CataLyst Express User Guide - Stanford...

Removable random-accessmicroplate hotel

Removable microplatefeeder hotel

Microplate servo gripper

Robotic arm

Base

E-stop control

Re-grip station

Parking bracket

Front panel

Arm power beacon

Guarding

Rearpanel

CRS CataLyst Express User Guide

UMI-CAT5-400

ii

Copyright © May 2004 Thermo CRS, Ltd.

CataLyst, ActiveRobot, POLARA, and RAPL are trademarks of Thermo CRS, Ltd. and may be used to describe only Thermo CRS 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.

Thermo CRS, Ltd. 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. Thermo CRS, Ltd. assumes no responsibility for any errors that may appear in this document. Thermo CRS, Ltd. makes no commitment to update nor to keep current the information contained in this document.

Thermo CRS, Ltd. software products shall remain the property of Thermo CRS, Ltd.

Additional copies of this guide, or other Thermo CRS literature, may be obtained from the Sales Department or from your distributor.

Rev. Revision History Date

001 First release 03-2002

CataLyst Express User Guide: Preface iii

P R E F A C E

About This Guide

This user guide accompanies the Thermo Electron CRS CataLyst Express™ articulated robot instrument loader. It contains installation instructions, specifications, and operating procedures for the CataLyst Express.

Who Uses This Guide

This guide is intended for scientists, technicians, and other users of laboratory equipment. It assumes the reader has basic electrical and mechanical skills, and knows how to operate a personal computer running Microsoft Windows.

How to Use This Guide

This manual is task-based and uses navigational aids to help you quickly find the topics and information you need. If a technical term is not familiar to you, refer to the Glossary.

Before following instructions in a section, read the entire section first.

This guide consists of the following chapters:

• Chapter 1, Introducing the CataLyst Express introduces the major features of the CataLyst Express.

• Chapter 2, Safe Use of the CataLyst Express discusses safety considerations.

• Chapter 3, Installing the CataLyst Express provides instructions for installing the robot in a work cell.

• Chapter 4, Using the CataLyst Express describes how to use the CataLyst Express hardware.

• Chapter 5, CataLyst Express Ports includes detailed pinouts and configuration information to help you attach other devices to the CataLyst Express.

• Chapter 6, Maintenance Procedures describes how to establish a service schedule, replace fuses, and perform other basic maintenance activities.

• Chapter 7, Troubleshooting helps you to resolve problems that you may encounter.

Throughout this manual warnings are marked by a “!” symbol in the left margin. Failure to comply with these warnings can result in system errors, memory loss, damage to the robot and its surroundings, or injury to personnel.

iv CataLyst Express User Guide: Preface

Preface: Contacts

• Appendix A, Technical Specifications contains physical and electrical specifications, including guidelines for nominal use.

• Appendix B, GPIO Termination Block Option provides installation and mounting instructions for the optional GPIO termination block.

• Appendix C, Installing New Firmware describes how to re-install or install a new version of the CataLyst Express operating system firmware.

• Glossary provides definitions of the terminology used in this guide.

• Index provides a list of subjects used in this guide and their page numbers.

Contacts

You can contact Thermo Electron at the following addresses:

Surface Mail/Shipping

Thermo Electron CorporationLaboratory Automation and Integration5344 John Lucas DriveBurlington, Ontario L7L 6A6Canada

Telephone

1-905-332-2000 (voice)1-800-365-7587 (voice: toll free in Canada and United States)1-905-332-1114 (facsimile)

E-Mail

Sales: [email protected] Support and Training: [email protected]: [email protected]

World Wide Web

www.thermo.com

CataLyst Express User Guide: Preface v

Preface: Contents

Chapter 1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

What is the CataLyst Express? . . . . . . . . . . . . . . . . . 1-2Benefits of the CataLyst Express . . . . . . . . . . . . . 1-2

CataLyst Express Features . . . . . . . . . . . . . . . . . . . . 1-3CataLyst Express Software . . . . . . . . . . . . . . . . . . . . 1-6CataLyst Express Options . . . . . . . . . . . . . . . . . . . . . 1-7

Chapter 2: Safe Use of the CataLyst Express . . . . . . . . . . . . . . . 2-1

Safety Conformance . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Designated Use . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Built-in Safety Features . . . . . . . . . . . . . . . . . . . . . . 2-3Triggering the E-Stop . . . . . . . . . . . . . . . . . . . . . . . . 2-4CataLyst Express Hazards . . . . . . . . . . . . . . . . . . . . 2-5Establishing a Safeguarded Perimeter . . . . . . . . . . . . 2-6Preventing Accidents . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Ensuring Operator Safety . . . . . . . . . . . . . . . . . . 2-7Locking Out the CataLyst Express . . . . . . . . . . . . 2-8

Chapter 3: Installing the CataLyst Express . . . . . . . . . . . . . . . . . 3-1

Preparing the Bench . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Unpacking the CataLyst Express . . . . . . . . . . . . . . . . 3-4Setting up the CataLyst Express . . . . . . . . . . . . . . . . 3-5Unpacking the Computer . . . . . . . . . . . . . . . . . . . . . 3-7Installing the Computer . . . . . . . . . . . . . . . . . . . . . . 3-8

Connecting the Cables . . . . . . . . . . . . . . . . . . . . . 3-8Testing the CataLyst Express . . . . . . . . . . . . . . . . . . 3-9

Re-teaching Paths to a Hotel or Re-grip Station . 3-10Connecting Instruments . . . . . . . . . . . . . . . . . . . . . 3-11

Chapter 4: Using the CataLyst Express . . . . . . . . . . . . . . . . . . . . 4-1

