way as solenoid operated valve 614 by drivers 626 and $28, one shot 604 and line 608.

The need for reap cooling is evaluated once every sample period. when the PID task or the control software deterninee tron seaeuring the block tenperature and comparing it to the desired block teaperature that ramp cooling is no longer needed, the RCOOL signal on line 600 is deactivated. This is done by the CP 450 by addressing the PIC 43: and writing data to it which reverses the state of the appropriate hit in the register in PIC 432 which is coupled to line 500.

The PIT 474 also has two other tilors therein which time a 20 H: interrupt and a heating LED which gives a visible indication -when the sample block is hot and unsafe to touch.

The syntax: also includes a beeper one shot 630 and a beeper 632 to warn the user when an incorrect keystroke has been jade.

The programmable interrupt controller 476 is used to detect 7 interrupts; Level 1- test: Level 2-20 3:; Level 3 - I Transmit Ready; Level 4 - Receive ready; Level 5 - Keyboard interrupt; Level 6 — Main heater turn on; and, Level 7 - A.c. line zero cross.

The peripheral interface controller 482 has four outputs (not shown) tor controlling the aultiplexers 492 and 494. These signals HUX1 ER and KUX2 IN enable one or the other of the two multiplexers 492 and 494 while the signals 1-IUX 0 and Km: 1 control which channel is selected for input to the aaplitier 578. These signals are managed so that only one channel from the two Iultiplsxers can be selected at any one time.

An RLTRIGII signal resets a tineout one shot 632 tor the heaters Imich disables the heaters via activation of the signal TIMEOUT RN’: to the PAL 484 it the CPU crashes. That is, the one shot 632 has a predstersined interval which it will wait after each trigger before it activates the signal TDIEOUT 211* which disables all the heater zones. The CPU 450 executes a routineperiodically which addresses the PIC (82 and writes data to the appropriate register to cause activation of a signal on line 634 totriggez the one shot 632. If the CPU 450 'crashes" tor any reason and does not execute this routine, the timeout one-shot 632 disables all the heater zones.

The PIC 482 also has outputs COVHTR DH ‘and BLKH‘I‘REN* (not shown) for enabling the heated cover and the sample block heater. Both of these signals are active low and are controlled by the CPU 450. via bus 636.

The PIC 482 also outputs the signals BEEP and BEEPCLR* on bus 640 to control the beeper one shot 630.

The PIC 482 also outputs a signal MEM1 which is used to switch pages between the high address section of EPROM 456 and the low address section of battery RAM 458. Two other signals PAGE SEL O and PAGE SEL 1 (not shown) are output to select between four 16K pages in EPROM 456.

The four temperature sensors are National LM 135 zener They are output to the PAL 484 (not shown) diode type sensors with a zener voltage/temperature dependence of 10 mV/‘K. The zener diodes are driven from the regulated power supply 498 through the 20K resistor 496.

The current through the zeners varies from approximately 560 uA to 615 uA over the 0°C to 100°C operating range. The zener self heating varies from 1.68 mw to 2.10 mw over the same range.

The multiplexers 492 and 494 are DG409 analog switches.

The voltages on lines 488 and 490 are amplified by an AD625KN instrumentation amplifier with a transfer function of Vun= 3*Vm - 7.5. The A/D converter 486 is an AD7672 with an input range from 0-5 volts. With the zener temperature sensor output from 2.73 to 3.73 volts over the 0°C to 100°C range, the output of the amplifier 578 will be 0.69 volts to 3.69 volts, which is comfortably within the A/D input range.

The key to highly accurate system performance are good accuracy and low drift with changes in ambient temperature.

Both of these goals are achieved by using a precision reference i.e., calibration voltage voltage source, generator 506, and continuously monitoring its output through the same chain of electronics as are used to monitor the outputs of the temperature sensors and the AC line voltage on line 510.

The calibration voltage generator 506 outputs two precision voltages on lines 650 and 652. one voltage is -93.. .75 volts and the other is 3.125 volts. obtained by dividing down a regulated supply voltage using a string of ultralov drift, integrated, thin tils resistors with a 0.05% match between resistors and a 5 ppm/degree C temperature drift coefficient between resistors. The calibration voltage generator also generates -5 volts for the A/D converter reference voltage and -7.5 volts for the instrumentation anplitier offset. These two voltages are communicated to the A/D 436 and the amplifier 578 by lines which are not shown. These two negative voltages are These voltages are »generated using the same thin fill resistor network and GP G2 op—anps (not shown). The gain setting resistors for the operational amplifier 578 are also the ultralow drift, thin-tile, integrated, matched resistors.

The control firmware, control electronics and the block design are designed such that vell-to-well and instrument- to-instrunent transportability of PCR protocols is possible.

High throughput laboratories benefit tron instruments which are easy to use tor a wide spectru or lab personnel and which require a sininal amount of training. The software for the invention was developed to handle complex Pch thernocycling protocols vnile remaining easy to program.

In addition, it is provided with safeguards to assure the integrity of samples during power interruptions, and can docunent the detailed events at each run in sate sesory.

Arte: completing power-up self-checks shown in Figures 53 and 54, to assure the operator that the systen is operating properly, the user interface of the invention offers a simple, top-level nenu, inviting the user to run, create or edit a tile, or to access a utility function. no progranning skills are required, since pre-existing default tiles can be quickly edited with customized tines and temperatures, then stored in semory for later use. A file protection scheme prevent: unauthorized changes to any user's progress. A file normally consists of a set of instructions to hold a desired Complex programs are created A commonly used temperature or to thermocycle. by linking files together to form a method. file, such as a 4°C incubation following a thermocycle, can be stored and then incorporated into methods created by other users. the AUTO file is a PCR cycling program which allows the user to specify which of A new type of file, several types of changes to control parameters will occur time incrementing (auto segment extension, for temperature each cycle: time decrementing, or For the highest degree of yield enhancement), incrementing or decrementing. acontrol precision and most reliable methods transferability, temperatures are setable to 0.1°C, and times are programmed to the nearest second. The invention has the ability to program a scheduled PAUSE at one or more setpoints during a run for reagent additions or for removal of tubes at specific cycles.

The system of the invention has the ability to store a 500 record history file for each run. This feature allows the user to review the individual steps in each cycle and to flag any special status or error messages relating to irre- the With the optional printer, invention hardcopy of file method parameters, run-time time/temperature data with a time/date file gularities. provides documentation and sorted configuration parameters, stamp, directories.

In order to assure reproducible thermocycling, the computed sample temperature is displayed during the ramp and hold segments of each cycle. A temperature one degree lower than the set temperature is normally used to trigger the ramp-time and hold-time clocks, but this can be altered by the user. Provided the proper time constant for the type of tube and volume is used, the sample will always approach the with the regardless of whether long or short sample incubation times desired sample temperature same accuracy, have been programmed. Users can program slow ramps for the specialized annealing requirements of degenerate primer ' -9‘- pools, or very short (1-5 see) high-temperature denaturation periods for very GC rich targets. Intelligent defaults are preprogrammed for 2- and 3-temperature PCR cycles.

Diagnostic tests can be accessed by any users to check the heating and cooling system status, since the software gives Pass/Fail reports. In addition, a system performance program performs a comprehensive subsystem evaluation and generates a summary status report.

The control firmware is comprised of several sections which are listed below: - Diagnostics - Calibration - Install - Real time operating system - Nine prioritized tasks that manage the system - start—up sequence - User interface The various sections of the firaware will be described with either textual description, pseudocode or both.

Features of the firmware are: A Control system that manages the average sample block temperature to within +/- 0.l'C as well as maintaining the temperature non-uniformity as between wells in the sample block to within +/- 0.5'C.

A tenperature control system that measures and compensates for line voltage fluctuations and electronic temperature drift. _ 95 _ Extensive power up diagnostics that determine if system components are working. comprehensive diagnostics in the install program which qualify the heating and cooling systems to insure they are working properly.

A logical and organized user interface, employing a menu driven system that allows instrument operation with minimal dependency on the operators manual.

The ability to link up to 17 PCR protocols and store them as a method.

The ability to store up to 150 PCR protocols and methods in the user interface.

A history file that records up to 500 events of the previous run as part of the sequence task.

The ability to define the reaction volume and tube si__ze type at the start’. of a run _for maximum temperature accuracy and control as part of the user interface and which modifies tau (the tube time constant) in the PID task.

Upon recovery from a power failure, the system drives the sample block to 4°C to save any samples that may be loaded in the sample compartment. The analyzer also reports the duration of the power failure as part of the sequence task.

The ability to print history file contents, "run time" stored PCR protocol parameters as part of the print task. parameters and —95a— The ability to configure to which the apparatus will return during any idle state.

The ability to check that the set point temperature is reached with a reasonable amount of time.

The ability to control the instrument remotely via an RS232 port.

There are several levels of diagnostics which are described below: A series of power—up tests are automatically performed each time the instrument is turned on. They evaluate critical areas of the hardware without user intervention.

Any test that detects a component failure will be run again.

If the test fails twice, an error message is displayed and the keyboard is electronically locked to prevent the user from continuing.

The following areas are tested: Programmable Peripheral Interface device Battery RAM device Battery RAM checksum EPROM devices .

Programmable Interface Timer devices Clock / Calendar device Programmable Interrupt Controller device Analog to Digital section Temperature sensors Verify proper configuration plug A Series of service only diagnostics are available to final testers at the manufacturer's location or to field "hidden" keystroke sequence Many of the tests are the service engineers through a (i.e. unknown to the customer)p same *as the ones in the start up diagnostics with the exception that they can be continually executed up to 99 times.

The following areas are tested: Programmable Peripheral Interface device Battery RAM device Battery RAM checksum EPROM devices Programmable Interface Timer devices (i.e. unknown to the customer).

Clock / Calendar device Programmable Interrupt Controller device Analog to Digital section RS-232 section Display section Keyboard Deeper Ramp Cooling Valves Check for EPROM mismatch Firmware version level Battery RAM Checksum and Initialization Autostart Program Flag Clear Calibration Flag Heated Cover heater and control circuitry Edge heater and control circuitry Manifold heater and control circuitry Central heater and control circuitry Sample block thermal cutoff test Heated cover thermal cutoff test User diagnostics are also available to allow the user to perform a quick cool and heat ramp verification test and an extensive confirmation of the heating and cooling system.

These diagnostics also allow the user to view the history file, which is a sequential record of events that occurred in the previous run. The records contain time, temperature, setpoint number, cycle number, program number and status messages.

Remote Diagnostics are available to allow control of the system from an external computer via the RS-232 port.

Control is limited to the service diagnostics and instrument calibration only.

Calibration to determine various parameters such as heater resistance, etc. is performed. Access to the "hidden" The following parameters calibration screen is limited by a key sequence _98_ are calibrated: The configuration plug is a module that rewires the chiller unit, sample block heaters, coolant pump and power supplies for the proper voltage and frequency (100V/5OHz, 100/6oHz, 120/60Hz, 220/50Hz or 230/50Hz). The user enters the type of configuration plug installed. this information to compute the equivalent resistance of the The firmware uses sample block heaters. Upon power-up, the system verifies that the configuration plug selected is consistent with the current line.voltage and frequency.

The heater calibration process so that precise calculations of heater resistance must be determined in the The user enters the actual (two power delivered can be made. main The resistances of the six sample block heaters heaters, two manifold heaters and two edge heaters). configuration plug physically wires the heater in series for The firmware computes the equivalent resistance of each of the -230 VAC and in parallel for 100-120 VAC operation. three heaters by the following formula: (7) For 100-120 VAC: R” = (R1 * R2) / R1 + R2 R = R For 220-230 VAC: Q 1 (3) + R2 The equivalent resistance is used to deliver a precise amount of heating power to the sample block (Power = Voltagez X Resistance).

The calibration of the A/D circuit is necessary so that temperatures can be precisely measured. This is performed by measuring two test point voltages (TP6 and TP7 on the CPU board) and entering the measured voltages. The output of the A/D at each voltage forms the basis of a two point calibration curve. These voltages are derived from a 5 volt source and are accurate and temperature At the start of each run, precision independent. these voltages are read by the system to measure electronic drift due to temperature because any changes in A/D output is due to temperature dependencies in the analog chain (multiplexer, analog amplifier and A/D converter).

