CRS Carousel User Guide

UMI-LH-200

CRS Carousel User Guide

Rev. 001 Revision History Original Issue Date 00-05

Copyright 2000 CRS Robotics Corporation POLARA, RAPL-3, RAPL-II, and RAPL are trademarks of CRS Robotics Corporation and may be used to describe only CRS Robotics products. All brand names and product names used in this guide are trademarks, registered trademarks, or trade names of their respective holders. The information in this document is subject to change without notice. CRS Robotics Corporation makes no warranty of any kind with regard to this material, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose. CRS Robotics Corporation assumes no responsibility for any errors that may appear in this document. CRS Robotics Corporation makes no commitment to update nor to keep current the information contained in this document. CRS Robotics Corporation software products shall remain the property of CRS Robotics Corporation. POLARA, RAPL-3 and robot training courses are offered at CRS Robotics in Burlington, Ontario, Canada, or can be conducted at your facility. For additional information contact the Customer Support Department. Additional copies of this guide, or other CRS Robotics literature, may be obtained from the Sales Department or from your distributor.

ii

PREFACE

About This Guide

This user guide contains general information and instructions for installing and using a CRS carousel.

Who Uses This Guide

This guide is intended for system integrators and administrators of automated laboratory systems. To install the peripheral described in this guide, you should have basic mechanical and electrical skills.

How to Use This User Guide

Throughout this users guide warnings are marked by a ! symbol in the left margin. Failure to comply with these warnings can result in erroneous operation or danger to the user. Before attempting to follow instructions or examples in a chapter, read the entire chapter first. This guide consists of the following chapters: Introducing the CRS Carousel, which describes the features, benefits, and design considerations of each type of CRS carousel. Safety, which instructs you in the safe operation of the CRS carousels. Installing the CRS Carousel, which describes how to unpack, mount, and connect a CRS carousel. Using the CRS Carousel, which describes a complete cycle of operation of each type of carousel and its control interface. Maintenance, which describes the maintenance, cleaning, disinfecting, decontamination, and shut down procedures for the carousel. Troubleshooting, which provides tips to help ensure that the carousel functions properly. General Specifications, which describes the physical and operating characteristics of the carousel, its communications interface, and the carousels optimal operating conditions.

CRS Carousel User Guide: Preface

iii

Preface: For More Information

For More Information

If you are integrating this carousel into a POLARA-based system, refer to the following documents. The specific POLARA Instrument Interface Guide for your model of carousel, which describes the software interface POLARA systems use to control this peripheral. It will be one of the following : POLARA Instrument Interface for the Microplate Carousel, which describes the software interface POLARA systems use to control this peripheral. POLARA Instrument Interface for the Platefeeder Carousel, which describes the software interface POLARA systems use to control this peripheral. POLARA Instrument Interface for the Stacker Carousel, which describes the software interface POLARA systems use to control this peripheral.

POLARA User Interface Integrator and Administrator Guide, which describes how to configure and maintain a POLARA system POLARA User Interface Researcher and Operator Guide, which describes how to set parameters of an instrument, like a carousel, in a profile or method of a POLARA system. The Single Axis Controller User Guide, which describes the operation of the Single Axis Controller.

You can obtain additional copies of this guide or other CRS Robotics literature from the Lab Automation Sales Department or from your distributor.

Training
Training courses for POLARA administrators and system integrators are offered at our facility in Burlington, Ontario, Canada, or can be conducted at your facility. For additional information, contact the Training Department.

Contacts
Surface Mail/Shipping CRS Robotics Corporation 5344 John Lucas Drive Burlington, Ontario L7L 6A6 Canada Telephone 1-905-332-2000 (voice) 1-800-365-7587 (voice: toll free in Canada and United States) 1-905-332-1114 (facsimile)

iv

CRS Carousel User Guide: For More Information

Preface: For More Information

E-Mail Sales: labaut@crsrobotics.com Customer Support: labsupport@crsrobotics.com Training: training@crsrobotics.com General: info@crsrobotics.com World Wide Web www.crsrobotics.com