Using the Front Panel . . . . . . . . . . . . . . . . . . . . . . . . 4-2Using the E-Stop Control . . . . . . . . . . . . . . . . . . . . . 4-3

Using the E-Stop . . . . . . . . . . . . . . . . . . . . . . . . . 4-3Understanding the Arm Status Indicators . . . . . . 4-4Using the Brake Release . . . . . . . . . . . . . . . . . . . 4-4

Using the Guarding . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6Pre-power Checklist . . . . . . . . . . . . . . . . . . . . . . . . . 4-7Starting the CataLyst Express . . . . . . . . . . . . . . . . . . 4-8Shutting Down the CataLyst Express . . . . . . . . . . . 4-10

Parking the Arm . . . . . . . . . . . . . . . . . . . . . . . . 4-10Performing a Controlled Shutdown . . . . . . . . . . 4-10Powering Off the CataLyst Express . . . . . . . . . . 4-11

Contents

vi CataLyst Express User Guide: Preface

Preface: Contents

Chapter 5: CataLyst Express Ports . . . . . . . . . . . . . . . . . . . . . . . 5-1

The Wrist/OPTIONS Ports . . . . . . . . . . . . . . . . . . . . . 5-2Serial Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3P.C. Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4General Purpose Input/Output (GPIO) Port . . . . . . . . 5-5

Pinouts for the GPIO Port . . . . . . . . . . . . . . . . . . 5-5Connecting Inputs and Outputs . . . . . . . . . . . . . 5-9Using the Relays . . . . . . . . . . . . . . . . . . . . . . . . . 5-9Using GPIO Devices in Your Application . . . . . . . 5-9

The E-Stop Port (Front Panel) . . . . . . . . . . . . . . . . . 5-10The E-Stop Port (Rear Panel) . . . . . . . . . . . . . . . . . . 5-12

Adding E-Stops . . . . . . . . . . . . . . . . . . . . . . . . . 5-12The Guarding Port . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Chapter 6: Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . 6-1

Backing up Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3Routine Inspections . . . . . . . . . . . . . . . . . . . . . . . . . 6-4Checking Front Panel Fuses and Circuit Breakers . . . 6-5Inspecting AC Fuses . . . . . . . . . . . . . . . . . . . . . . . . . 6-7Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . 6-8

Chapter 7: Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

The LCD Display Remains Blank . . . . . . . . . . . . . . . . 7-2Arm Power Cannot Be Turned On . . . . . . . . . . . . . . . 7-3Contacting the Customer Support Group . . . . . . . . . 7-4

Chapter A: Technical Specifications . . . . . . . . . . . . . . . . . . . . . . A-1

Physical Characteristics . . . . . . . . . . . . . . . . . . . . . . A-2Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . A-3Operating Environment . . . . . . . . . . . . . . . . . . . . . . . A-3

Chapter B: GPIO Termination Block Option . . . . . . . . . . . . . . . . B-1

Chapter C: Installing New Firmware . . . . . . . . . . . . . . . . . . . . . . C-1

Backing up Files from the CataLyst Express . . . . . . . C-2Downloading the CataLyst Express Firmware . . . . . . C-4Configuring the Robot Controller . . . . . . . . . . . . . . . . C-6

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

CataLyst Express User Guide: Preface vii

Preface: Figures

List of Figures

Figure 1-1: CataLyst Express workstation . . . . . . . . . . . . . . . . . . . . . . 1-2

Figure 1-2: Main hardware features of the CataLyst Express . . . . . . . . 1-3

Figure 1-3: CataLyst Express with front- and rear-side guarding . . . . 1-5

Figure 2-1: Removing the fuse drawer . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Figure 3-1: Positioning of the CataLyst Express . . . . . . . . . . . . . . . . . . 3-2

Figure 3-2: Dimensions of the CataLyst Express in in.[mm] . . . . . . . . . 3-2

Figure 3-3: Location of guarding frame components. . . . . . . . . . . . . . . 3-5

Figure 3-4: Push the storage unit base down onto the mount. . . . . . . . 3-6

Figure 3-5: Reach of the CataLyst Express in in.[mm] . . . . . . . . . . . . 3-11

Figure 3-6: Location of instrument mounting plate holes . . . . . . . . . . 3-12

Figure 4-1: Front panel of CataLyst Express . . . . . . . . . . . . . . . . . . . . 4-2

Figure 4-2: The E-Stop control cuts power. . . . . . . . . . . . . . . . . . . . . . 4-3

Figure 4-3: The Easy Teach Setup main screen . . . . . . . . . . . . . . . . . . 4-9

Figure 5-1: Pin numbering for the wrist/OPTIONS ports . . . . . . . . . . . 5-2

Figure 5-2: SERIAL port pin numbering. . . . . . . . . . . . . . . . . . . . . . . . 5-3

Figure 5-3: P.C. port pin numbering . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Figure 5-4: Pin numbering scheme used by the GPIO connector . . . . . 5-5

Figure 5-5: Wiring schematic for the GPIO connector. . . . . . . . . . . . . . 5-8

Figure 5-6: Pin numbering scheme for the E-Stop port (front panel) . . 5-10

Figure 5-7: Wiring schematic for the E-Stop port . . . . . . . . . . . . . . . . 5-11

Figure 5-8: Pin numbering scheme for the E-Stop port (rear panel) . . 5-12

Figure 5-9: Pin numbering for the GUARDING port . . . . . . . . . . . . . . 5-14

Figure 6-1: Location of front panel fuses and circuit breakers . . . . . . . 6-5

Figure B-1: The GPIO termination block. . . . . . . . . . . . . . . . . . . . . . . .B-1