Calibration of the four temperature sensors (sample block, ambient, accurate temperature measurements. coolant and heated cover) is performed for Prior to installation into an instrument, the ambient, coolant, and heated cover temperature sensors are placed in a water bath where their output is recorded (XX.X°C at YYYY mV).

Since temperature accuracy in These values are then entered into the system. these areas is not critical, a one point calibration curve is used.

The sample block sensor is calibrated in the instrument. An array of 15 accurate temperature probes is strategically placed in the sample block in the preferred embodiment. The output of the temperature probes is collected and averaged by a computer. The firmware commands the block to go to 40‘C. the user enters the average block temperature as read by the After a brief stabilizing period probes. This procedure is repeated at 95°C, forming a two point calibration curve.

Calibration of the AC to DC line voltage sampling circuit is performed by entering into the system the output of the AC to DC circuit for two given AC input voltages, The output of the circuit is not linear over the required range (90 - 260 VAC) forming a two point calibration curve. and therefore requires two points at each end (100 and 120, 220 and 240 VAC), but only uses one set based on the current input voltage.

An accurate measure of AC voltage is necessary to deliver a precise amount of power to the sample block (Power = Voltagez x Resistance).

The Install program is a diagnostic tool that performs an extensive test of the cooling and heating systems.

Install measures or calculates control cooling conductance, ramp cooling conductance at 10°C and 18°C, cooling power at °C and 20°C, sample block thermal and coolant capacity and sample block sensor lag. The purpose of install is three fold: . To uncover marginal or faulty components.

. To use some of the measured values as system constants stored in battery backed up RAM to optimize the control system for a given instrument.

. To measure heating and cooling system degradation over time Install is executed once before the system is shipped and should also be run before use or whenever a major component is replaced. The Install program may also be run by the user under the user diagnostics.

The heater ping test verifies that the heaters are properly configured for the current line voltage (i.e. in parallel for 90-132 VAC and in series for 208-264 VAC). The firmware supplies a burst of power to the sample block and then monitors the rise in temperature over a 10 second time period. If the temperature rise is outside a specified ramp rate window, then the heaters are incorrectly wired for the current line voltage and the install process is terminated.

The control cooling conductance tests measures the thermal conductance K“ across the sample block to the control cooling passages. This test is performed by first driving the sample block temperature to 60°C (ramp valves are closed), then integrating the heater power required to maintain the block at 60°C over a 30 second time period.

The integrated power is divided by the sum of the difference between the block and coolant temperature over the interval. (9) K = W 2 Heater Power ww / 2 Block - Coolant Temp Typical values are 1.40 to 1.55 Watts/°C.

A high K“ may be due to a ramp A low K“ may indicate a clogged liner(s). valve that is not completely closed, leakage of the coolant to the outside diameter of the liner, or-a liner that has shifted.

The block thermal capacity (Elk Cp) test measures the thermal capacity of the sample block by first controlling the block at 35°C then applying the maximum power to the heaters for 20 seconds. The block thermal capacity is equal to the integrated power divided by the difference in block the effect of bias cooling power is subtracted from the integrated power. temperature. To increase accuracy, (10) Blk Cp = ramp time * (heater - control cool pwr) / delta temp. where: seconds watts (2 block - coolant temp) * ramp time = heater power = control cool = delta temp = TBlockum — TBlock"o The typical value of Block Cp is 540 watt-seconds/°C : . Assuming a normal K“ value, an increase in block thermal capacity is due to an increase in thermal loads, such as moisture in the foam backing, loss of insulation around the sample block, or a decrease in heater power such as a failure of one of the six heater zones or a failure of the electronic circuitry that drives the heater zones, or an incorrect or an incorrectly wired voltage configuration module.

A chiller test measures the system cooling output in watts at 10°C and 18°C. or The system cooling power, to the The main chiller output, at. a given temperature is equal summation of thermal loads at that temperature. components are: 1. heating power required to maintain the block at a given temperature, 2. power dissipated by the pump used to circulate the coolant around the system, and 3.

The chiller power parameter is measured by controlling the coolant losses in the coolant lines to the ambient. temperature at either 10°C or 18°C and integrating the power applied to the sample block to maintain a constant coolant temperature, over a 32 Asecond interval. The difference between the block and coolant temperature is also integrated to compute losses to ambient temperature. (11) 2 Heating power + Pump power + (Kamb * Z (blk—cool temp)) Chiller power = where: heating power = Sum of heating power required to maintain coolant at 10°C or 18°C over time 32 seconds.

Pump Power = Kamb = Circulating pump, 12 watts Conductance to ambient, 20 watts/‘C blk-cool temp = Sum of difference in block and coolant temp over time 32 seconds Low chiller power may The typical value for chiller power is 230 watts : at 10°C and 370 watts t 30 at 18°C. be due to an obstruction in the fan path, a defective fan, or a marginal or faulty chiller unit. It may also be due to a miswired voltage configuration plug.

(Kg the thermal conductance at 10°C and 18°C across the sample block A ramp cooling conductance test measures to the ramp and control cooling passages. This test is performed by first controlling the coolant temperature at °C or 18°C, then interval, the heating power applied to maintain the coolant at the given temperature divided by the difference of block integrating, over a 30 second time and coolant temperature over the time interval. (12) K = 2 Heating power 1/ 2 (block - coolant C temperature) Typical values for Kc are 28 watts/°C t 3 at 10°C and 31 watts/‘C t 3 at 18°C. A low K: may be due to a closed or obstructed ramp valve, kinked coolant tubing, weak pump or a hard water/Prestone‘ mixture.

A sensor lag test measures the block sensor lag by first controlling the block temperature to 35°C and then applying 500 watts of heater power for 2 seconds and measuring the time required for the block to rise 1°C.

Typical values are 13 to 16 units, where each unit is equal to 200 ms. interface between the sensor and the block, such as lack of A slow or long sensor lag can be due to a poor thermal grease, a poorly machined sensor cavity or a faulty sensor.

The remaining install tests are currently executed by the install program but have limited diagnostic purposes due to the fact that they are calculated values or are a function of so many variables that their results do not determine the source of a problem accurately.

The install program calculates the slope of the ramp cooling conductance (Sc) between 18°C and 10°C. measure of the linearity of the conductance curve.

It is a It is also used to approximate the ramp cooling conductance at 0°C. 0.2. attest to the fact that it is just an approximation.

Typical values are 0.40 i The spread in values (13) S: = (Kc_18° - Kc_10°) / (l8°C - lO°C) The install program also calculates the cooling conductance Kw. Kw is an approximation of the cooling The value is extrapolated from the Typical values are 23 watts/°C conductance at 0°C. actual conductance at 10°C. : 5. The formula used is: (14) K = w Kc_10 - (Sc * 10°C) The install program also calculates coolant capacity (Cool Cp) which is an approximation of thermal capacity of the entire coolant stream (coolant, plumbing lines, heat exchanger, and valves). The cooling capacity is equal to components that pump heat into the coolant minus the components that remove heat from the coolant. The mechanics used to measure and calculate these components are complex and are described in detail in the source code description section. In this measurement, the coolant is allowed to stabilize at 10°C. sample block for a period of 128 seconds.

Maximum heater power is applied to the (15) Cool Cp = Heat Sources - Coolant sources (16) Cool Cp = Heater Power + Pump Power + Kamb * (ZTamb - 2Tcool) - Block Cp * (Tblockuo - Tblockuua) - Average Chiller Power between Tcooluo and Tcool {I123 Characters enclosed in { } indicate the variable names used in the source code.

Heater-Ping Test Eseudocode: The heater ping test verifies that the heaters are properly wired for the current line voltage.

Get the sample block and coolant to a known and stable point.

Turn ON the ramp cooling valves Wait for the block and coolant to go below 5°C Turn OFF ramp cooling valves Measure the effect of control cooling by measuring the block temperature drop over a 10 second Wait 10 seconds for stabilization before cooling time interval. taking any measurements.

Wait 10 seconds templ = block temperature Wait 10 seconds tempz = block temperature {tempa) = tempz - templ Examine the variable {linevolts} which contains the actual measured line voltage. Pulse the heater with 75 watts for a line voltage greater then 190V or with 300 watts if it less than 140v- if ({linevolts} > 190 Volts) then deliver 75 watts to heater else deliver 300 watts to heater Measure the temperature rise over a 10 second time period. The result is the average heat rate in 0.01 °/second. templ = block temperature Wait 10 seconds temp2 = block temperature (tempb} = tempz - templ subtract the average heat rate {tempb} from the control cooling effect to calculate true heating rate (17) heat_rate = {tempb} - {tempa} Evaluate the heat_rate. ‘For 220V—23OV, the heat rate should be less than 0.30 °/second. For 100V-120V the heat rate should be greater than 0.30 °/second. if (linevoltage = 220V and heat_rate > 0.30 °/second) then Error —> Heaters wired for 120 Lock up keyboard if (linevoltage = 120V and heat_rate < 0.30 °/second) then Error -> Heaters wired for 220 Lock up keyboard KCC est eudocode: This test measures the control cooling conductance also known as K“.

K“ is measured at a block temperature of 60°C.

Drive block to 60°C Maintain block temperature at 60°C for 300 seconds Integrate the power being applied to the sample block heaters over a 30 second time period. Measure and integrate the power required to maintain the block temperature with control cooling bias. {dt_sum} {main_pwr_sum} = 0 (main heater power sum) (delta temperature sum) (aux_pwr_sum} 0 (auxiliary heater power sum) for (count = 1 to 30) { {dt_sum} - {dt_sum} + (block temperature — coolant temperature) wait 1 sec Accumulate the power applied to the main and auxiliary heaters. The actual code resides in the PID_control tank and is therefore eummed every 200ms. {main_pwr_sum} - {main_pwr_sum} + {actual_power} {aux_pwr_sum} n {aux_pvr_sum} + {aux1_actual} + {aux2_actual} Compute the conductance by dividing the power sum by the temperature sum. Note that the units are 10 mw/°C.

LOC? CP T at do ex This test measures the sample block thermal capacity.

Drive the block to 35'C Control block temperature at 35°C for 5 seconds and record initial temperature. initial_temp - block temperature Deliver maximum power to heater: for 20 seconds while summing the difference in block to coolant temperature as well an heater power.

Deliver 500 watts {dt_eum) - o for (count = l to 20 seconds) { {dt_sum} = {dt_sum} + (block temperature - coolant temperature) wait 1 second } (19) delta_temp = block temperature - initial_temp Compute the joules in cooling power due to control cooling which occurs during ramp. (20) cool_joule = Control cooling conductance (Kn) {dt_sum) Compute the total joules applied to the block from the main heater and control cooling. Divide by temp change over the interval to compute thermal capacity. (21) Block CP = ramptime * (heater power - cool_joule) / delta_temp where: ramptime = 20 seconds heater power = 500 Watts COOL_PWR_l0: This test measures the chiller power at 10°C.

Control the coolant temperature at 10°C and stabilize for SECS. count = 120 do while (count != O) { if (coolant temperature = 10 : 0.5°C) then count = count - 1 else count = 120 wait 1 second At this point, the coolant has been at 10°C for 120 seconds and has stabilized. Integrate, over 32 seconds, the power being applied to maintain a coolant temperature of 10°C. coolant temperature 0 0 {delta_temp_sum} = O {cool_init} {main_pwr_sum) {aux_pwr_sum} for (count = 1 to 32) { Accumulate the power applied to the main and auxiliary heaters. The actual code resides in the control task. {main_pwr_sum} = {main_pwr_sum} + actual_power {aux_pwr_sum} {aux_pwr_sum} + auxl_actual + aux2_actual delta_temp_sum = delta_temp_sum + (ambient temp - coolant temp) wait 1 second } Compute the number of joules of energy added to the coolant mass during the integration interval. "(coolant temp - cool_init)" is the change in coolant temp during the integration interval. 550 is the Cp of the coolant in joules, thus the product is in joules. It represents the extra heat added to the coolant which made it drift ~ 110 - from setpoint during the integration interval. This error is subtracted below from the total heat applied before calculating the cooling power. (22) cool_init = (coolant temp - cool_init) * SSOJ Add the main power sum to the aux heater sum to get joules dissipated in 32 seconds. Divide by 32 to get the average joules/sec. (23) {main_pwr_sum} = ({main_pwr_sum}+{aux_pwr_sum} — cool_init) / 32 Compute the chiller power at 10°C by summing all the chiller power components. (24) Powerww = main_power_sum + PUMP PWR + (K_AMB * delta_temp_sum) where: {main_pwr_sum} = summation of heater power over interval PUMP PWR = 12 Watts, pump that circulates coolant delta_temp_sum = summation of amb - coolant over interval X_AMB = 20 Watts/K, thermal conductance from cooling to ambient.