CRS Carousel User Guide: For More Information

Preface: Contents

vi

CRS Carousel User Guide: Contents

Preface: Contents

Contents
CHAPTER 1 .............................................................................. 1 Introducing the CRS Carousels ................................................. 1 Purpose .............................................................................. 1 Features ............................................................................. 4 Benefits .............................................................................. 5 Appropriate Use .................................................................. 5 Design Considerations ........................................................ 6 CHAPTER 2 .............................................................................. 9 Safety....................................................................................... 9 Motion Hazards .................................................................. 9 E-Stop ................................................................................ 9 Ground ............................................................................... 9 CHAPTER 3 ............................................................................ 11 Installing the Carousel............................................................ 11 Package Contents ............................................................. 11 Unpacking Instructions ..................................................... 11 Mounting .......................................................................... 12 Assembling the Carousel ................................................... 14 Connecting to the System.................................................. 14 Homing the Carousel ........................................................ 15 Restoring Calibration on Powerup ..................................... 18 CHAPTER 4 ............................................................................ 19 Using the Carousel ................................................................. 19 Typical Operation.............................................................. 19 Control Interface ............................................................... 19 CHAPTER 5 ............................................................................ 21 Maintenance .......................................................................... 21 Daily................................................................................. 21 Periodic ............................................................................ 22 Yearly ............................................................................... 22 Routine Cleaning .............................................................. 22 Disinfecting/Decontaminating........................................... 22 Replacing Parts ................................................................. 22 Shutdown ......................................................................... 22 Storage ............................................................................. 23 Shipping ........................................................................... 23 CHAPTER 6 ............................................................................ 25 Troubleshooting ..................................................................... 25 Tips .................................................................................. 25 Troubleshooting Communication Problems ........................ 25 Error Information.............................................................. 25

CRS Carousel User Guide: Contents

vii

Preface: Contents

Support Contact Information............................................. 25 CHAPTER 7 ............................................................................ 27 General Specifications ............................................................ 27 Physical Characteristics .................................................... 27 Glossary ................................................................................. 29

viii

CRS Carousel User Guide: Contents

CHAPTER 1

Introducing the CRS Carousels

This chapter describes the purpose, features and benefits, and design considerations of the CRS line of carousels.

Purpose
CRS carousels were designed for use in an automated laboratory system, such as POLARA, to provide storage of microplates, lids, or tip boxes. The carousel is a motorized unit controlled through a Single Axis Controller (SAC). When commanded by the SAC, the carousel rotates to present a storage unit to a preprogrammed location. The CRS carousel is available in the following models: Microplate Carousel: Standard and Tall versions are available Platefeeder Carousel Stacker Carousel

Figure 1-1: The fully assembled Microplate Carousel (Standard version)

CRS Carousel User Guide: Introducing the CRS Carousels

Introducing the CRS Carousels: Purpose

Figure 1-2: The fully assembled Platefeeder Carousel

Figure 1-3: The fully assembled Stacker Carousel

CRS Carousel User Guide: Introducing the CRS Carousels

Introducing the CRS Carousels: Purpose

Hotel

Spine

Shelf

Attachment points for hotel

Mounting Plate

Microplate with lid

Mounting fasteners

Carousel base

Figure 1-4: Key parts of the Microplate and Platefeeder Carousel models, loaded with one hotel

CRS Carousel User Guide: Introducing the CRS Carousels

Introducing the CRS Carousels: Features

Magazine

Magazine locators

Carousel base Figure 1-5: Key parts of the Stacker Carousel, loaded with 2 magazines

Features
The CRS carousel has the following features: DC servo motor drive mechanism with incremental encoder Software motor amplifier Removeable hotels Hotel configurations include: adjustable shelf, platefeeder, and magnetic shelf Titertek magazines (Stacker Carousel only) Anodized aluminum base plate and hotel back support Mounting hardware

CRS Carousel User Guide: Introducing the CRS Carousels

Introducing the CRS Carousels: Benefits

All necessary cables to connect to the Single Axis Controller 1 year parts and labor warranty

Benefits
The features of a CRS carousel provide the following benefits: A closed loop servo motor with an optical encoder ensures accurate positioning. Removeable hotels allow loading to be performed away from the system. By loading the individual hotels, then placing them on the carousel afterwards, greater efficiencies can be achieved Shelved hotels have shelves to accomodate standard and deep-well microplates with or without lids, and pipette tip boxes Shelved hotels allow random access to any plate at any time Platefeeder hotels allow stacking and greater capacity than shelved hotels Magnetic shelf hotel allows the use of magnetic separation technology Titertek magazines are compatible with Titertek stackers, and other instruments

Appropriate Use
CRS carousels are intended for use in typical laboratory environments. A carousel is not intended for use under extremes of temperature, in cleanroom environments, or with hazardous or corrosive materials.