Figure C-1: The ActiveRobot Explorer window . . . . . . . . . . . . . . . . . . .C-2

viii CataLyst Express User Guide: Preface

Preface: Figures

CataLyst Express User Guide: Preface ix

Preface: Tables

Table 3-1: Instrument Names of factory-taught paths . . . . . . . . . . . 3-10

Table 5-1: Pinouts for the wrist/OPTIONS connector . . . . . . . . . . . . . 5-2

Table 5-2: SERIAL port pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Table 5-3: P.C. port pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Table 5-4: Pinouts for the GPIO connector . . . . . . . . . . . . . . . . . . . . . 5-6

Table 5-5: Pinouts for the E-Stop port (front panel) . . . . . . . . . . . . . 5-10

Table 5-6: Pinouts for the E-Stop port (rear panel) . . . . . . . . . . . . . . 5-12

Table 5-7: Pinouts for the GUARDING port . . . . . . . . . . . . . . . . . . . 5-14

Table 6-1: Front panel fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Table 6-2: AC fuses required for the CataLyst Express . . . . . . . . . . . 6-7

Table A-1: Physical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Table A-2: Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Table A-3: Operating Environment . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

List of Tables

x CataLyst Express User Guide: Preface

Preface: Tables

CataLyst Express User Guide: Introducing the CataLyst Express 1–1

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C H A P T E R 1

Introducing the CataLyst Express

The CRS CataLyst Express from Thermo Electron Corporation enables scientists to automate the transfer of microplates between instruments and storage units. For a detailed introduction to the CataLyst Express, see the following topics:

• “What is the CataLyst Express?” on page 1-2

• “CataLyst Express Features” on page 1-3

• “CataLyst Express Software” on page 1-6

• “CataLyst Express Options” on page 1-7

1–2 CataLyst Express User Guide: Introducing the CataLyst Express

Introducing the CataLyst Express: What is the CataLyst Express?

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What is the CataLyst Express?

The CRS CataLyst Express enables scientists to automate the transfer of microtiter plates between instruments and storage units. The CataLyst Express provides the reliability, precision, and dexterity of Thermo’s CRS CataLyst robot in an integrated package that makes it easy for researchers to automate the loading and unloading of several, microtiter plate-based instruments.

Figure 1-1: CataLyst Express integrated with two Thermo CRS random-access Microplate Hotels, a Thermo CRS Platefeeder Hotel, and a Thermo Labsystems MicroDrop dispenser

Benefits of the CataLyst Express

Users of the CataLyst Express enjoy the following benefits:

• Continuous, error-free operation

• Precise, repeatable motion

• The ability to handle a wide range of containers

• The ability to automate loading and unloading of instruments, such as microscopes, that no other laboratory plate mover has the dexterity to handle

• Safety features that meet OSHA requirements

• Easy to use, yet powerful method development and scheduling

Introducing the CataLyst Express: CataLyst Express Features


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CataLyst Express Features

The CataLyst Express has the following main features:

Figure 1-2: Main hardware features of the CataLyst Express

• The robotic arm gets microplates from receptacles, or nests, and puts microplates into nests.

• The base supports the arm and microplate storage devices, and houses the electronics that power and control the system.

• The removable storage units provide the following types of storage:

• Random-access microplate hotels provide 15 nests, each of which can be accessed by the arm at any time. They are available in both portrait and landscape orientations.

• Microplate feeder hotels provide storage for up to 40, stacked microplates. The arm accesses microplates at the top of the stack.

The base can support up to three random-access hotels or three microplate feeder hotels.

• The re-grip station provides a nest for the CataLyst Express to temporarily put a microplate, so that it can change the way it grips the microplate: from portrait orientation to landscape orientation, for example.

Removable random-accessmicroplate hotel

Removable microplatefeeder hotel

Microplate servo gripper

Robotic arm

Base

E-stop control

Re-grip station

Parking bracket

Front panel

Arm power beacon

Guarding

Rearpanel



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• The microplate servo gripper holds the microplates as the arm moves them. Its features enable the CataLyst Express to control the strength of the grip and the distance between the fingers, allowing the CataLyst Express to apply the optimum gripping force for each type of microplate and to confirm that it has a microplate in its grasp.

Thermo CRS offers two types of fingers with the microplate servo gripper: offset fingers, which are the standard type of fingers provided with the CataLyst Express, and straight, which are required for use only with the random-access, portrait-orientation hotel.

• The parking bracket provides a parking location for the arm, a known physical position that enables the CataLyst Express to establish an origin in space, or home, for the arm.

Note: The arm must be homed before it can move microplates.

• The E-Stop control provides an emergency stop button that, when pressed, immediately cuts power to the arm. The control also provides arm status indicators, and a brake release that enables operators to manually move the arm into its parking bracket. For details, see “Using the E-Stop Control” on page 4-3.

• The arm power beacon glows yellow when the arm is powered, providing a clear signal to operators that the arm is capable of moving.

• The front panel provides a system status display, controls, input/output ports, and fuses and circuit breakers. For details, see “Using the Front Panel” on page 4-2.

• The rear panel provides the main AC power input, the AC fuses, and three electrical ports: an E-Stop port, the guarding port, and an options port that provides access to the end-of-arm user port.

• The teaching jig (not shown) is used for testing and teaching paths to instruments.



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• The guarding protects operators from the arm while it is moving. When opened, it immediately cuts power to the arm. Rear-side guarding is available as an option. For details, see “Setting up the CataLyst Express” on page 3-5.