KC 10 Iest Eseudocode: This test measures the ramp cooling conductance at 10°C.

Control the coolant temperature at 10°C : 0.5 and allow it to stabilize for 10 seconds.

At this point, the coolant is at setpoint and is being * lll - controlled. Integrate, over a 30 second time interval, the power being applied to the heaters to maintain the coolant at 10°C. Sum the difference between the block and coolant temperatures. {main_pwr_sum} = O {aux_pwr_sum} = O {dt_sum} = O for (count = 1 to 30) { Accumulate the power applied to the main and auxiliary heaters. The actual code resides in the PID control task. {main_pwr_sum} {main_pwr_sum} + actual_power {aux_pwr_sum} {aux_pwr_sum} + aux1_actual + aux2_actua1 {dt_sum} = {dt_sum} + (block temperature - coolant temp) wait 1 second } Compute the energy in joules delivered to the block over the summation period. Units are in 0.1 watts. (25) {main_pwr_sum} = {main_pwr_sum} + {aux_pwr_sum} Divide the power sum by block - coolant temperature sum to get ramp cooling conductance in 100 mw/K. (26) Kc_1O = {main_pwr_sum} / {dt_sum) COOL_PWR 18 Test Pseudocode: This test measures the chiller power at 18°C Get the sample block and coolant to a known and stable point. Control the coolant temperature at 18°C and stabilize for 128 secs. count = 128 do while (count != O) if (coolant temperature = 18°C : 0.5) then count = count - 1 else count = 120 wait 1 second At this point the coolant has been at 18°C for 120 seconds and has stabilized. Integrate, over 32 seconds, the power being applied to maintain a coolant temperature of 18°C. {cool_init} - coolant temperature {main_pwr_sum} = 0 {aux_pwr_sum} = O {de1ta_temp_sum} = 0 for (count = 1 to 32) { Accumulate the power applied to the main and auxiliary heaters. The actual code resides in the control task. {main_pwr_sum} = (main_pwr_sum} + actual_power {aux_pwr_sum} - {aux_pwr_sum} + aux1_actual + aux2_actual delta_temp_sum = delta_temp_sum + (ambient temp - coolant temp) wait 1 second } Compute the number of joules of energy added to the coolant mass during the integration interval. "(coolant temp - cool_init)" is the change in coolant temp during the integration interval. 550 is the Cp of the coolant in joules, thus the product is in joules. It represents the extra heat added to the coolant which made it drift setpoint during the integration interval. This error is subtracted below from the total heat applied before calculating the cooling power. (27) cool_init = (coolant temp - cool_init) * 550 Add main power sum to aux heater sum to get joules dissipated in 32 seconds. Divide by 32 to get the average joules/sec. (28) (main_pwr_sum} = ({main_pwr_sum}+{aux;pwr_sum} - cool_init) / 32 Compute the chiller power at 18°C by summing all the chiller power components. (29) Powergrc = main_power_sum -+ PUMP PWR -+ (K_AMB * delta_temp_sum) where: {main_pwr_sum} = summation of heater power over interval PUMP PWR = 12 Watts, pump that circulates coolant delta_temp_sum summation of amb - coolant over interval K_AMB = 20 Watts/K, Thermal conductance from cooling to ambient. est eudoc d : This test measures the ramp cooling conductance at 18°C.

Control the coolant temperature at 18°C : 0.5 and allow it to stabilize for 10 seconds.

At this point, the coolant is at setpoint and being controlled. Integrate, over a 30 second time interval, the power being applied to the heaters to maintain the coolant at 18°C. Sum the difference between the block and coolant temperature. ll 0 {main_pwr_sum} {aux_pwr_sum} = 0 {dt_sum} ll 0 for (count = 1 to 30) { Accumulate the power applied to the main and auxiliary heaters. The actual code resides in the control task. {main_pwr_sum} = {main_pwr_sum} + actual_pover (aux_pwr_sum} = {aux_pwr_sum} + aux1_actual + aux2_actual {dt_sum} = {dt_sum} + (block temperature - coolant temp) wait 1 second seconds then - 115 ' Compute the energy in joules delivered to the block over the summation period. Units are in 0.1 watts. (30) {main_pwr_sum} - {main_pwr_sum} + {aux_pwr_sum} Divide power sum by block — coolant temperature sum to This test measures the sample block sensor lag.

Drive the block to 35°C. Hold within : 0.2°C for 20 record temperature of block. {tempa} = block temperature Deliver 500 watts of power to sample block.

Apply 500 watts of power for the next 2 seconds and count the amount of iterations through the loop for the block temperature to increase 1°C. Each loop iteration executes every 200 ms, therefore actual sensor lag is equal to count * 200 ms. secs - 0 count - 0 do while (TRUE) if (secs >= 2 seconds) then shut heaters off if (block temperature - tempa > 1.0°C) then exit while loop count = count + 1 end do while sensor lag = count Coo an st s ud d This test computes the coolant capacity of the entire system. stabilize the coolant temperature at 10°C i 0.5.

Send message to the PID control task to ramp the coolant temperature from its current value (about 10“C) to 18°C.

Wait for the coolant to cross 12°C so that the coolant CP ramp always starts at the same temperature and has clearly started ramping. Note the initial ambient and block temperatures. do while (coolant temperature < 12°C) { wait 1 second } {blk_delta} - block temperature {h2o_delta} - coolant temperature For the next two minutes, while the coolant temperature is ramping to 18°C, sum the coolant temperature and the difference between the ambient and coolant temperatures. (temp_sum} = 0 {cool_sum} = 0 for (count 1 to 128 seconds) { (32) {cool_sum) = temperature. {temp_sum) = ambient - coolant temperature cool_temp_sum + coolant wait 1 second count = count + l } Calculate the change in temperatures over the two minute period. (34) {blk_delta} = block temperature - {blk_delta} (35) {h2o_delta} = coolant temperature - {h2o_delta} Compute Kchill, i.e., the rate of change of chiller power with coolant temperature over the coolant range of 10°C to 20°C. Note that units are in watts/10°C. (36) Kchill = (Chiller Pwr G 18°C - Chiller Pvr 6 10°C) e Sc which is the slope of the ramp cooling 8°C to Comput conductivity) versus the temperature range of 1 °C. The units are in watts/10°C/10°C. (37) SC = (KC_18 - Kc_10) / 8 Compute Kc_0, the ramp cooling conductance extrapolated to 0°C. (38) Kc_0 = Kc_10 - (Sc * 10) Compute Cp_Cool, the Cp of the coolant by: (39) Cp_Coo1 = ( HEATPOWER * 128 + PUMP_PWR * 128 h2o_delta where: HEATPOWER = PUMP_PWR = Pwr_o°c Block_Cp = blk_delta - K_AMB = temp_sum = h2o_delta = Kchill Power 9 0°C * 128 Block_Cp * blk_delta K_AMB * temp_sum Kchill * cool_temp_sum ) / W, the heater power applied to warm the block, thus heating the coolant.

It is multiplied by 128, as the heating interval was 128 secs.

W, circulates the coolant multiplied by the power of the pump that seconds.

The chiller power at 0°C multiplied by l28 seconds.

Thermal capacity of sample block.

Change in block temp over the heating interval.

Watts/K, thermal conductance from cooling to ambient.

The sum once per second of ambient - coolant temperature over the interval.

Change in coolant temperature over interval of heating (approximately 6°C). slope of chiller power versus coolant temp. cool_sum = The sum of coolant temp, once per second, over the heating interval.

REAL TIME OPERATING SYSTEM - CRETIE CRETIN is a stand alone, multitasking kernel that provides system services to other software modules called tasks. Tasks are written in the "C" language with some time , Each task has a priority level and provides an independent function.

CRETIN resides in low memory and runs after the startup critical areas written in Intel 8085 assembler. diagnostics have successfully been executed.

CRETIN handles the task scheduling and allows only one task to run at a time. CRETIN receives all hardware interrupts thus enabling waiting tasks to run when the proper interrupt is received. CRETIN provides a real time clock to allow tasks to wait for timed events or pause for CRETIN communication through a system of message nodes. known intervals. also provides intertask The firmware is composed of nine tasks which are briefly described in priority order below. subsequent sections will describe each task in greater detail.

. The control task (PID) is responsible for controlling the sample block temperature.

. The keyboard task is responsible for processing keyboard input from the keypad.

. The timer task waits for a half second hardware interrupt, then sends a wake up message to both the sequence and the display task.

. The sequence task executes the user programs.

. The pause task handles programmed and keypad pauses vhen a program is running.

The display task updates the display in real time.

The printer task handles the RS-232 port communication and printing.

The LED task is responsible for driving the heating LED. It is also used to control the coolant temperature while executing Install.

The link task starts files that are linked together in a method by simulating a keystroke.

Block Temperature Control Program (PID Tasgl The Proportional Integral Differential (PID) task is block as well as controlling the sample (TNU, defined as the temperature of the hottest well minus the temperature of the coldest well) to less than t power to the perimeter of the block to compensate for losses The PID task is responsible for controlling the temperature of the heated responsible for controlling the absolute sample temperature to O.l°C, block temperature non-uniformity 0.5°C by applying more heating through the guard band edges. also cover to a less accurate degree. This task runs 5 times per second and has the highest priority.

The amount of heating or cooling power delivered to the sample block is derived from the difference or "error" between the user specified sample temperature stored in called the setpoint, and the current calculated This scheme follows the standard loop memory, sample temperature. control practice. In addition to a power contribution to the film heaters directly proportional to the current error, i.e., the proportional component, (setpoint temperature minus sample block temperature), the calculated power also incorporates an integral term that serves to close out any static error (Setpoint temperature - Block temperature less than O,S°C). This called the To avoid integral term accumulation or "wind- component is integral component. up", contributions to the integral are restricted to a small band around the setpoint temperature. The proportional and integral component gains have been carefully selected and tested, sensor and sample tube severely restrict the system's phase as the time constants associated with the block margin, thus creating a potential for loop instabilities.

The proportional term gain is P in Equation (46) below and the integral term gain is Ki in Equation (48) below.

The PID task uses a where the block temperature often overshoots its final "controlled overshoot algorithm" steady state value in order for the sample temperature to arrive at its desired temperature as rapidly as possible.

The of the the block temperature to overshoot in a controlled manner but does not use overshoot algorithm causes cause the sample temperature to overshoot. This saves power and is believed to be new in PCR instrumentation.

The total power delivered to all heater of the sample block to achieve a desired ramp rate is given by: (40) Power = (CP / ramp_rate) + bias where: bias Thermal mass of block bias or control cooling power ramp_rate = T - THHH“ / desired ramp rate final This power is clamped to a maximum of 500 watts of heating power for safety. system applies heating or ramp cooling power (if necessary) With every iteration of the task (every 200ms) based on the following algorithms.