CRS Carousel User Guide: Introducing the CRS Carousels

Introducing the CRS Carousels: Design Considerations

Design Considerations
CRS carousels are available in the following models: Microplate Carousel: Standard and tall versions Platefeeder Carousel Stacker Carousel

Each model of carousel uses the same communication protocol and motor and encoder design. The differences between the carousels lie in their external design, the type of hotels used, and the method of access.

Microplate Carousel
This model is the most versatile of the carousels. It is available in two versions as follows: Standard Tall

Both versions of the Microplate Carousel use eight shelved hotels to store microplates (also called microtiter plates or MTPs). The individual shelves of a hotel can be removed, to allow standard or deep-well plates to be used. A magnetic plate hotel option is available, which allows the user the option of using magnetic bead separation technology. Note: Hotels are not interchangeable between the standard and tall carousel versions. The shelved configuration allows the robot to directly access any plate. Table 1-1 summarizes the hotel options available for the Carousel Microplate. Table 1-1: Microplate Carousel Hotel Options Carousel Version Standard Standard Standard Tall Tall Tall Hotel Capacity 8 deep-well MTPs 15 standard MTPs 4 MTPs for magnetic bead separations 13 deep-well MTPs 25 standard MTPs 30 standard MTPs Total Capacity 64 deep-well MTPs 120 standard MTPs 32 standard MTPs 104 deep-well MTPs 200 standard MTPs 240 standard MTPs

CRS Carousel User Guide: Introducing the CRS Carousels

Introducing the CRS Carousels: Design Considerations

Platefeeder Carousel
This model uses eight platefeeder hotels, which hold stacked plates. A robot equipped with microplate fingers adds and removes plates from the top of the stack in FILO (First In Last Out) order. The Platefeeder Carousel has the following capacities: 40 unlidded MTPs per platefeeder hotel, for a total capacity of 320 34 lidded MTPs per platefeeder hotel, for a total capacity of 272 14 deep-well MTPs per platefeeder hotel, for a total capacity of 112

Stacker Carousel
This model holds twelve magaziness, which hold stacked plates. A robot transfers an entire magazine of plates to and from another instrument station. This second instrument removes plates from the magazine, processes the plates, and returns the plates to the magazine. The robot does not handle individual plates. The Stacker Carousel has the following capacity: 20 MTPs per magazine provide a total capacity of 240

Interchanging Hotels
The shelved hotels used for the Microplate Carousel and the platefeeder hotels used for the Platefeeder Carousel are interchangeable. Users can interchange hotels to accomodate a combination of standard microplates, deep-well microplates, and tip boxes.

CRS Carousel User Guide: Introducing the CRS Carousels

Introducing the CRS Carousels: Design Considerations

CRS Carousel User Guide: Introducing the CRS Carousels

CHAPTER 2

Safety

This chapter provides safety information you must know to safely install and operate a CRS carousel.

Motion Hazards
Since the carousel is remotely controlled by software, it can rotate without warning. Observe the following guidelines when working around the Carousel: Take care not to catch hair or clothing on the edges of the shelves. Older versions of the carousel may have sharp edges that can catch hair or clothing as they rotate. Do not place anything in the path of carousel rotation. This can cause damage to the carousel or personal injury.

E-Stop
The CRS carousel is controlled through a CRS Single Axis Controller (SAC). The SAC has an emergency stop (E-Stop) button that when pushed, will stop the motion of all motors under its control.

Ground
The carousel must be grounded to the SAC through the ring terminal connector found on the rear panel of the SAC. Note: If the SAC does not have a ring terminal connector, ground the carousel to the SAC using one of the rear panel assembly screws.