Figure 1-3: CataLyst Express with front- and rear-side guarding attached and open


Introducing the CataLyst Express: CataLyst Express Software

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CataLyst Express Software

The CataLyst Express package also includes a Dell computer with pre-installed and configured software, and two serial cables to connect it to the CataLyst Express.

The CataLyst Express software includes the following software for Microsoft Windows computers:

• POLARA 2.1, a version of Thermo’s advanced laboratory automation software created specifically for the CataLyst Express, which includes Easy Teach for simple point-and-click teaching and control.

• CataLyst Express Self Test, software that ensures the factory-taught paths are accurate.

Introducing the CataLyst Express: CataLyst Express Options


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CataLyst Express Options

Thermo Electron LAI offers the following options for the CataLyst Express:

• Rear-side guarding, which protects operators from the arm of the CataLyst Express

• Removable storage units:

• CRS Microplate Hotels provide 15 nests, each of which can be accessed by the arm at any time. They are available in both portrait and landscape orientations.

• CRS Platefeeder Hotels provide storage for up to 40, stacked microplates. The arm accesses microplates from the top of the stack.

The base can support up to three storage units. The CataLyst Express can access a combination of random-access, landscape-orientation hotels and microplate feeder hotels, but it cannot access these types of hotel in combination with random-access, portrait orientation hotels.

• Gripper fingers:

• CRS Offset Microplate Fingers, which are the standard type of fingers provided with the CataLyst Express

• CRS Straight Microplate Fingers, which are required for use only with the portrait-orientation Microplate Hotel.

• The GPIO Termination Block, which extends the GPIO port to a termination block for easier access

• Mounting kits that simplify instrument connections to the CataLyst Express

• POLARA instrument interfaces for popular lab instruments

• CataLyst Express DLL, an easy to use ActiveX component that enables Windows applications to load and unload instruments with the CataLyst Express

• ActiveRobot, a set of ActiveX components that provide extensive control of every feature of the CataLyst Express, including its integrated input/output capabilities

For more information, contact Thermo LAI sales at [email protected].


Introducing the CataLyst Express: CataLyst Express Options

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CataLyst Express User Guide: Safe Use of the CataLyst Express 2–1

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C H A P T E R 2

Safe Use of the CataLyst Express

Before installing or using the CRS CataLyst Express, ensure that you are familiar with the safety directives in this chapter.

For details, see the following topics:

• “Safety Conformance” on page 2-2

• “Built-in Safety Features” on page 2-3

• “Triggering the E-Stop” on page 2-4

• “CataLyst Express Hazards” on page 2-5

• “Establishing a Safeguarded Perimeter” on page 2-6

• “Preventing Accidents” on page 2-7

Caution! It is your responsibility to ensure that the robot system is safely installed and operated.

2–2 CataLyst Express User Guide: Safe Use of the CataLyst Express

Safe Use of the CataLyst Express: Safety Conformance

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Safety Conformance

The CataLyst Express has been designed and built in accordance with the following safety standards:

• UL 1740:1998 Robots and Robotic Equipment

• ANSI/RIA15.06-1992 Industrial Robots and Robot Systems - Safety Requirements

• CAN/CSA-C22.2 No. Z434-94 Industrial Robots and Robot Systems --General Safety Requirements

• EN60204-1:1992, EN292:1991, EN954:1997 Category-1, and the Essential Health and Safety Requirements of the EC Machinery Directive

• ISO10218:1992 Manipulating industrial Robots -- Safety

Ensure that your CataLyst Express application complies with all additional safety regulations and standards in effect at the site where the system is installed.

Designated Use

The CataLyst Express should not be operated in the following conditions:

• In explosive environments

• In radioactive or biohazardous environments, except as part of a system that has been specifically designed for such use

• Directly on humans (e.g. surgery)

If you are unsure whether your robot application falls within the designated use for the CataLyst Express system, contact the Thermo LAI Customer Support Group, as described in “Contacting the Customer Support Group” on page 7-4.

Safe Use of the CataLyst Express: Built-in Safety Features


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Built-in Safety Features

The CataLyst Express robot system includes the following basic safety features:

• An E-Stop button enables you to cut power to the arm at any time.

• Guarding connected to the E-Stop circuit protects operators while the arm is moving and cuts arm power when the guarding is opened.

• The CataLyst Express automatically cuts arm power when it detects collisions or robot runaway.

• Fail-safe brakes built into all joints engage automatically when arm power is cut, preventing the arm from motion due to gravity.

• Arm speed is restricted to 10% until the arm is homed and while teaching.

• The CataLyst Express enforces single point of control, preventing more than one person or process from controlling the arm at any time.


Safe Use of the CataLyst Express: Triggering the E-Stop

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Triggering the E-Stop

In case of emergency, operators can quickly halt all arm motion by triggering an emergency stop.

To stop the arm in case of emergency• Press the E-Stop button on the E-Stop control, or any other E-Stop that

has been integrated into the CataLyst Express’s E-Stop circuit.

To recover from an E-Stop1 Remove all dangers from the workcell and verify that it is safe to power

the arm.

2 Twist the E-Stop button to reset it or, if other devices have been connected to the E-Stop chain, close the E-Stop device that triggered the stop.

3 Press the Arm Power button to restore power to the arm.

4 If arm power cannot be restored, see “Arm Power Cannot Be Turned On” on page 7-3 for the relevant troubleshooting procedure.

Safe Use of the CataLyst Express: CataLyst Express Hazards


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CataLyst Express Hazards

• A fire hazard may be exposed if the arm comes in contact with a piece of equipment that is at a different electrical potential. If a charged piece of equipment is in contact with the arm for an extended period of time, the wiring in the CataLyst Express could overheat and catch fire.