The control system is driven by the calculated sample temperature. The sample temperature is defined as the average temperature of the liquid in a thin walled plastic sample tube placed in one of the wells of the sample block (herafter the "block"). (sample tube and its contents) is a function of the tube The time constant of the system type and volume. At the start of a run, the user enters the tube type and the amount of reaction volume. The system For the MicroAmp' tube and 100 microliters of reaction volume, computes a resultant time constant (7 or tau). tau is approximately 9 seconds. (41) T = T urn“ bu + Power * (200ms / CP) (42) Tmpm“ = Twp + (Tbwnw - Twp) * 200ms / tau where: Tmbmfi = Current block temperature Tut = Block temperature 200ms ago Power = Power applied to block CP = Thermal mass of block T"w”" = Current sample temperature I;mD = Sample temperature zooms ago tau = Thermal Time Constant of sample tube, adjusted for sensor lag (approximately 1.5) The error signal or temperature is simply: (43) error - setpoint - T;‘c_ As a corrective action (heating or cooling power) in any closed loop system, is applied to close out part of the current error. In Equation (45) below,F is the fraction of the error signal to be closed out in one sample period (zooms). (44) T = T ._ww“ + F « (sp - T“_g) also where SP = the user setpoint temperature Due to the large lag in the system (long tube time constant), the fraction F is set low.

Combining formulas (42) and (44) yields: T = T + (45) In;-new um (SP-Tum) (T T * .2 / tau = T + F * blk-new- sacs) Combining formulas (41) and (45) and adding a term P (the proportional term gain) to limit block temperature oscillations and improve system stability yields: (46) Pm: = cp * P/T * ((5? - Tm) * F * tau/T + T_ - Tm) where P = the proportional term gain and T = the sample period of 0.2 seconds (200 msec).

P/T = 1 in the preferred embodiment Equation (46) is a theoretical equation which gives the power (Pwr) needed to move the block temperature to some desired value without accounting for losses to the ambient through the guardbands, etc.

Once the power needed to drive the block is determined via Equation (46), this power is divided up into the power to be delivered to each of the three heater zones by the areas of these zones. Then the losses to the manifolds are determined and a power term having a magnitude sufficient to compensate for these losses is added to the amount of power to be delivered to the manifold heater zone. Likewise, another power term sufficient to compensate for power lost to the block support pins, the block temperature sensor and the ambient is added to the power to be delivered to the eddge heater zones. These additional terms and the division of power by the area of the zones convert Equation (46) to (4) and (5) given above. (45) embodiment of the control system to determine the required Equations (3), Equation is the formula used by the preferred heating or cooling power to the sample block.

When the computed sample temperature is within the "integral band", i.e., : O.5°C around the target temperature (SP), close out the remaining error. the gain of the propc:tional term is too small to Therefore an integral term is added to the proportional term to close out small errors.

The integral term is disabled outside the integral band to prevent a large error signal from accumulating. The algorithm inside the "integral band" is as follows: (47) Int_sum (new) (48) pwr_adj Int_sum (old) + (SP - T;m¢) Ki * Int;sum (new) where, Int_sum = the sum of the sample period of the difference between the SP and Tgmp temperature; and Ki = the (512) preferred embodiment). integral gain in the Once a heating power has been calculated, the control software distributes the power to the three film heater zones 254, 262 and 256 in Figure 13 based on area in the preferred embodiment. based temperature and The edge heaters receive additional block Similarly, the power upon the difference between the ambient temperature. manifold heaters receive additional power based upon the difference between the block temperature and the coolant '12?‘- temperature.

P_I.D._r;ze4:.d2s;9s1.e Upon system Power up or Reset Turn or! ramp cooling Turn of: all heater: calculate heater resistances Do Forever - executes every 200:5 If (block temperature > 105) then Turn otf heaters Turn on ramp valves Display error message Read the line voltage {linevolts} Read— the coolant sensor and convert to tenparature (h2otenp} Read the ambient sensor and convert to temperature {anbtenp} Read the heated cover eeneor and convert to temperature {cvrtenp} Read the sample block eeneor and convert to temperature (b1ktanp}. This portion or the code« also reads the temperature stable voltage reterence and compare: the voltage to a reference voltage that was detarained during calibration of the inetrunent. If there is any discrepancy, the electronics have drifted and the voltage readings from the temperature sensors are adjusted accordingly to obtain accurate temperature readings.

Compute the sample temperature {tubetenths} or the temperature that gets displayed by using a low-pass digital filter. (49) tubetenths = TTN, + (TBn - TTW1) * T/tau where TT~1 = last sample temp {tubetenths} TB“ = current block sensor temp {blktenths} T = sample interval in seconds - 200ms tau = tau tube {cf_tau} - tau sensor {cf_lag} Equation (49) represents the first terms of a Taylor series expansion of the exponential that defines the calculated sample temperature given as Equation (6) above. compute the temperature of the foam backing underneath the sample block, {phantenths} known as the phantom mass. The temperature of the phantom mass is used to adjust the power delivered to the block to account for heat flow in and out of the phantom mass. The temperature is computed by using a low pass digital filter implemented in ' software. (50) phantenths = TTW1 + (TBn - TTm‘) * T/tau where TTW, = Last phantom mass temp {phantenths} TB“ = Current block sensor temp {blktenths} T = sample interval in seconds - zooms taunu‘ = Tau of foam block = 30 secs.

Compute the sample temperature error (the difference between the sample temperature and the setpoint temperature) {abs_tube_err}.

Determine ramp direction {fast_ramp} = UP_RAMP or DN_RAMP If (sample temperature is within ERR of setpoint (SPJ) then PID not in fast transition mode. {fast_ramp} = OFF where ERR = the temperature width of the "integral band", i.e., the error band surrounding the target or setpoint temperature.

Calculate current control cooling power {cool_ctrl} to determine how much heat is being lost to the bias cooling channels.

Calculate current ramp cooling power {cool_ramp} Calculate {cool_brkpt}. {cool_brkpt} is a cooling power that is "used to determine when to make a transition from ramp to control cooling on downward ramps. It is a function of block and coolant temperature.

The control cooling power {cool_ctrl} and the ramp cooling power {cool_ramp} are all factors which the CPU must know to control downward temperature ramps, i.e., to calculate how long to keep the ramp cooling solenoid operated valves open.

The control cooling power is equal to a constant plus the temperature of the coolant times the thermal Conductance from the block to the bias cooling channels. Likewise, the ramp cooling power is equal to the difference between the block temperature and the coolant temperature times the thermal conductance from the block to the ramp cooling channels.

The cooling breakpoint is equal to a constant times the difference in temperature between the block and the coolant.

Calculate a heating or cooling power {int_pvr} needed to move the block temperature from its current temperature to the desired eetpont (SP) temperature. (51) {int_ps.n.-} - xx: - or vs ((3? - T”) - {ci'_kd} «- Ts - T3“) where: ’ xr Proportional gain - P/T in Equation (46) - approximately one in the preferred embodiment CP - Thermal mass of block SP 8 Temperature setpoint Tn” I Sample temperature T“; - Block temperature ct_kd - Tau t X‘ / De1ta_t where tau is the same tau as used in Equation (49) and X3 is a constant and Delta_t is the 200 Iaec sample period.

If (sample temperature is within {cr_iband} of setpoint) then integrate sample error {i_sun} else (52) clear {i_sun - 0}. calculate the integral term power. (53) integral term - {i_eun} t constant {of_tern}.

Add the integral term to the power. (54) {int_pwr) - {int_pur} + integral term Adjust power to compensate tor heating load due to the effects or the phantom mass (roam backing) by first finding the phantom mass power then adding it to power {int_pwr}.

Calculate phantom mass power {phant_pwr} by: (55) phant_pwr = C * (blktenths — phantenths) / 10 where: C = thermal mass of foam backing (1.0 W/K) Adjust heater power {int_pwr} = {int_pwr} + {phant_pwr} Compute power needed in manifold heaters {aux1_power} which will compensate for loss from the sample block into the manifold edges that have coolant flowing through it.

Note that if the system is in a downward ramp, {auxl_power} = O. The manifold zone power required is described below: l5 (57) {auxl_power} - K1*('rm - Tm) + x2*('rm - mm“) + K5*(dT/dt) where: X1 = Coefficient {cf_1coeff} X2 = Coefficient {cf_2coeff} X5 = Coefficient {cf_5coeff} dT/dt - Ramp rate T“: = Block temperature Tn“ = Ambient temperature Tam_= Coolant temperature Compute power needed in edge heaters (aux2_power} which will compensate for losses from the edges of the sample block to ambient. Note that if we are in a downward ramp {aux2_power} = O. The edge zone power prequired is described below: (S8) {aux2_power} = K3*('rm TAMB) + K4*('rm Team) + K6*(dT/dt) where: K3 = Coefficient {cf_3coeff} X4 = Coefficient {cf_4coeff} X6 = Coefficient {cf_6coeff} dT/dt = Ramp rate T“: .= Block temperature T“, = Ambient temperature TunL = Coolant temperature Delete contribution of manifold {aux1_power} and edge heater power {aux2_power} to obtain total power that must be supplied by main heaters and coolers.

(S9) {int_pwr} = {int_power} - {aux1_power} - (aux2_power} Decide if the ramp cooling should be applied. Note that {cool_brkpt} is used as a breakpoint from ramp cooling to control cooling.

If (int_pwr < cool_brkpt and performing downward ramp) to decide whether block temperature is so much higher than the setpoint temperature that ramp cooling is needed then Turn ON ramp valves else Turn OFF ramp valves and depend upon bias cooling At this point, {int_pwr} contains the total heater power and {auxl_power} and {aux2_power} contain the loss from the block out to the edges. The power supplied to the auxiliary heaters is composed of two components: aux_power and int_power. The power is distributed {int_pwr} to the main and auxiliary heaters based on area. total_pwr = int_pwr int_pwr total_pwr 1 66% total_pwr * 20% + auxl_power aux1_power aux2_power total_pwr * 14%+ aux2_power Compute the number of half cycles for the triac to conduct for each end zone and each iteration of the control loop to This loop executes once every 1/5 second, therefore there are 120/5 = 24 half cycles at 60Hz or 100/5 - 20 at Sofiz. The number of half cycles is a function of requested power send the appropriate amount of power to the heaters. {int_pwr}, the current line voltage {linevolts} and the heater resistance. Since the exact power needed may not be delivered each loop, a remainder is calculated {delta_power} to keep track of what to include from the last loop. (60) int_pwr = int_pwr + delta_power Calculate the number of 1/2 cycles to keep the triac on.

Index is equal to the number of cycles to keep the triac on. (51) linevolts squared where Equation (61) is performed once for index = power * main heater ohms * [20 or 24] / each heater zone and where "power" a int_pwr for the main heater zone, auxl_pwr for the manifold heater zone and aux2_pwr for the edge heater zone.

Calculate the amount of actual power delivered. (62) actual_power = linevolts squared * index / main heater resistance Calculate the remainder to be added next time. (53) delta_power = int_pwr - actual_power Calculate the number of 1/2 cycles for the edge and manifold heaters using the same technique described for the main substituting Equation (60). heaters by {aux1_pwr} and {aux2_pwr} into Load the calculated counts into the counters that control the main, manifold and edge triacs.

Look at heated cover sensor. If heated cover is less than 100°C, then load heated cover counter to supply 50 watts of power.

Look at sample temperature. If it is greater than 50°C, turn on HOT LED to warn user not to touch block.

END OF FOREVER LOOP fieyboard Iask The purpose of the keyboard task is to wait for the user to press a key on the keypad, compare the key to a list of valid keystrokes for the current state, execute the command function associated with the valid key and change to a new Invalid keystrokes are indicated with a beep and This task is the heart of the state driven user interface. It is “state driven" taken depends on the current state of the user interface. state. then ignored. because the action Keyboard Task Pseudocode: Initialize keyboard task variables.

Turn off the cursor.

If (install flag not set) then Run the install program.

Send a message to pid task to turn on the heated cover.

If (the power failed while the user was running a program) then Compute and display the number of minutes the power was off for.

Write a power failure status record to the history file.

Send a message to the sequence task to start a 4°C soak.

Give the user the option of reviewing the history file.

If (the user request to review the history file) then Go to the history file display.

Display the top level screen.

Do Forever Send a message to the system that this task is waiting for a hardware interrupt from the keypad.

Go to sleep until this interrupt is received. when awakened, read and decode the key from the keypad.

Get a list of the valid keys for the current state.

Compare the key to the list of valid keys.

If (the key is valid for this state) then Get the "action" and next state information for this key.

Execute the "action" (a command function) for this state.

Go to the next state.

Else Beep the beeper for an invalid key.