CRS Carousel User Guide: Safety

Safety: Ground

10

CRS Carousel User Guide: Safety

CHAPTER 3

Installing the Carousel

This chapter describes how to unpack, mount, assemble, and connect the CRS carousel.

Package Contents
The package contains the following items: One CRS carousel Hotels or magazines Carousel Mounting Kit Plate alignment fixture (shipped only with the Microplate Carousel) Motor extension cable

Unpacking Instructions
Warning! The encoder cap is exposed on the underside of the carousel base and can be easily damaged. Always ensure that the carousel is placed on a level surface that is free of debris. To unpack the carousel and the hotels or magazines, take the following steps:
1 2 3 4 5

Place the container right side up. Open the container and remove any shrink wrap or bubble wrap packing material. The carousel is bolted to plywood to secure it while shipping. Carefully remove the carousel and plywood from the container. Carefully remove the hotels or magazines from the container. Carefully remove the plywood from the carousel base. Take care not to damage the encoder cap when removing the plywood. Figure 3-2 shows the location of the encoder cap. Store all packing material and shipping containers, in case you need to ship the carousel and the hotels or magazines in the future.

CRS Carousel User Guide: Installing the Carousel

11

Installing the Carousel: Mounting

Mounting
To mount the CRS carousel perform the following:
1

Position the carousel and mounting plate on the table. This includes testing the reach of the robot to ensure it can access each nest of the carousel. Attach the carousel base assembly and mounting plate to the table.

See the following sections for details on how to perform these steps.

Positioning the Carousel and Mounting Plate

Position the carousel and the mounting plate to the laboratory table using these steps:
1

Using Figure 3-1 as a guide, press the dowel pins provided into the two 1/4 in. dowel pin holes in the mounting plate.

Hole for 3/8-16 flathead screw

Front
Hole for 3/8-16 flathead screw

Holes for 3/8 -16 cap screws

Holes for 1/4 in. dowel pins

3/4 in.hole for motor cable Holes for 3/8-16 cap screws

Hole for 3/8-16 flathead screw

Hole for 3/8-16 flathead screw

Figure 3-1: The carousel mounting plate 2

Tuck the motor cable into the base of the carousel to protect it from being pinched, and to protect the encoder cap of the carousel from being damaged. Figure 3-2 shows the location of the encoder cap. Using Figure 3-2 as a guide, position the carousel on the mounting plate by placing the two 1/4 in. holes over the dowel pins.

12

CRS Carousel User Guide: Installing the Carousel

Installing the Carousel: Mounting

Holes for 1/4 in. dowel pins

Encoder cap

Figure 3-2: The underside of the carousel base assembly

4 5 6 7

Attach one hotel rack to the carousel. Test the reach of the robot. Position the carousel to allow the robot to access each nest without reaching an arm pinch point. Mark the table surface at the four corners of the mounting plate. Remove the carousel from the mounting plate.

Attaching the Carousel and Mounting Plate to the Table

Attach the carousel and the mounting plate to the laboratory table using these steps:
1 2 3 4 5 6 7 8 9

Align the mounting plate to the marks on the table. Using a transfer punch, mark the hole positions for the 3/8-16 cap screws and the 3/4 in. motor cable hole on the table surface. Remove the plate from the table, and drill the holes for the 3/8-16 cap screws using a 31/64 in. drill. Insert the four 3/8 in. T-nuts from beneath the table. Drill the 3/4 in. hole for the motor cable, as marked. Place the mounting plate into position on the table. Secure the mounting plate to the table using four 3/8-16 flathead screws. Remove the motor cable from inside the carousel casing. Feed the cable through the hole in the mounting plate. Carefully place the carousel into position on the mounting plate using the dowel pins.

10 Secure the carousel base to the plate using the provided fasteners.

CRS Carousel User Guide: Installing the Carousel

13

Installing the Carousel: Assembling the Carousel

Assembling the Carousel

Once the carousel base assembly is properly mounted, complete the assembly by performing the following step: Attach the hotels onto the spine or load the magazines onto the nests.