• The space between moving links presents a crushing/pinching hazard. Do not touch or lean against the arm when arm power is on and the arm is capable of motion.

• The brakes in the arm do not instantaneously halt arm motion when arm power is removed. It takes about 0.2 seconds for the arm to stop moving.

• Water or other liquids may cause a short circuit, which could cause robot runaway. Water or other electrically conductive liquids must not be allowed to enter the arm or base.

• The servo gripper will drop its payload if power to the CataLyst Express is cut. Do not use the CataLyst Express if a dropped payload presents a severe hazard. The servo gripper will continue to grasp the payload if arm power is removed by triggering the E-Stop or opening the guarding.

• The fingers on the servo gripper pose a severe injury hazard. You must install the guarding to protect users against inadvertent contact with the fingers, and users must wear safety goggles while in the immediate vicinity of the arm.

Warning! All users of the CataLyst Express must be made aware of the following potential hazards:


Safe Use of the CataLyst Express: Establishing a Safeguarded Perimeter

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Establishing a Safeguarded Perimeter

Use the guarding supplied with the CataLyst Express to protect operators and other personnel from the arm while it is powered.

The guarding connects to the E-Stop circuit via the GUARDING port on the rear of the base. Opening the guarding opens the circuit, cutting power to the arm. When the arm is not powered, the brakes on its joints engage, preventing gravity from moving it.

Perform a risk assessment before installing the CataLyst Express. If a wall or an instrument blocks operator access to the arm’s workspace on that side, it might not be necessary to install the guarding on that side.

For more information, see the following topics:

• “Preparing the Bench” on page 3-2

• “Setting up the CataLyst Express” on page 3-5

Safe Use of the CataLyst Express: Preventing Accidents


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Preventing Accidents

In order to minimize risks to personnel and equipment near the CataLyst Express, obey the following safety rules:

• Wear safety goggles and have the E-Stop control within reach whenever you are using or in the vicinity of the CataLyst Express.

• Test your installation of the CataLyst Express after initial setup and after any changes.

• Alert all operators to the potential hazards presented by the CataLyst Express.

• Make all persons entering the safeguarded area aware of potential hazards and of the need to wear safety goggles and have an E-Stop button in reach at all times.

• Schedule routine inspections of all safety devices to ensure that they are functioning normally.

• If the system is under repairs or acting abnormally, lock-out the CataLyst Express to prevent the system from being used. See “Locking Out the CataLyst Express” on page 2-8.

Ensuring Operator Safety

Ensure that all personnel who program, operate, or maintain the CataLyst Express are adequately trained to perform their jobs safely. You should attend a Thermo CRS training course before programming a custom application for the CataLyst Express.

Ensure that all operators:

• Have a clear definition of their duties.

• Receive adequate training.

• Are fully aware of the potential hazards of the CataLyst Express.

• Know the location and use of all safety devices.

Warning! If incorrectly installed or programmed, the arm may perform unexpected movements at high speeds.


Safe Use of the CataLyst Express: Preventing Accidents

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Locking Out the CataLyst Express

If the CataLyst Express is awaiting or undergoing service, you must lock it out to ensure it can’t be used.

Note: OSHA safety procedure 1910-147 recommends locking out the AC power outlet at the main panel. If you prefer to implement the OSHA-recommended procedure, refer to OSHA 1910-147 Control of Hazardous Energy (Lockout/Tagout) for further information.

To lock out the CataLyst Express1 Unplug the AC power cord from the AC input module in the rear of the

base.

Figure 2-1: Removing the fuse drawer

2 Insert a flat head screwdriver below the fuse drawer clip and remove the fuse drawer from the AC input module. See Figure 2-1 for the location of the fuse drawer and clip.

3 Create a tag labeled “DO NOT POWER THE ROBOT” and hang it on the front of the CataLyst Express. The tag must be conspicuous and easy to read.

CataLyst Express User Guide: Installing the CataLyst Express 3–1

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C H A P T E R 3

Installing the CataLyst Express

The CataLyst Express has been designed to be easy to install. For details, see the following topics:

• “Preparing the Bench” on page 3-2

• “Unpacking the CataLyst Express” on page 3-4

• “Setting up the CataLyst Express” on page 3-5

• “Unpacking the Computer” on page 3-7

• “Installing the Computer” on page 3-8

• “Testing the CataLyst Express” on page 3-9

• “Connecting Instruments” on page 3-11

3–2 CataLyst Express User Guide: Installing the CataLyst Express

Installing the CataLyst Express: Preparing the Bench

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Preparing the Bench

The bench on which you place the CataLyst Express should conform to the layout shown in Figure 3-1.

Figure 3-1: Positioning of the CataLyst Express, an instrument, and the bench

Follow these guidelines:

• Select a bench wide enough to provide at least 1 m clearance between the side of the CataLyst Express and the side edge of the bench. For the dimensions of the CataLyst Express, see Figure 3-2.

Figure 3-2: Dimensions of the CataLyst Express in in.[mm]

• Place the bench against a wall to restrict access to the rear side of the CataLyst Express.

Note: You can provide access to the CataLyst Express from the rear if you install the optional rear-side guarding.

Wall

BenchInstrument

Front-side guarding

Installing the CataLyst Express: Preparing the Bench


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• Make sure the bench is level, fixed in place, and clean.


Installing the CataLyst Express: Unpacking the CataLyst Express

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Unpacking the CataLyst Express

The CataLyst Express ships in a wooden crate. The following procedures describe how to unpack the CataLyst Express and its components from the crate.