End of Forever Loop r 137 - Timer Iask overview The purpose of the timer task is to wake up the sequence and the real time display task every half a second. The timer task asks the system (CRETIN) to wake it up whenever the half second hardware interrupt that is generated by the clock/calendar device is received. The timer task then in turn sends 2 wake up messages to the sequence task and the real time display task respectively. This intermediate task is necessary since CRETIN will only service one task per interrupt and thus only the higher priority task (the sequence task) would execute.

Timer Iask Pseudocode: Do Forever send a message to the system that this task is waiting for a hardware interrupt from the clock/calendar device.

Go to sleep until this interrupt is received.

When awakened, send a message to the sequence and to the real time display task.

End Forever Loop runtime information.

Sequence Task Overview The purpose of the sequence task is to execute the contents of a user defined program. It sequentially steps through each setpoint in a cycle, consisting of a ramp and a hold segment, and sends out setpoint temperature messages to the pid task which in turn controls the temperature of the sample block. At the end of each segment, it sends a message to the real time display task to switch the display and a message to the printer task to print the segment's The user can pause a running program by pressing the PAUSE key on the keypad then resume the program by pressing the START key. The user can prematurely This task executes every half a second when it is awakened by the abort a program by pressing the STOP key. ' timer task.

Segnence Iask Eseudocode: Do Forever Initialize sequence task variables.

Wait for a message from the keyboard task that the user has pressed the START key or selected START from the menu or a message from link task that the next program in a method is ready to run.

Go to sleep until this message is received.

Whenawakened,update the ADC calibration readings to account for any drift in the analog circuitry.

If (not starting the 4°C power failure soak sequence) then Send a message to the printer task to print the PE title line, time and date, configuration system program parameters, the program type and its number.

If (starting a HOLD program) then Get the temperature to hold at {hold_tp}.

Get the number of seconds to hold for {hold_time}.

If (ramping down more than 3°C and {hold_tp} > 45°C) then Post an intermediate setpoint.

Else Post the final setpoint {hold_tp}.

While (counting down the hold time {hold_time}) 2 Wait for half second wake up message from timer task.

Check block sensor for open or short.

If (keyboard task detected a PAUSE key) then Post a setpoint of current sample temp.

Send a message to wake up the pause task.

V’ Go to sleep until awakened by the pause task.

Post pre-pause setpoint.

If (an intermediate setpoint was posted) then Post the final setpoint.

If (the setpoint temp is below ambient temp and will there for more than 4 min.) then set a flag to tell pid task to turn off the heated cover.

Increment the half second hold time counter {store_time}.

Post the final setpoint again in case the hold time expired before the intermediate setpoint was reached - this insures the correct setpoint will be written the history file. write a data record to the history file. send a message to the printer task to print the HOLD info.

End of HOLD program Else if (starting a CYCLE program) then Add up the total number of seconds in a cycle {secs_in_run}, taking into account the instrument ramp time and the user programmed ramp and hold times.

Get the total number of seconds in the program by multiplying the number of seconds in a cycle by the number of cycles in a program {num_cyc}.

Total {secs_in_run} = {secs_in_run} per cycle * {num_cyc}.

While (counting down the number of cycles {num_cyc}) ramp) While number of setpoints {num_seg}) (counting down the Get the ramp time {ramp_time}.

Get the final setpoint temp {t_final}.

Get the hold time {local_time}.

Send a message to the real time display task to display the ramp segment information.

If (the user programmed a ramp time) then the programmed ramp time and the actual ramp time as Compute error {ramp_err} between the follows. data.

This equation is based on empirical {ramp_err} = prog ramp_rate * 15 + 0.5 (up ramp) {ramp_err} = prog ramp_rate * 6 + 1.0 (down where: prog ramp_rate = (abs(T, - Tc) - 1) / {ramp_time} T, -_setpoint temp {t_final} T: = current block temp {blktemp} abs - absolute value of the expression Note: the '- 1' is there because the clock starts within 1°C of setpoint. new ramp_time - old {ramp_time) - {ramp_err} If (new ramp_time > old {ramp_time}) then new ramp_time = old {ramp_time}.

Else new ramp_time = 0.

While (sample temp is not within a user configured temp {cf_clk_dev} of setpoint) Wait for half second wake up message from timer task.

Post a new ramp setpoint every second.

Else if (ramping down more than 3°C and {t_final} °C) then Post an intermediate setpoint.

While (sample temp is not within a user configured temp {cf_clk_dev} of setpoint) Wait for half second wake up message from timer task.

Increment the half second ramp time counter.

Check block sensor for open or short.

If (keyboard task detected a PAUSE key) then Post a setpoint of current sample temp. send a message to wake up the pause task.

Go to sleep until awakened by the pause task.

Post pre-pause setpoint.

Post the final setpoint.

While (sample temp is not within a user configured temp (cf_clk_dev} of setpoint) Wait for half second wake up message from timer task. i Increment the half second ramp time counter.

Check block sensor for open or short.

If (keyboard task detected a PAUSE key) then Post a setpoint of current sample temp.

Send a message to wake up the pause task.

Go to sleep until awakened by the pause task.

Post pre-pause setpoint.

Send a message to the printer task to print the ramp information.

Beep beeper to signal end of ramp segment. send a message to the real time display task to display the ramp segment information.

While (counting down the hold time) Wait for half second wake up message from timer task.

Increment the half second hold time counter.

Check block sensor for open or short.

If (keyboard task detected a PAUSE key) then Post a setpoint of current sample temp.

Send a message to wake up the pause task.

Go to sleep until awakened by the pause task.

Post pre-pause setpoint.

Write a data record to the history file.

Send a message to the printer task to print the hold information.

If (the final setpoint temp has drifted more than the user configurable amount {cf_temp_dev}) then write an error record to the history file.

Check for a programmed pause.

Go to next segment.

Send a message to the printer task to print an end of cycle message.

Go to next cycle.

End of CYCLE program. ‘ 143 - Else if (starting an AUTO-CYCLE program) then Add up the total number of seconds {secs_in_run) taking into account the instrument ramp time the which automatically incremented or decremented by a programmed in each program and user programmed hold times can be amount each cycle.

While (counting down-the number of cycles {num_cyc}) While the number of {num_seg}) Get the final setpoint temp {t_final}.

Get the hold time {time_hold}.

Check if the user programmed an auto increment or (counting down setpoints decrement of the setpoint temp and/or the hold time and adjust them accordingly.

If (the auto increment or decrement of the temp causes the setpoint. to go below 0°C or above 99.9°C) then An error record is written to the history file.

The setpoint is capped at either 0°C or 99.9°C.

Send a message to real time display task to display the ramp segment information.

If (ramping down more than 3°C and {t_final) > °C) then Post an intermediate setpoint.

While (sample temp is not within a user configured temp {cf_c1k_dev} of setpoint) Wait for half second wake up message from timer task.

Increment the half second ramp time counter.

Check block sensor for open or short.

If (keyboard task detected a PAUSE key) then Post a setpoint of current sample temp.

Send a message to wake up the pause task.

Go to sleep until awakened by the pause task.

Post pre-pause setpoint.

Post the final setpoint.

While (sample temp is not within a user configured temp {cf_clk_dev} of setpoint) Wait for half second wake up message from timer task.

Increment the half second ramp time counter.

Check block sensor for open or short.

If (keyboard task detected a PAUSE key) then Post a setpoint of current sample temp.

Send a message to wake up the pause task.

Go to sleep until awakened by the pause task.

Post pre-pause setpoint.

Send a message to the printer task to print the ramp segment information.

Beep beeper to signal end of ramp portion of segment.

Send a message to the real time display task to display the hold segment information.

While (counting down the hold time) Wait for half second wake up message from timer task.

Increment the half second hold time counter.

Check block sensor for open or short.

If (keyboard task detected a PAUSE key) then Post a setpoint of current sample temp.

Send a message to wake up the pause-task.

Go to sleep until awakened by the pause task.

Post pre—pause setpoint.

Write a data record to the history file. send a message to the printer task to print the hold information.

If (the final setpoint temp has drifted more than user configurable amount {cf_temp_dev}) then Write an error record to the history file.

Go to next segment.

-Send a message to the printer task to print an end of cycle message.

Go to next cycle.

End of AUTO-CYCLE program.

Else if (starting a POWER FAILURE sequence) then Post a setpoint of 4°C.

Set a flag {subamb_hold} so that the pid task will shut off the heated cover.

DO FOREVER Wait for a half second wake up message from the timer task.

Increment the half second hold time counter.

END FOREVER LOOP End of power failure sequence write a run end status record to the history file.

If (running a method) Set a flag {weird_flag} so the link task will know to send a message to the sequence task to start the next program running.

Else Return user interface to idle state display.

End of Forever Loop Eause Task Overview The purpose of the pause task is to handle either a pause that the user programs in a CYCLE program or a pause when the user presses the PAUSE key on the keypad.

When the sequence task encounters a programmed pause while executing a CYCLE program, it goes to sleep and awakens the pause task. The pause task in turn sends a message to the real time display task to continually display and decrement the time the user asked to pause for. When the pause timer times out, the pause task sends a message to awaken the sequence task and then goes to sleep. The user can prematurely resume the program by pressing the START key on the keypad or can prematurely abort the program by pressing the STOP key. when the keyboard task detects a PAUSE key while a program is running, it sets a flag {pause_flag} then waits for the sequence task to acknowledge it. when the sequence task sees this flag set, it sends an acknowledgment message back When the it awakens the pause to the keyboard task then puts itself to sleep. keyboard task receives this message, task. display task to continually display and increment the amount The pause task sends a message to the real time of time the program is paused for. The timer will time out when it reaches the pause time limit set by the user in the configuration section. The user can resume the program by pressing the START key on the keypad or abort the program by pressing the STOP key.

Pause Task Eseudocode: Do Forever Wait for a message from the keyboard task indicating a form the indicating a user programmed pause. keypad pause, or a message sequence task Go to sleep until a message is received.

When the initiated. awakened, check a flag for of pause type If (it is a programmed pause) then Send a message to the real time display task to display the pause timer counting up.

Else Send a message to the real time display task to display the pause timer counting down.

While (counting down the time out counter) Send a message to the system to suspend this task for half a second.

Send a message to the printer task to print the pause einformation.

If (it is a programmed pause) then The pause has timed out so send a message to the wake up the sequence task.

Send a message to the real time display task to halt the pause display.

Send a message to the real time display task to resume the running program display.

Else (it is a keypad pause) The pause has timed out and the program must be aborted so send a message to the system to halt the sequence task and send it back to the top of its FOREVER loop.

If (the program running was a HOLD program) send a message to the printer task to print the hold information.

Write a status record to the history file.

Return the user interface to its idle state.

Display an abort message.

End of Forever Loop ' 148 - Di play Iask Ovegview The purpose of the real time display task is to display temperatures, timers, sensor readings, ADC channel readings, and other parameters that need to be continually updated every half second. seudoc de: 's a as Initialize display task variables.

Do Forever “wait for a message every half second from the timer task.

Go to sleep until the message is received.

When awakened, check if another task has sent a list of parameters to display or a flag to halt the current update.

Toggle the half second flag {half_sec}.

If (there's a list of parameters to display) then Set a semaphore so no one else will update the display.

Turn off the cursor.

While (stepping through the list of parameters) If (it is a time parameter) then Display the time.

If (half second flag {ha1f_sec} is set) then Increment or decrement the time variable.

Else if (it is a decimal number) then Display a decimal number.

Else if (it is an integer number) then Display the integer.

Else if (it is an ADC channel readout) then Read the counts from the ADC channel.

If (need it displayed as mV) then Convert counts to mv.

Display the value.

Else if (it is a power display) then Display the power in terms of watts.

Else if (it is the hours left parameter) then Convert seconds to tenths of hours.

Display the hours left in tenths of hours.

If (half second flag {half_sec} is set) then Decrement the seconds variable.

If (the cursor was on) then Turn it back on.

Store the current system time in battery RAM.

Clear the semaphore to release the display.

End of Forever Loop 'n e as V v'ew The purpose of the printer task is to handle the runtime printing.

It is a low priority task and should not interfere with other time critical tasks.

Printer Task Pseudocode: Do Forever Wait for a message from another task that wishes to print.