Attaching a Hotel
1 2

Place the two shoulder bolts protruding from the back of the hotel into the holes in the spine of the carousel. Slide the hotel down, until it is firmly in place. Note: The shoulder bolts are mounting points. Do not screw them to the spine.

Loading a Magazine
Slide the white guide pin on the bottom of the magazine into the groove on the inside of the front locator. The magazine should rest snugly between the four locators.

Connecting to the System

A CRS carousel has the following port for interfacing to the system: A Hirose RP17 connector which supplies power, control, and feedback to the carousel motor. This connector must be connected to a CRS Single Axis Controller (SAC).

Hirose RP17 Connection

Connect a motor extension cable to the cable in the carousel. Connect the other end to a SAC by plugging in the Hirose RP17 connector at the rear of the SAC. Figure 3-3 shows the pin numbering for the carousel Hirose connector, as seen when looking into the cable.
White dot on casing

Figure 3-3: Pin numbering of the Hirose RP17 connector

14

CRS Carousel User Guide: Installing the Carousel

Installing the Carousel: Homing the Carousel

The following table lists the functions of the pins on the Hirose RP17 connector. Table 3-1: Pin functions of the Hirose RP17 connector Pin 1 2 3 4 5 6 7 8 9 10 11 12 Function PROX. ENC. GND. ENC. +5V CHA CHA* CHB CHB* PROX +12V CHZ CHZ* PROX SIGNAL MOTOR POWER RET. MOTOR POWER

Homing the Carousel

Once you have connected the carousel to a SAC, you must calibrate it relative to a home position. This calibrated position is recorded as the zero position in the carousel configuration file. The tool that you use to home the SAC will depend on the type of system you are using: For non-POLARA systems, use a terminal communication software package such as Hyperterminal, found in Windows NT. For POLARA systems, use the sacshell utility, part of CROS for Windows NT. Note: You should first ensure that the appropriate Carousel Instrument Interface has been installed and configured. See the CRS POLARA Instrument Interface Guide for more information. These methods are detailed in the next sections.

CRS Carousel User Guide: Installing the Carousel

15

Installing the Carousel: Homing the Carousel

Non-POLARA systems
To calibrate the motor using a terminal communications package, perform the following steps:
1

Establish communication with the SAC using the following settings for your terminal communications package: Baud rate: 9600, Data bits: 7, Parity: Even, Stop bits: 1 Emulation: TTY ASCII Setup: Send line ends with line feeds (LF) Echo typed characters locally Wrap lines that exceed terminal width

2 3 4 5 6 7

Enter the following to place the SAC in Manual mode:

:01RM-2D
Enter the following to engage limp mode:

MO-??
Manually position your system in the place you want to call the ZERO or calibrated location. Enter the following to zero the position counter:

ZR??
Enter the following to disengage limp mode:

MO+??
Enter the following to calibrate the carousel:

CL??
Note: The carousel should start moving in the direction of the home sensor. Once it finds it, it will back off, and look for the encoders zerocross signal.
8 9

Enter the following to save all of the current settings:

SC??
Enter the following to repower the motor:

MO+??
10 Enter the following to home the motor:

HM++
11 Enter the following to move the carousel to the zero/calibrated position:

MA0++
The motor is now calibrated.

16

CRS Carousel User Guide: Installing the Carousel

Installing the Carousel: Homing the Carousel

POLARA Systems
To calibrate the motor using CROSnt and the sacshell, perform the following steps:
1

At the CROSnt command prompt, enter the sacshell command with the name of the instance of your carousel, with an s added as the last character. For example:

sacshell my_carousels
2 3 4 5 6 7 8 9

Make sure that the E-Stops are not activated and that motor power is on. Check that the green button on the SAC is lit. Enter the following to power the motor:

MO+
Enter the following to home the motor:

HM
Enter the following to limp the motor:

MOManually position your system in the place you want to call the ZERO or calibrated location. Enter the following to power the motor, and unlimp the motor:

MO+
Enter the following to zero the encoder register:

ZR
Enter the following to calibrate the motor:

CL
Note: The carousel should start moving in the direction of the home sensor. Once it finds it, it will back off, and look for the encoders zerocross signal.
10 Enter the following to save the configuration:

SC
11 Enter the following to repower the motor:

MO+
12 Enter the following to home the motor:

HM
13 Enter the following to move the motor to the zero/calibrated position

(this is the same as the manual position set in step 6):

MA0
The motor is now calibrated.