To unpack the CataLyst Express1 Remove the top of the crate, using the supplied screwdriver.

2 Remove the sides of the crate.

3 Using at least two people, lift the unit out of the box and place it on the bench.

To unpack the microtiter plate storage units• Cut the ribbons fastening the storage units to the side of the crate.

The remaining components of the CataLyst Express, including cables, teaching jig, and software CD, are stored in the box attached to the inside of the crate.

To unpack the guarding• Lift the front guarding door up and off the hook holding it on the side of

the crate.

• Remove protective wrapping.

Caution! The CataLyst Express weighs 76 kg [167 lb]. Use at least two people to lift it out of the crate.

Installing the CataLyst Express: Setting up the CataLyst Express


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Setting up the CataLyst Express

To setup the CataLyst Express hardware, you attach the guarding, install the storage units, connect the E-Stop control, and connect the AC power supply.

Figure 3-3: Location of guarding frame components

To install the front guarding

1 Peel off the protective covering from the guarding doors.

2 Drop the front door onto the hinges on the frame. See Figure 3-3 for the location of the door hinges.

3 Slide the guarding as far as possible under the base of the CataLyst Express.

4 Adjust the set screws on the side door hinges with a 2 mm hex key to set the position for each side door.

5 Remove the dummy plug from the GUARDING port on the rear panel and plug in the guarding cable.

To install each microplate storage unit

1 Grasp the storage unit by the base and by the handle at the top, so that the Thermo CRS label is facing you.

Frame mounting pins

Guarding frame

Mounting screws

Door hinges


Installing the CataLyst Express: Setting up the CataLyst Express

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2 Position the storage unit over the mounting bracket, with the number matching the one on the storage unit, and push it down until it snaps into place. See Figure 3-4 for guidance.

Figure 3-4: Push the storage unit base down onto the mount until it snaps in place.

To connect the E-Stop control• Plug the E-Stop control into the E-STOP port on the front panel.

Note: To connect other E-Stops into the E-Stop circuit of the CataLyst Express, remove the dummy plug from the E-STOP port on the rear panel and connect the E-Stops between pins 8 and 9 on the port. For details, see “Adding E-Stops” on page 5-12.

Adjust the guarding• Adjust the position of the guarding frame under the base of the

CataLyst Express so that the closed guarding door does not touch the storage units.

To connect AC power1 Move the POWER switch on the front panel of the CataLyst Express to the

‘0’ position.

2 Plug the female end of the power supply cord into the socket labelled “AC” on the rear of the CataLyst Express.

3 Plug the male end of the power supply cord into the main AC power supply plug.

Caution! Ensure that the number on the storage unit matches the number of the mounting bracket. Paths are factory-taught with the hotels positioned as shown by the numbers.

Installing the CataLyst Express: Unpacking the Computer


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Unpacking the Computer

Follow the manufacturer’s instructions for unpacking the computer.

You do not install any CataLyst Express software; it is already installed.

The software CD contains configuration, calibration, and instrument files unique to your CataLyst Express. Create a backup copy of the software CD and store it in a secure location.


Installing the CataLyst Express: Installing the Computer

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Installing the Computer

Place the computer out of reach of the CataLyst Express arm, but close enough to allow cable connections.

Place the monitor and keyboard so that you can see the movement of the CataLyst Express at all times. Do not operate the CataLyst Express remotely.

Connecting the Cables

The two serial cables must be connected between ports on the personal computer and the CataLyst Express. The cables are labelled with yellow and green ties, and the computer ports are labelled with yellow and green stickers.

To connect the cables• Plug the female end of the yellow serial cable into the serial port labelled

yellow on the computer.

• Plug the female end of the green serial cable into the serial port labelled green on the computer.

• Plug the male end of the yellow serial cable into the port labelled P.C. on the front panel of the CataLyst Express.

• Plug the female end of the green serial cable into the port labelled SERIAL 0 on the front panel of the CataLyst Express.

Warning! Ensure power is off for both the PC and the CataLyst Express before connecting cables.

Installing the CataLyst Express: Testing the CataLyst Express


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Testing the CataLyst Express

Before putting the CataLyst Express into regular use, test it with the supplied CataLyst Express Self Test program. If necessary, re-teach the paths, as described in “Re-teaching Paths to a Hotel or Re-grip Station” on page 3-10.

To test the CataLyst Express

1 Set the POWER switch on the front panel of the CataLyst Express to the ‘1’ position. The CataLyst Express powers up.

2 Remove all containers from the hotels mounted on the CataLyst Express.

3 Place the teaching jig into the regrip station.

4 Run the CataLyst Express Self Test program by selecting Start > Programs > CRS Robotics > CataLyst Express > Self Test.

To halt the tests at any time, click Abort.

The Self Test program proceeds through the tests listed on the left side of the program screen, highlighting each in yellow as it performs the test, and placing a check mark beside each when it completes the test.

Note: The unparking and homing test takes several minutes to complete, since arm speed is limited before it has been homed.

5 During the motion test part of the setup test, carefully monitor the arm’s movements, and confirm the following conditions:

• When the arm grips the jig, the jig does not slip or twist.

• When the arm places the jig in a hotel or in the regrip station, the plate does not drop or lie tilted.

Warning! A collision will occur if any containers are still in the hotels when the test starts! Make sure all containers are removed.

Warning! If a collision occurs during the test, click Abort immediately, and contact Thermo CRS Customer Support.


Installing the CataLyst Express: Testing the CataLyst Express

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• If the arm is moving the jig in and out of a Platefeeder Hotel, the jig moves freely up and down the hotel without binding with the sides.