Go to sleep until a message is received. when awaken, make local copies of the global variables to be printed.

Post a printer acknowledgement message.

If (need to print a status or error message) then Else Else Else Print the information contained in the current history record. if (need to print the page header) then Print the company name, instrument ID, firmware version number and the current system time and date. if (need to print the program header) then Print the type of program and its number. if print the program (need to configuration parameters) then Else Else Else End of Print the tube type, reaction volume and the sample temperature deviation from setpoint that starts the clock. if (need to print end of cycle information) then Print the ending time and temperature. if (need to print segment information) then Print either the ramp or hold segment information. if (need to print a pause status message) then Print the amount of time paused for and at what temp.

Forever Loop LED Iask overview The purpose of the LED task is to make the illumination of - 151 ~ the "Heating" LED reflect the power applied to the main heater. This is a low priority task that runs once a second.

D ask o : Initialize LED task variables.

Do Forever send a message to the system to wake this task every second.

Go to sleep. when awaken, load counter 2 of PIC timer A with a value that reflects the power applied to the main heater as follows: load counter with value = {K_htled} * (ht_led} Where: {K_htled} holds a constant to compute the time to pulse the heating LED and is equal to 15200 / 500. 15200 is a little greater than the PIC's clock of 14.4KHz and this is the value loaded into the timer to keep the LED constantly on. 500 is the main heater power. {ht_1ed} will be a value between 0 and 500 and will be equal to the watts applied to the main heater.

End of Forever Loop Link Iask Ovgzvigw The purpose of the link task is to simulate the user START key on the keypad. This task necessary so that programs can be executed one right after The link task wakes up the sequence task and it begins running pressing the is the other (as in a method) without user intervention. r 152 - the next program as if the START key were pressed.

Link Iggk Eseugocodez Initialize link task variables.

Do Forever If (the flag {weird_f1ag} is set and it is not the first file in the method) then Send a message to the sequence task to wake up.

End of Forever Loop Start Up sequence POWER-UP szqumzcz When the power to the instrument is turned on or the software does a RESET, the following sequence takes place.

Note: the numbers below correspond to numbers on the flow Transmit a Ctrl—G (decimal 7) character out the RS- 232 printer port. Poll the RS-232 port for at least 1 second and if a Ctrl-G is received, it is assumed that an external computer is attached to the port and all communication during the power-up sequence will be redirected from the keypad to the RS-232 port. If no Ctrl-G is received, the power-up sequence continues as normal.

Check if the MORE key is depressed. If so, go straight to the service-only hardware diagnostics.

The next 3 tests are an audio/visual check and cannot report an error: 1) the beeper beeps 2) the hot, cooling, and heating LEDS on the keypad are flashed 3) each pixel of the display is highlighted. The copyright and instrument ID screens are displayed as the power-up diagnostics execute.

Should an error occur in one of the power-up diagnostics, the name of the component that failed is displayed and the keypad is locked except for the code ‘MORE 999' which will gain access to the service—only hardware diagnostics.

Check channel 0 of the PPI—B device to see if the automated test bit is pulled low. If it is, run the UART test. If the test passes, beep the beeper continuously.

Start the CRETIN operating system which in turn will start up each task by priority level.

Check a flag in battery RAM to see if the instrument If not, message and lock the keypad except for the code ‘MORE 999' calibration tests.

Run a test that measures the voltage and line frequency and see if both these values match the has been calibrated. display an error which will gain access to the service-only configuration plug selected while calibrating’ the instrument. If not, lock the keypad except for the code ‘MORE 999' which will gain access to the service-only calibration display an error message and tests.

Perform the heater ping test as described in the Install section. If the heaters are wired wrong, display an error message and lock the keypad except for the code ‘MORE 999' which will gain access to the service-only calibration tests.

Check a flag in battery RAM to see if the instrument has been installed. If not, display an error message ‘MORE 999' which will gain access to the install routine. and lock the keypad except for the code If not in remote mode, check a flag in battery RAM to see if there was a power failure while the instrument _ was running.’ If so, start a 4°C soak and display the amount of time the power was off for. Ask the user if they wish to view the history file which will tell them exactly how far along they were in the run when the power went-off. If they select yes, they go straight to the user diagnostics.

Beep the beeper and clear the remote mode flag so all communication now is back through the keypad.

Check a flag in battery RAM to see if manufacturing wants their test program automatically started. If so, start the program running and reset the instrument after its done.

Display the top level user interface screen. reaction mixture.

Referring to Figure 50, there is shown a cross- sectional view of a larger volume, thin walled reaction tube marketed under the trademark MAXIAMP. This tube is useful for PCR reactions wherein reagents or other materials need to be added to the reaction mixture which will bring the total volume to greater than 200 microliters. The larger tube shown in Figure 50 made of Himont P0701 polypropylene or Valtec HH-444 polypropylene and has a thin wall in contact with the Whatever material selected should be compatible with the DNA and other components of the PCR reaction mixture so as to not impair PCR reaction processing such as by having the target DNA sample block. is stick to the walls and not replicate. Glass is generally not a good choice because DNA has been known to stick to the walls of glass tubes.

The dimension A in Figure 50 is typically 0.012 1 .001 inches and the wall angle relative to the longitudinal axis of the tube is typically 17°. The advantage of a 17° wall angle is that while downward force causes good thermal contact with the sample block, the tubes do not jam in the The advantage of the thin walls is that it minimizes the delay between changes in temperature of the sample wells. sample block and corresponding changes in temperature of the This means that if the user wants the reaction mixture to remain within 1°C of 94°C for 5 seconds in the denaturation segment, and programs in these parameters, he or she gets the 5 second denaturation interval with less time lag than with conventional tubes with thicker walls. being able to program a short soak interval such as a 5 This performance characteristic of second denaturation soak and get a soak at the programmed temperature for the exact programmed time is enabled by use In the system described herein, the timer to time an incubation of a calculated sample temperature to control the timer. or soak interval is not started until the calculated sample temperature reaches the programmed soak temperature.

Further, with the thin walled sample tubes, it only takes about one-half to two-thirds as long for the sample mixture to get within 1°C of the target temperature as with prior art thick-walled microcentrifuge tubes and this is true both with the tall MAXIAMP' tube shown in Figure 50 and the smaller thin walled MICROAMP‘ tube shown in Figure 15.

The wall thickness of both the MAXIAMP' and MICROAMP' tubes is controlled tightly in the manufacturing process to be as thin as possible consistent with adequate structural Typically, for polypropylene, this will be anywhere from 0.009 to 0.012 inches. If new, strength. more exotic materials which are stroger than polypropylene are used to achieve the advantage of speeding up the PCR reaction, the wall thickness can be less so long as adequate strength is maintained to withstand the downward force to assure good With a of 1.12 inches and a thermal contact, and other stresses of normal use. height dimension C of 0.780 inches and an upper section wall thickness (dimension of D) 0.395 inches, the MAXIAHP tube's time constant is approximately 14 seconds although this has not been precisely measured as of the time of filing. The MICROAMP tube time constant for the shorter tube shown in (dimension B in Figure 50) Figure 15 is typically approximately 9.5 seconds with a tube‘ wall thickness in the conical section of 0.009 inches plus or minus 0.001 inches.

Figure 51 shows the results of use of the thinner walled HICROAMP tube. target temperatures will result from use of the thin walled MAXIAMP tube.

Referring to Figure 51, there is shown a graph of the A similar speeded up attainment of relative times for the calculated sample temperature in a MICROAMP tube versus the time for a prior art tube to reach 1°C temperature of 94°C from a starting temperature of 72°C. denaturation In a temperature within of a target Figure 51, a 100 microliter sample was present in each tube.

The curve with data points marked by open boxes is the calculated sample temperature response for a HICROAMP tube with a 9.5 second response time and a 0.009 inch wall thickness. The curve with data points marked by X's represents the calculated sample temperature for a 100 thick walled microcentrifuge tube with a 0.030 inch wall thickness. This graph shows that the thin walled MICROAMP tube sample reaches a calculated temperature within 1°C of the 94°C microliter sample in a prior art, target soak temperature within approximately 36 seconds while the prior art tubes take about 73 seconds. This is important because in instruments which do not start their timers until the soak temperature is substantially achieved, the prior art tubes can substantially increase overall processing time especially when considered in light of the fact that each PCR cycle will have at least two ramps and soaks and there are generally very many cycles performed.

Doubling the ramp time for each ramp by using prior art tubes can therefore drastically increase processing time. which their based block/bath/oven temperature without regard to actual sample In systems start times upon temperature, these long delays between changes in block/bath/oven temperature and corresponding changes in mixture can have serious negative sample temperature consequences. The problem is that the long delay can cut into the time that the reaction mixture is actually at the temperature programmed for a soak. For very short soaks as the reaction soak starts are popular in the latest PCR processes, mixture may never actually reach the programmed the attempting to change the reaction mixture temperature. temperature before heating/cooling system Figure 50 shows a polypropylene cap 650 connected to the MAXIAMP sample tube by a plastic web 652. diameter E of the cap and the inside diameter F of the tube The outside upper section are sized for an interference fit of between 0.002 and 0.005 inches. should be free of flash, nicks and scratches so that a gas- The inside surface 654 of the tube tight seal with the cap can be formed.

Figure 52 shows a plan view of the tube 651, the cap 650 and the web 652. being pushed too A shoulder 656 prevents the cap from the tube sufficient projection of the cap above the top edge of the This also allows sufficient cap deformation such that the minimum far down into and allows sample tube for making contact with the heated platen. acceptable force F in Figure 15 can be applied by deformation of the cap. ’ In the preferred embodiment, the tube and cap are made of Himont PD701 polypropylene which is autoclavable at temperatures up to 126°C for times up to 15 minutes. This allows the disposable tubes to be sterilized before use.

Since the caps are permanently deformed in use in machines with heated platens, the tubes are designed for use only once. the MICROAMP tubes in connected strips of 8 or 12 caps with each cap numbered or Caps for are available as individual caps. Single rows of caps may be used and the rows may be easily shortened to as few as desired or Caps for MAXIAMP tubes are either attached as shown in Figure 50, individual caps may be cut off the strip. or are separate individual caps.

The maximum volume for post-PCR reagent additions to permit mixing on the MICROAMP tube is 200 microliters and is up to 500 microliters for the MAXIAMP tube. limits are -70°C to 126°C.

The response time depends upon the volume of the Temperature sample. Response is measured as the time for the sample to come within 37% of the new temperature when the block suddenly changes temperature. Typical response time for a 50 microliter fill are 7.0 seconds and for a 20 microliter fill are 5.0 seconds.

APPENDIX A User Interface The of the GeneAmp PCR System 9600 user interface is to provide a simple way to develop and run objective programs that perform PCR.

There are 3 types of programs available. The HOLD program consists of a single setpoint held for a set amount of time or held for an infinite amount of time and terminated by the STOP key. The CYCLE program adds the features of timed ramps and programmable pauses. This program allows up to 9 setpoints and up to 99 cycles. The AUTO program allows the user to increment or decrement the setpoint time and/or This program also allows up to 9 setpoints and_up to 99 cycles. A METHOD program provides a way to link up to 17 hold, cycle or auto temperature a fixed amount every cycle. programs together.

A total of 150 programs can be stored with numbers ranging from 1 to 150. Programs can be created, stored, protected, printed, or deleted. A directory of the stored programs can be viewed or printed.

THE SYSTEM 9600 KEYPAD RUN MORE 7 8 9 Heating BACK STEP 4 5 6 Cooling PAUSE OPTION 1 2 3 Hot STOP CE 0 ENTER RUN starts a program running from the program display or restarts a programmed or keypad pause.

MORE toggles the runtime displays and also accesses the service-only functions (if followed by the code 999).

BACK moves to the previous field within the same screen. If currently positioned on the first field, it moves to the previous screen.

STEP moves down to the first field in the next screen.

PAUSE starts a paused time-out for manual interruptions.

OPTION either moves the cursor left-to—right through the menu items (rolling over to the leftmost option) or toggles the YES/NO response.

STOP aborts a running program or moves the user up one level in the user interface.