CRS Carousel User Guide: Installing the Carousel

17

Installing the Carousel: Restoring Calibration on Powerup

Restoring Calibration on Powerup

After you have successfully calibrated the carousel, it will powerup with the most recently saved configuration. However, after turning off the SAC, you must tell the motor to move to the zero position.

Non-POLARA systems
Use a terminal communications package, such as Hyperterminal, found in Windows NT, to perform the following steps:
1

Establish communication with the SAC using the following settings for your terminal communications package: Baud rate: 9600, Data bits: 7, Parity: Even, Stop bits: 1 Emulation: TTY ASCII Setup: Send line ends with line feeds (LF) Echo typed characters locally Wrap lines that exceed terminal width

2 3 4 5

Enter the following to place the SAC in manual mode:

:01RM-2D
Enter the following to turn motor power on:

MO+??
Enter the following to home the motor:

HM??
Enter the following to move the motor to the zero/calibrated position:

MA0??

POLARA systems
Use the sacshell to perform the following steps:
1

At the CROSnt command prompt, enter the sacshell command with the name of the instance of your carousel, with an s added as the last character. For example:

sacshell my_carousels
2 3 4 5

Make sure that the E-Stops are not activated and that motor power is on. Ensure the green button on the SAC is lit. Enter the following to turn motor power on:

MO+
Enter the following to home the motor:

HM
Enter the following to move the motor to the zero/calibrated position:

MA0

18

CRS Carousel User Guide: Installing the Carousel

CHAPTER 4

Using the Carousel

This chapter describes the operation of a CRS carousel and its control interface.

Typical Operation
Typically, a CRS carousel receives commands through a SAC, which in turn is controlled by a program on a host computer. This program could be an instrument server of POLARA. A typical operation of the carousel in this situation, is as follows:
1 2 3

The controlling computer sends an action command to the SAC to turn the carousel a specified number of pulses. The SAC provides power to turn the carousel. The carousel revolves the instructed number of pulses. As the carousel revolves, the SAC keeps track of the encoder pulses and withdraws power to stop the carousel at the desired location. The controlling computer sends an query command to the SAC to determine if the carousel has completed its motion. If the carousel has completed its motion, the SAC returns a TRUE signal to the controlling computer. If the carousel has not completed its motion, the SAC returns a FALSE signal to the controlling PC. When the controlling PC recieves the signal that the motion is complete, it will instruct the robot to interact with the carousel. The type of interaction will vary, depending upon the configuration of the carousel, but could include removal or replacement of one or more microplates, lids, or tip boxes.

Control Interface
The carousel is controlled by a SAC, which in turn is controlled by a host computer. Typically, the host computer runs POLARA software, a CRS automated laboratory system. POLARA users employ the sacshell utility while testing and troubleshooting the carousel. During normal operation of a POLARA system the carousel is controlled though a carousel server interface. Non-POLARA users typically employ a terminal communications program to test and troubleshoot the carousel, and write their own software to operate the carousel as part of an automated system. Table 4-1 lists the command set used by the SAC to control a CRS carousel.

CRS Carousel User Guide: Using the Carousel

19

Using the Carousel: Control Interface

Table 4-1: Carousel Command Set Function Command

MO +/HM ZR CL MA MI SP SC MA0

Powers the motor on/off Homes the axis Zeroes the motor Calibrates the motor Moves the motor an absolute value Moves the motor an incremental value Sets the motor speed to a percentage of full speed Saves the current configuration Moves the motor to the zero position

For a detailed explanation of these commands and the complete SAC command set, please see the Single Axis Controller User Guide.

20

CRS Carousel User Guide: Using the Carousel

CHAPTER 5

Maintenance

This chapter covers the following topics: Maintenance of the carousel, including replacement parts Cleaning, disinfecting, and decontaminating procedures Shut down and storage procedures.