If any of the conditions are not met during the test, you must re-teach the paths to the re-grip station or to the hotel where the problem occurs.

Re-teaching Paths to a Hotel or Re-grip Station

The paths to the re-grip station and to hotels on your CataLyst Express are pre-taught at the factory. These instruments have standard names, as listed in Table 3-1. The instrument names for the hotels vary by the type of hotel and its mounting position (1, 2, or 3) on the CataLyst Express.

Table 3-1: Instrument Names of factory-taught paths

To re-teach the paths to a hotel or to the re-grip station, you use the Easy Teach program and re-teach the locations that define the paths. For details about the Easy Teach program, see Chapter 5: Defining Motion in your POLARA 2.cx User Guide.

Storage Unit Instrument Names of Factory-taught Paths

Thermo CRS Microplate Hotel StdShelf1, StdShelf2, StdShelf3

Thermo CRS Portrait Hotel PortShelf1, PortShelf2, PortShelf13

Thermo CRS Platefeeder Hotel StdFeeder1, StdFeeder2, StdFeeder3

Re-grip station regrip

Warning! Do not edit the Park.v3 and robot.v3 files in the V3_Files directory! Doing so will cause the CataLyst Express to behave unpredictably! These files are created at the factory and are unique to each CataLyst Express.

Installing the CataLyst Express: Connecting Instruments


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Connecting Instruments

You can connect any instrument whose nests fall within the reach of the CataLyst Express. For details on the reach, see Figure 3-5.

Figure 3-5: Reach of the CataLyst Express in in.[mm]

Tip: You might have to raise and/or rotate the instrument to enable the CataLyst Express to reach it.

Once the instrument’s nests are within the reach of the CataLyst Express, both must be prevented from moving, relative to each other. You can fix them in position in the following ways:

• Stick the supplied corner stops to the bench, around the feet of the instrument and the CataLyst Express.


Installing the CataLyst Express: Connecting Instruments

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• Before connecting the instrument, fix it to a mounting plate that has dowel pins that can slip into the matching holes on the base of the CataLyst Express. (See Figure 3-6 for the location of the holes.)

Figure 3-6: Location of instrument mounting plate holes on bottom surface

Note: Thermo CRS supplies mounting kits for many instruments. Contact Thermo CRS sales for more information, as described in “Contacting the Customer Support Group” on page 7-4.

Rear instrument mounting holes

Side instrument mounting holes

Side instrument mounting holes

CataLyst Express User Guide: Using the CataLyst Express 4–1

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C H A P T E R 4

Using the CataLyst Express

This chapter describes how to operate the CataLyst Express. For details, see the following topics:

• “Using the Front Panel” on page 4-2

• “Using the E-Stop Control” on page 4-3

• “Pre-power Checklist” on page 4-7

• “Starting the CataLyst Express” on page 4-8

• “Shutting Down the CataLyst Express” on page 4-10

4–2 CataLyst Express User Guide: Using the CataLyst Express

Using the CataLyst Express: Using the Front Panel

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Using the Front Panel

The front panel provides basic hardware controls and connectors for the CataLyst Express.

Figure 4-1: Front panel of CataLyst Express

The front panel has the following features:

• The MAIN POWER switch controls power to the CataLyst Express.

• The LCD panel displays status messages and prompts.

• The fuse panel contains fuses and circuit breakers. For details about the fuse panel, see “Checking Front Panel Fuses and Circuit Breakers” on page 6-5.

• The ARM POWER button controls power to the arm. When its LED glows, the arm is powered. If the LED does not glow, pressing the ARM POWER button turns on power to the arm.

• When the HOME button’s LED glows, the arm is homed. If the LED does not glow, pressing the HOME button when the arm is powered homes the arm.

• The PAUSE/CONTINUE button’s LED flashes when the CataLyst Express needs confirmation of a request to take control of the arm. To confirm the request, the operator must press the PAUSE/CONTINUE button. For more information, see “Understanding the Arm Status Indicators” on page 4-4.

• ActiveRobot applications can use the F1 and F2 buttons to get input from the operator.

• The E-Stop control plugs into the E-STOP port. For more information about the E-Stop control, see “Using the E-Stop Control” on page 4-3. For details about the connector, see “The E-Stop Port (Front Panel)” on page 5-10.

• The GPIO port provides access to the input/output features of the CataLyst Express. For details, see “General Purpose Input/Output (GPIO) Port” on page 5-5.

• The personal computer used to teach and control the CataLyst Express plugs into the P.C. port. For details, see “P.C. Port” on page 5-4.

• The SERIAL port enables other devices that to communicate with the CataLyst Express. For details, see “Serial Port” on page 5-3.

Using the CataLyst Express: Using the E-Stop Control


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Using the E-Stop Control

The E-Stop control enables you to cut power immediately to the arm. The E-Stop control also displays arm status, and provides a brake release that enables you to move the arm manually.

Figure 4-2: The E-Stop control cuts power to the arm, displays its status, and provides a brake release.

Note: The CataLyst Express cannot apply power to the arm unless the E-Stop is plugged into the E-STOP port on the front panel.

Note: To connect other E-Stops into the E-Stop circuit of the CataLyst Express, remove the dummy plug from the E-STOP port on the rear panel and connect the E-Stops between pins 8 and 9 on the port. For details, see “Adding E-Stops” on page 5-12.

Using the E-Stop

Use the E-Stop to immediately cut power to the arm.

To trigger the E-Stop

• Press the E-Stop button. The CataLyst Express cuts power to the arm and engages the brakes. The arm power beacon turns off, as do the arm power indicators on the front panel and the E-Stop control.