CE clears invalid numeric entries.

ENTER accepts the current numeric entry, accepts a menu item, accepts a YES/NO response, or skips to the next field of a display. If the numeric entry is the last of a display, ENTER steps to the next display. - 161 — COKHON SYSTEM 9600 DISPLAYS PROGRAH display Example: CYCL #17 Done 74.oc.

Prog ff} Hsg Temp Menu RUN-STORE-PRINT-HOME Prog is either HOLD, CYCL, AUTO or METH V f## is the program I (1-150) or ??? if it is not stored yet Msg is either Done, Error, Abort or blank Temp is the current sample temperature Menu are the available options RUNTIME display Example: Action ' Temp Timer Progégzc ‘Hold at xx.xC' Ramp to 94.oc l29.6C :00 Ezcle 14 Action is either or ‘Ramp to xx.xC' Temp is the current sample temperature Timer counts down the hold or ramp time or counts up a hold time of FOREVER Prog/Cyc for a HOLD file is 'Prog xxx‘ for a CYCL or AUTO file is ‘Cycle xx‘ - counts up MORE display Example: setpt - ‘Tot Cyc Setpt #3’ Tot Cyc 25 Timer " Prog Hrs left 2.5 Pro: 17 Setpt is the current setpoint f (1-9) - counts up Tot Cyc is the total # of cycles (1-99) in the current program Timer is the time left in the program in hrs - counts down Prog is the current program i (l—1S0) KEYPAD PAUSE displny Example: Prog {ff Temp AUTO #18 . 55.0C PAUSE Timer PAUSE 9:45 Prog is either HOLD, CYCL, AUTO_or METH f## is the program I (1-150) or ??? if it is not stored yet Temp is the current sample temperature Timer is the configurable pause time - counts down — 163 - TOP LEVEL USER INTERFACE Select Option 9600 RUN-CREATE-EDIT-UTIL TOP LEVEL display Enter program fixxx RUN display Create program HOLD-CYCL-AUTO-METH CREATE display select function DIR-CONFIG-DIAG-DEL UTIL display I Edit .

Enter program fxxx EDIT display Programs are created by selecting a program type in the CREATE display. The user is brought directly to the first display of the program to be edited.

Stored programs are retrieved by entering a number 1 to 150 from the RUN, EDIT, or program displays. Entering a valid program number from the RUN display automatically begins the run. Entering a valid program number from the EDIT or program display brings the user to the first display of the program to be edited.

Programs are edited by pressing STEP (move down a screen), BACK (move to the previous field) or ENTER (move to the next field). ‘ - Programs are run by selecting RUN the BUN-STORE-PRINT-HOME menu or by pressing the RUN key on the keypad. The user must first enter 2 parameters required for each run.

The OPTION key toggles the tube type from MICRO (MicroAmp tube) to THIN (thin-walled GeneAmp tube). If the user configured a special tube, then the option of OTHER is added. A different reaction volume may be entered.

These parameters are stored with Tube type: KICRO React vol: 100uL this program. ENTER accepts these values.

If the user configured t1?e select print mode aprclynctleer aougtoarof: Iileethgcsl OFF-C -SETPOINT ’ .

YCLE program, then the following printer choices are offered. the program is started. CYCLE prints a message only upon completion of a cycle. SETPOINT prints runtime data for every setpoint (ramp/hold time and temps).

Select print mode OFF-ON Cover temp is xx°C Run starts at 100°C Accepting HOME - 165 — If the user configured the runtime printer ON and he is running a hold program, then the following printer choices are offered.

If the heated cover is below 100°C[ the following screen is displayed. If the user is on this display when the heated cover reaches 100°C, the run automatically begins. If the user hit STOP to return to the program display, then the run must be manually re-started. at the RUN—STOR£-PRINT-fiOME menu without saving a program displays the screen: Prog fxxx not stored Continue? YES HOLD PROGRAM HOLD fxxx xx.xC RUN-STORE-PRINT-HOME PROGRAM display The user can choose between an Held at xx_xC infinite soak or a time limited Hold FOREVER-xxxzxx h°1d- '.'_"""-""""'-""—""' The beeper will sound once a Beep while Hold? NQ 5e°°“d‘ HOLD PROGRAK - Runtimo displays Hold at xx.xC xx.xC xxxzxx Pro xx RUNTIME display None MORE display HOLD fxx PAUSE xx:xx KEYPAD PAUSE display xx.xC None PROGRAMMED PAUSE HOLD PROGRAH - Runtino printout GeneAmp PCR System 9600 Ver xx.x Nov 14, 1990 xxzxx am Tube type:MICRO Reaction vol:100uL Start clock within x.xC of setpt HOLD program #xxx .

HOLD Program: xx.xC xxx:xx or HOLD Program: xx.xC FOREVER Actual: xx.xC xxxzxx HOLD program {xxx - Run Complete Nov 14, 1990 xxzxx am Actual: xx.xC xxx:xx CYCLE PROGRAH -CYCL {xxx *xx.xC RUN-STORE-PRINT-HOME ‘U 50 0 CE? 0: ..J.

In '0 9-‘ D! ’< Temperature PCR Setpt fl Ramp xzzxx xx.xC “Hold xxzxx Total cycles = xx Pause during run? NO Pause after setpt fix Beep while pause?YEs st pause at Eye; xx _ Pause eve xx cls Pause time xxixx The default is 3. This determines the number of setpoints in this program. 1 to 9 setpoints are allowed.

The number of setpoints entered above determines how many setpoint edit displays will be offered. The user can enter a ramp and hold time for each setpoint. The hold timer will start when the sample temp gets within a user configurable temp of setpoint.

If the user does NOT want to pause, then the next 3 displays are skipped. 1 to 99 cycles are allowed.

Entering a 0 for setpoint number also means the user does NOT want to pause therefore the next 2 displays are skipped.

The cycle number is limited to the total number of cycles entered above.

The default pause time is set in the user configuration. - 168 — CYCLE PROGRAM - Runtimo displays Ramp to xx.xC xx.xC xxx:xx ' cle xx RUNTIHE display (ramp) Setpt-ix ‘Tot Cyc xx Hrs left X.X Progxxx MORE display Hold at xx.xC xx.xC xxxzxx cle xx RUNTIME display (hold) CYCL fxxx xx.xC PAUSE xxzxx KEYPAD PAUSE display "Setpt Ix xx.xC PAUSE xx:xx cle xx VPROGRAMMED PAUSE CYCLE PROGRAM - Runtimo printout PE Cetus xxzxx am Tube type:MICRO Reaction vo1:l0OuL Start clock within x.xC of setpt GeneAmp PCR System 9600 Ver xx.x Nov 14, 1990 CYCL program fxxx Cycle fxx Setpt ix RAMP Program: xx.xC xxzxx Actual: xx.xC xxzxx HOLD Program: xx.xC xxzxx Actual: xx.xC XX1XX . (up to 9 setpoints) . (up to 99 cycles) CYCL program fxxx - Run Complete Nov 14, 1990 xxzxx am CYCL program {xxx — User Aborted Nov 14, 1990 xx:xx am (only if aborted) ~ 169 — AUTO PROGRAM AUTO {xxx xx.xC RUN-STORE-PRINT-HOME PROGRAM display Temperature PCR setpt #1 xx.xC Hold for xxzxx Setpt #1 xx.£C Chance time‘temp?YES I xx.xC delta _ x.xC delta xx:xx The default is 3. This determines the number of setpoints in this program. 1 to 9 setpoints are allowed.

The number of setpoints entered above determines how many setpoint edit displays will be offered. No ramp time is offered thus the instrument ramps ‘as fast as possible. The hold timer start when the sample temp gets within a user configurable temp of setpoint.

If the user wants to increment or decrement the time and/or temperature every cycle, then the following display is offered.

The OPTION key toggles the arrow up (increment every cycle) or down (decrement every cycle).

The max time allowed to decrement is limited to the setpoint hold time.

Up to 99 cycles are allowed. - 170 — AUTO PROGRAH - Runtimo displays Hold at xx.xC xx.xC xxxzxx Szcle xx RUNTIME display Setpt Ix Tot Cyc xx Hrs left X.X Progxxx MORE display AUTO ixxx PAUSE xx:xx KEYPAD PAUSE display xx.xC "None PROGRAMMED PAUSE AUTO PROGRAH - Runtimo printout PE Cetus xx:xx am Tube type:MICRO Reaction vol:100uL Start clock within x.xC of setpt GeneAmp PCR System 9600 Ver xx.x Nov 14, 1990 AUTO program fxxx Cycle fxx Setpt fix RAMP Program: xx.xC xx:xx Actual: xx.xC xxzxx HOLD Program: Actual: xx.xC XX.XC XXIXX XXIXX . (up to 9 setpoints) . ‘(up to 99 cycles) AUTO program {xxx - Run Complete Nov 12, 1990 xxzxx am AUTO program ixxx - User Aborted Nov 12, 1990 xxzxx am (only if aborted) - 171 — METHOD PROGRAH METH {xxx xx.xC RUN-STORE-PRINT-HOME PROGRAM display Up to 17 programs can be linked in a method. If the user tries to enter a non-existant program f, the message "Prog does not exist" is displayed. If the user tries to link another method, the message "Cannot link a method" is displayed.

KETEOD PROGRAX - Runtimo displays The RUNTIME, MORE and PAUSE displays will be those of the program currently running. Two additional MORE displays are offered when the program running is linked in a method.

The number of the program METH ‘xxx aaa_bbb_ currently running will flash. ccc-ddd-eee-fff- - ADDITIONAL MORE display hhh-iii-jjj‘-kkk-llb Inmm-nnn-Ooo-BUB-SSS HETHOD PROGRAH - Runtimo printout PE Cetus 1990 xx:xx am Tube type:MICRO Reaction vol:100uL Start clock within x.xc of setpt — GeneAmp PCR System 9600 Ver xx.x Nov 14, METHOD program #xxx — preceeds all linked program data - 172 — METHOD program fxxx - Meth Complete - follows all linked progra data HETHCD PROGRAM - Print ------------I Select option METHOD-PROGRAM DATA prints the header of each prooram linked in the method.

PROGRAM DATA METHOD prints the header and contents of each program linked in the method. - 174 — STORING A PROGRAM knowledge of the user number. and link the protected file in their view, edit, run, other users will be able to methods but will not be able to alter the stored version.

Store Enter program #xxx Progxxx is protected Enter user #xxxx Progxxx is protected Wron user number! Progxxx is linked in Hethxxx Continue?YES Can't overwrite prog Linked in method xxx Store Protect to ram? NO store Enter user fixxxx xxx is the first available program number from 1 - 150.

The user has entered the f of a protected program. The correct user f must be entered in order to overwrite this program.

The wrong user # was entered.

This display remains for 5 seconds before reverting to the previous one. The user is given 3 chances to enter the correct #. to overwrite a linked in a If the user tries program that is method, the user is warned and given the option of continuing or not.

If the user tries to overwrite a program that is linked in a method with another method, an error message is given.

The user is given the chance to protect a program as well as unprotect a previously protected program.

The user wants to protect the program and therefore must enter a user #.

Ready to store the program in an available slot. The user # appears only if the program is protected.

Prog fxxx User fxxxx OK to store? YES -175 — Prog fxxx User fxxxx OK to overwrite? YES Ready t o overwr ite an existi n 9 progra m. The user f appear only if the progra m is protec ted.

UTILITY FUNCTIONS select function DIR-CONFIG-DIAG-DEL UTIL display allow the user to view or print a directory of the stored programs by either their program number, user number or program type.

CoN?IG allows the user to tailor the use of the instrument DIAG l0 DEL to their specific needs. offers the user a problems and instrument. means verifying the of diagnosing runtime performance of the allows the user to delete stored programs by program number, user number or program type. - 177 — UTIL - DIRECTORY Directory -PROG-TYPE-USER-PRINT Directory by PRoGrem number Directory Enter program {xxx HOLD I124 Directory by program TYPE Directory HOLD-CYCL-AUTO-METH CYCL #15 O P- H O 0 ff 0 Q U‘ "4 C1 OI fl E O H Directory Enter user fxxxx METH #150 User #1234 Directory PRINT Programs will be listed in numerical order starting at the given number. The STEP and BACK keys move through the directory displays. The beeper sounds at the beginning or end of the program list.