Daily
Each day, perform the following maintenance procedures: Make sure the carousel rotates freely in either direction and remove any apparent obstacles. Check that the hotels and shelves are not bent or damaged. A slight misalignment may interfere with the robot removing or replacing a plate (or lid or tip rack). Some versions of the Microplate Carousel are equipped with hotels that have metal shelves. Align metal shelves using the following steps:
a b c

Remove the rubber stopper from the bottom of the hotel. Attach the Lexan plate alignnment fixture to the bottom of the hotel and screw it into place. Visually, line up the edge of each shelf with each line in the plate alignment fixture. Note: There may be less shelves in your hotel than lines on the plate alignment fixture, depending on your hotel configuration. Line up the shelf with the nearest line on the alignment fixture.

d e f

Using your hand, gently bend the shelves until they are level and aligned correctly. Remove the plate alignment fixture from the hotel. Turn the plate alignment fixture around, and line up the grooves of the plate alignment fixture with the edges of the shelves. They should slide smoothly into the grooves. Repeat steps b to f as necessary.

CRS Carousel User Guide: Maintenance

21

Maintenance: Periodic

Periodic
Each month, perform the following maintenance procedure: Check the servo cable to ensure that it is properly attached to the carousel.

Yearly
Lubrication of the carousel motor should should be performed by CRS service personnel, or a CRS factory trained service technician, after 12,000 hours of operation (roughly 18 months of 100% duty cycle). Note: At 100% duty cycle the carousel operates 24 hrs per day and 7 days per week. If the duty cycle is less, then the time until cleaning and greasing is done can be proportionally increased.

Routine Cleaning
Wipe the exterior of the carousel with a lint free cloth or paper towel to remove dust and foreign particles.

Disinfecting/Decontaminating
To disinfect the carousel, spray it with 10% bleach solution, and wipe clean using a lint free cloth. If a spill contains radioactive substances, take the following steps:
1 2

Clean with an appropriate agent such as Decon. Use a wipe test to monitor for residual activity.

Replacing Parts
You can order the following replacement parts from CRS Robotics sales department. Table 5-1: Carousel Replacement Parts Part Name Hotel shelf-plastic Hotel shelf-metal Self adhesive pad Description Plastic shelf for a hotel Metal shelf for a hotel Pad for the bottom of a metal hotel shelf Part Number R-MM1366-001-00 R-M/C-MB13101 R-HWM-ADPD08

Shutdown
To shut down the carousel during a system shutdown, turn off the carousel by pressing the power button on the front panel of the SAC.

22

CRS Carousel User Guide: Maintenance

Maintenance: Storage

Storage
Store the carousel indoors in a cool, dry, climate-controlled environment.

Shipping
To ship the carousel and hotels or magazines, take the following steps:
1 2 3 4 5

Remove the hotels or magazines from the carousel. Secure the motor cable inside the housing of the carousel base. Bolt the carousel to a piece of wood to secure it during shipping. Secure the hotels or magazines to a piece of wood using plastic ties or cord and wrap them with bubble wrap to prevent damage. Ship using the original box or other suitable container.

CRS Carousel User Guide: Maintenance

23

Maintenance: Shipping

24

CRS Carousel User Guide: Maintenance

CHAPTER 6

Troubleshooting

This chapter provides information that will help keep your CRS carousel functioning properly, and troubleshoot communication problems.

Tips
Follow these practices to ensure reliable operation: Do not obstruct the motion of the carousel. Check to ensure that the path is free and the carousel rotates freely in either direction. When lifting the carousel be careful not to catch the Hirose connector on the bottom on the lab table. This can damage the pins necessary to control the motor.

Troubleshooting Communication Problems

Problem: The host cannot communicate with the SAC. Solution: Perform the following step: Check that the serial cable is not pinched or damaged. Make sure all pins are present and not bent. Replace the cable if necessary.

Problem: You can communicate with the SAC, but you cannot operate the carousel as expected. Solution: Perform the following step: Check that the motor cable is not pinched or damaged. Make sure all pins are present and not bent. Replace if necessary.

Error Information
The carousel is controlled by a SAC, which in turn is controlled by a host computer. The SAC responds when addressed by the host computer. Please see the Single Axis Controller User Guide for more information on the error codes that the SAC uses.

Support Contact Information

See the section Contact Information at the beginning of this guide.

CRS Carousel User Guide: Troubleshooting

25

Troubleshooting: Support Contact Information

26

CRS Carousel User Guide: Troubleshooting

CHAPTER 7

General Specifications

This chapter describes the physical characteristics of the carousel and its operational requirements.

Physical Characteristics
Table 7-1 lists the physical characteristics of the various CRS carousels. Table 7-1: Physical Characteristics of the CRS Carousels Dimension Length Width Height Weight Microplate Carousel Standard 22.3 in. (56.5 cm) 22.3 in. (56.5 cm) 22.4 in. (56.9 cm) 98.0 lb (44.5 kg) Tall 22.3 in. (56.5 cm) 22.3 in. (56.5 cm) 34.8 in. (88. 4 cm) 110.5 lb (50.2 kg) Platefeeder Carousel 23.0 in. (58.4 cm) 23.0 in. (58.4 cm) 22.4 in. (56.9 cm) 92.0 lb (41.7 kg) Stacker Carousel 22.1 in. 56.2 cm) 22.1 in. (56.2 cm) 28.5 in. (72.4 cm) 82 lb (37.2 kg)

Note: All measurements apply to the carousel when empty, with no hotels or magazines attached.

Materials
Base: Anodized Aluminum Hotel Shelves: Older models of the Microplate Carousel hotels use metal shelves Newer models of the Microplate Carousel hotels use plastic shelves

Operating Requirements
Power: +24V DC @ 1A Ambient temperature: 50 F to 104 F (10 C to 40 C) Maximum relative humidity: 80% at 50 F (10 C) 60% at 104 F (40 C)

CRS Carousel User Guide: General Specifications

27

General Specifications

28

CRS Carousel User Guide: General Specifications

Glossary

carousel A peripheral that is used in an automated laboratory system, such as a POLARA based system. The carousel is a motorized device controlled through a Single Axis Controller (SAC). When commanded by the SAC, the carousel rotates to present a nest or array of nests to a robot. CRS supplies three versions of a carousel. They are: Microplate, Platefeeder, and Stacker. container A physical object that is transported by the robot and acted on by an instrument. Examples: microplate, tip box, magazine. A container can have sub-containers. For example, a magazine can have 20 microplates. E-Stop A safety feature that when pressed, stops the motion of a robot or motorized device, such as a carousel. hotel A place to hold microplates, lids, or tip boxes. Hotels fit onto CRS carousels and come in two basic designs: Shelved: A shelved hotel can hold microplates, tip boxes, or lids, and allows random robot access. Platefeeder: A platefeeder hotel holds a stack of plates, and allows robot access only to the plate at the top of the stack.

lid A cover of a microplate. magazine A container used on the Stacker Carousel to hold stacks of microplates. Magazines are compatible with Titertek instruments and allow a large number of microplates to be transfered between instruments at one time. microplate A container with a number of wells that hold material for analysis or processing. mounting plate A metal plate that attaches to a laboratory table. A carousel is mounted to the mounting plate. MTP See microplate. nest In POLARA, a position where a container is placed. The robot moves a microplate, lid, tip box, magazine from the nest.

CRS Carousel User Guide: Glossary

29

Glossary

POLARA (programming architecture for laboratory automation) A CRS Robotics control architecture for automated laboratory systems. The carousel can be integrated into a POLARA system using a software interface available from CRS. POLARA lab system, POLARA-based lab system Any lab system built according to the POLARA architecture. servo cable The cable that allows communication to occur between the Single Axis Controller to the carousel. The cable also supplies power to the motor. shelf The horizontal part attached to a hotel that provides a nest for a microplate. Single Axis Controller (SAC) A CRS peripheral device that controls a motorized device such as a carousel. spine The vertical aluminum post of the carousel that supports a hotel. A Microplate or Platefeeder carousel has 8 spines. tip box A box that contains pipette tips. Pipette tips are used by dispensers to handle liquid.

30

CRS Carousel User Guide: Glossary