STOP returns the user to the above display.

The program numbers will be listed for the selected type of program.

All programs stored under the given user number will be listed.

""""""""""" The user can get a hardcopy of the directory listing in the same manner the directory is viewed above.

Directory Print PROG-TYPE-USER - 179 — UTIL - USER CON?IGURATION Configuration EDIT-PRINT Time: Date: xx:xx mm dd Runtime printer OPE Runtime bee er ON Pause time-out limit xx:xx Allowed setpt error x.x°C Idle state setpoint xx°C Start clock within x.x°C of set oint The configuration file can be edited by accepting EDIT from the menu or by pressing the STEP key. PRINT prints the contents of this file.

The user can set the system time and date.

If the runtime printer is ON, the user will be prompted with printer option as the start of each run. If the runtime beeper is ON, then a beep will sound at the end of each segment (after a ramp or hold portion of a sequence) while running a program.

This time represents the maximum amount of time a program can pause for before it is aborted.

This pertains only to the keypad pause.

This time represents the number of degrees the actual sample temp may vary from the setpoint before an error is flagged.

This setpoint is useful for balancing the control cooling power which is always present.

The sample temp will be maintained at the idle state setpoint whenever the instrument is idle.

The clock which times the hold segment of a running program can be configured to be triggered when it gets within this temperature of the sample temp.

The nominal value is 1.0°C.

If the user wishes to use a different type of tube other than the MicroAmp or Thin-walled GeneAmp tubes, they must set this option to YES and enter at least 3 pairs of ' reaction volume and tube time special tube? NO constant data. This curve will be ‘ used to extrapolate the correct II-Z--Z-—-ii Tau (tube time constant) for each run using this special tube depending on the reaction volume entered by the user at the start of a run.

UTIL - USER CONFIGURATION (cont) """"""""""" 3 sets of this screen will be offered if the user sets Rxn vo1=xxxuL T=xxxs "Special tube?" to YES.

Rxn vol=xxxuL Taxxxs - 182 — UTIL - DELETE ‘Delete PROGRAM-USER-ALL Delete by PROGRAK Delete Enter ro ram {xxx Can't delete progxxx Linked in methodxxx! Progxxx is protected Enter user fxxxx Progxxx is protected Wron user number! Prog {xxx User fxxxx Delete r am? YES Delete by USER Delete _ Enter user fxxxx Delete No progs with fxxxx All programs (files and methods) can be deleted by number.

A program cannot be deleted if it linked in a method.

The user has entered the # of a protected program. The correct user I must be entered in order to delete this program.

The wrong user f was entered.

This display remains for 5 seconds before reverting to the previous one.-The user is given 3 chances to enter the correct Ready to delete the program. The~ user # appears only if the program was protected.

Programs can be deleted under a given user number.

If no programs exist with the given -user f, the following message is displayed. — 183 - Programs cannot be deleted if Frogs linked in math they are l;nked in a method. The STEP to list Bragg STEP key Vlll cycle through the list of linked programs.

UTIL - DELETE (cont) Can't delete proqxxx Linked in methodxxx! User fxxxx Delete all Bro2s?YES Delete ALL Delete every unprotected pro3?YES The list of the”linked programs will show which method the program is linked to.

This will delete all the programs under the given user f that are not linked.

This will delete every unprotected program that is not linked in a protected method.

UTIL - USER DIAGNOSTICS While running any diagnostic test, the STOP key always returns the user to the top level diagnostic screen and automatically increments the test number and name to the next test. This facilitates manually cycling through the available diagnostics.

The user can enter the number of the diagnostic to run or can use the STEP or BACK keys to cycle through the available tests.

Every time the STEP or BACK key is pressed, the test number is incremented or decremented and Enter Diag Test fl REVIEW HISTORY FILE the associated test name is displayed. This feature eliminates the need for the user to memorize the number associated with each test.

REVIEV HISTORY ?ILE The history file is a circular buffer in battery RAM which can store up to 500 records of the latest run. When the buffer is full, the oldest entries will be overwritten. The buffer will automatically be cleared before a program is executed.

Enter Diag Test fl REVIEW HISTORY FILE The history file header displays HISTORY nnn recs ythe current number of records in ALL-STAT-ERRORS-PRNT the file ('“““') ° ——é——-————-—- ALL views all the records STAT views only the status records ERRORS views only the records with error messages PRNT prints all or part of the history file The two types of records are 1) status records which give information about the program and 2) data records which give information abount each hold and ramp segment in a program.

A Hold program is treated as one hold segment and the data record will be stored when the file ends. since there could be hundreds of entries (50 cycles X 6 setpoints 350 entries), fast, bi-directional movement through the file is required. Note that most PCR programs will be 3 or 6 setpoints and 40 cycles or less. The entries .will normally be reviewed in reverse order, thus the first — 186 — record seen will be the last record written.

If the user has chosen a type of record to view, STEP or BACK will move down or up the buffer by one entry of the chosen type. By preceding STEP or BACK with a number, the second line is replaced with "Skip {XXX entries". The user enters a number and presses ENTER to accept the value and that number of entries is skipped going forward (STEP) or backward (BACK).

By preceding STEP or BACK with the RUN key, the user can quickly move to the largest record # (the newest record) or record #1 (the oldest record) of the chosen type.

STOP terminates the review mode and displays the file header. ~ffff Ixxx/mmm ------n-- ’nnn' status no: Tube Type: Reaction v Clk starts start xx/x End xx/x Meth Compl Pause xxzx Fatal stat Sensor Err Power fail User Abort Pause Time Fatal Setp If! ‘xxx’ sagas xxxxx ol: xxxuL w/in x.xC x/xx xxzxx x/xx xxzxx ete x at xx.xC us messages or xxx.x hrs out xx:xx oint Error - 187 — STATUS RECORD 'ffff' AUTO ‘xxx’ is the program number '/mmm' is the method number for a linked program, else blank is either HOLD, CYCL or is the record number 'message' is one of the following: Type of sample tube used in the run Reaction volume used in the run The hold clock starts within this temp of setpoint Time and date of the start of the run Time and date of the end of the run All programs linked in the method are complete The program paused for this time at this temp A sensor had a bad reading 10 times in a row The power was off for this amount of time The user pressed the STOP key during the run The keypad pause has reached its configurable time limit.

Is the requirement to abort a program if the setpoint is not reached within a calculated amount of time. A 10 X lookup table of starting ramp temperature (o°c - 100°C in 10°C increments) vs. ending ramp temperature (same axis labeling) will hold the average time the TC2 should take to ramp up or down any given amount of degrees. The file will be aborted if the setpoint is not reached in the amount of time calculated as follows: programmed ramp time + (2 * lookup table value) + minutes DATA RECORD is either HOLD, CYCL or AUTO is the program number ,/mmm. is the method nu-Inber for ffxxx/mum ddd_dc nnn e llnked ' pyogram else blenk C C Set t Z mmmzss ddd.d 15 the endzng setpolnt ix-L-I-is temp 'nr1n' is the record number 'yy' is the cycle number '2' is the setpoint number 'mmm:ss' is the setpoint time The cycle and setpoint number fields will be omitted for a Hold program.

DATA ERROR RECORD ------------ 'ddd.d' is the ending setpoint d _d temp message d d C nnn 'nnn' is the record number 'yy' is the cycle number '2' is the setpoint number 'mmm:ss' is the setpoint time ‘message’ indicates a non-fatal error as follows: Non-fatal Error massages Setp Error The setpoint was not reached in the calculated time: -. programmed ramp time + (2 * lookup table value).

Prog Error An Auto program auto increment/decrement of the setpoint temp or time caused the hold time to go negative or the temp to go out of the range o.1°c to 100°C.

At the end of the segment, the setpoint temp has drifted +/- a user configurable amount.

Temp Error For the Hold program, the cycle and setpoint fields will be omitted.

PRINTING THE HISTORY FILE Access to the history file print routines is through the history file header menu. The OPTION key cycles the cursor through the options: HISTORY innn recs.

' ALL-STAT-ERRORS-ERNT Pressing the ENTER key when the cursor is positioned under PRNT displays the print screen: Print History. ' ALL-STAT-ERRORS ALL prints all the records in the file STAT prints only the status records ERRORS prints only the records with error messages When one of print options is selected, the is displayed: following screen I Print_HistoryAiAA ‘ Print from pro: fxx The first (most recent) program number will be the default program. The user can change the program number from which to begin printing. While printing, the following screen is displayed: Print'History?7flm‘ ...printing ~“~‘A I At the end of printing, the Print History menu is again displayed. —»->-., ' HEATER rzsr Enter Diag Test #1 HEATER TEST The heater test calculates the heat rate of the sample block as its temperature rises from 35°C to 65°C. The following screen is displayed as it forces the block temperature to °C.

Heater Test Blk=XX.X going to 35C...

When the temperature stabilizes, all heaters are turned on full power. The display now reads "going to 65C" and the block temperature is monitored for 20 seconds after it passes 50°C. After 20 seconds, a pass or fail message is displayed.

Heater Test PASSES ‘)5 ,0 temperature to 35°C.

CHILLER TEST III--I--I------I Enter Diag'Test I1 'CHILLER TEST I I---------n-- The chiller test calculates the cool rate of the sample block as its temperature drops from 35°C to 15°C. The following screen is displayed as it forces the block X going to 35C... ~ When the temperature stabilizes, display now reads "going to 15C" and the block temperature is monitored for 20 seconds after it passes 25°C. After 20 seconds, a pass or fail message is displayed. the chiller is on. The Chiller test PASSES '

Claims (9)

Claims:

1. Thermocycler apparatus suitable for performing the polymerase chain reaction comprising at least one sample well (66,68) capable of receiving a capped sample tube (376) containing a sample mixture, a heated platen with heating means being provided to heat said platen (14) for contacting the top of a said sample tube, and heater control means (20) for controlling the heating means so that the platen heats the upper part of a sample tube to a temperature above the condensation point such that condensation and refluxing of sample in a sample tube is avoided.

2. Thermocycler apparatus as claimed in claim 1, wherein at least one sample well is comprised in a sample block (12).

3. Thermocycler apparatus as claimed in claim 1, or claim 2, further comprising means (312, 314, 316, 318) for forcing the heated platen against the top of a sample tube.

4. Thermocycler apparatus as claimed in any of claims 1 to 3, wherein the force of the heated platen in use against the tops of sample tubes is such that all sample tubes are pressed firmly into their respective sample wells.

5. Thermocycler apparatus as claimed in any preceding claim, wherein the force of the heated platen in use against the tops of sample tubes is such that the caps of the sample tubes are deformed. 35 194

6. Thermocycler apparatus as claimed in any of claims 2 to 5, wherein the sample block is of metal and has an array of spaced—apart sample wells each of which has an inside surface, said wells capable of receiving one or more sample tubes each containing a sample mixture placed in a microtiter plate having an uppermost edge, which plate is seated on said sample block, and wherein the heated platen is in the form of a cover (316) to enclose said sample tubes, which cover comprises a flat, horizontal rectangular portion and downwardly projecting skirt portions along the periphery thereof and further comprises a device for heating at least the underside of said horizontal portion, said cover being dimensioned to contact said sample block and to enclose said microtiter plate and sample tubes on said sample block when the tops of the caps on said sample tubes deform, due to the application of heat and a downwardly directed force by said cover.

7. Thermocycler apparatus as claimed in claim 6, wherein said skirt portions of the cover are dimensioned such that they contact said sample block at substantially the same time as the underside of said cover contacts the uppermost edge of said microtiter plate as the cover encloses the plate.

8. Thermocycler apparatus as claimed in claim 7, wherein the downwardly directed force is sufficient to ensure a snug Contact between a lower portion of each sample tube and the inside surface of the well which contains said portion.

9. Thermocycler apparatus as claimed in claims 6 to 8, further comprising knob (318) and screw (312) means for lowering said cover from one height to another, said knob and screw means including indication means (332) for identifying a knob position corresponding to the cover height at which said cover contacts said uppermost edge.