E-Stop button

Arm status indicators

Brake release



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To reset the E-Stop1 Remove all hazards from the CataLyst Express and the instruments, and

confirm that it is safe to power the arm.

2 Twist the E-Stop button clockwise until it pops up.

Understanding the Arm Status Indicators

The arm power status indicator glows when arm power is on.

To turn on arm power• Press the ARM POWER button on the front panel of the CataLyst Express.

The ARM POWER indicators on the front panel and the E-Stop control light.

Note: If you cannot turn on arm power, see “Arm Power Cannot Be Turned On” on page 7-3.

The pause/continue status indicator flashes when the CataLyst Express needs you to manually confirm that you want control of the arm. For example, suppose another Windows application had gained control of the arm and then crashed, leaving it unable to release control. If Easy Teach then requests control of the arm, the CataLyst Express, for safety reasons, requires you to manually confirm that request by pressing the PAUSE/CONTINUE button on the front panel.

To confirm a request for control of the arm1 Determine whether it is safe to confirm the request. In particular, ensure

that the work space is free of obstructions and that all personnel are outside the safeguarded area.

2 If it is safe to confirm the request for control, press the flashing PAUSE/CONTINUE button on the front panel.

Note: You may also need to press the ARM POWER button to restore power to the arm.

Using the Brake Release

Use the brake release when you need to manually move the arm: for example, when you need to return the arm to its parking bracket.

To manually move the arm1 Trigger the E-Stop or open the guarding. The CataLyst Express cuts

power to the arm.

2 With one hand, support the arm.

3 With the other hand, press and hold the brake release button on the E-Stop control. The arm sags.

4 Manually rotate the arm’s joints to the desired position.

5 Release the brake release button. The arm’s brakes engage.



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6 Reset the E-Stop and close the guarding.


Using the CataLyst Express: Using the Guarding

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Using the Guarding

The guarding consists of a Lexan barrier with a safety interlock

To open the guarding1 Ensure the CataLyst Express is not moving.

2 Pull the handle on the front door. The arm power indicators go dark and the arm’s brakes engage.

To close the guarding1 Close the front door so that the door key is in the key interlock on the

guarding frame. The door and frame magnets align and meet to hold the door closed.

2 Turn on arm power by pressing the ARM POWER button on the front panel of the CataLyst Express.

Using the CataLyst Express: Pre-power Checklist


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Pre-power Checklist

Before turning on the power to the CataLyst Express, confirm the following conditions:

• The arm is not carrying anything.

• There are no people or unusual objects within the reach of the arm.

• The E-Stop circuit is closed:

• The E-Stop button is reset.

• The guarding is closed.

• The computer is connected to the P.C. port on the front of the CataLyst Express.

• The CataLyst Express is connected to main AC power.


Using the CataLyst Express: Starting the CataLyst Express

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Starting the CataLyst Express

Before you can use the CataLyst Express for moving microplates or teaching paths, you must power it up, test the E-Stop and guarding, and unpark and home it.

Note: If you are starting the CataLyst Express for the first time, perform the self-test after startup, as described in “Testing the CataLyst Express” on page 3-9.

To power up the CataLyst Express• Switch the MAIN POWER button to the ‘1’ position. The CataLyst Express

turns on. When it has finished its boot sequence, the LCD panel displays the following ready message:

C500C CROS

Note: If you do not see the ready message on the front panel display or if you encounter any errors, do not use the CataLyst Express. To correct boot-up problems, refer to Chapter 7, Troubleshooting.

To turn on arm power1 Confirm that the guarding is closed and connected, and that the E-Stop

button is reset and within reach.

2 Press the ARM POWER button on the front panel of the CataLyst Express. The arm power beacon, the ARM POWER LED on the front panel, and the Arm Power indicator on the E-Stop control glow, indicating that the arm is powered.


To test the E-Stop and guarding1 Press the E-Stop. The arm power indicators go dark and the arm’s brakes

engage.

2 Reset the E-Stop.

3 Turn on arm power. The arm power indicators glow and the arm’s brakes release.

4 Open the guarding. The arm power indicators go dark and the arm’s brakes engage.

5 Close the guarding.

Caution! If the arm power LED remains lit when the E-Stop button has been pressed, do not start the CataLyst Express! Inform all users that the CataLyst Express is unavailable and contact Thermo CRS Customer Support immediately.

Caution! If the arm power LED remains lit when the guarding is open, do not start the CataLyst Express! Inform all users that the CataLyst Express is unavailable and contact Thermo CRS Customer Support immediately.

Using the CataLyst Express: Starting the CataLyst Express


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6 Turn on arm power. The arm power indicators glow and the arm’s brakes release.


To unpark and home the arm1 Turn on the computer and its display, and wait until Windows has

started.

2 Log in to Windows and take the following step to start the Easy Teach Setup program:

• In the Windows Start menu, choose Programs > CRS Robotics > CataLyst Express > Easy Teach.

The Easy Teach Setup program opens.

Figure 4-3: The Easy Teach Setup main screen

3 Click Unpark and Home. The CataLyst Express moves the arm out of the homing bracket, homes the arm, and puts it into the Ready position.

Tip: To halt the unpark and home operation, click Abort. To issue arm commands again, click Clear Abort.

4 Click Park to park the arm before starting a POLARA run.


Using the CataLyst Express: Shutting Down the CataLyst Express

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Shutting Down the CataLyst Express

To shut down the CataLyst Express, you park the arm, perform a controlled shutdown, and power it off.


• “Parking the Arm” on page 4-10

• “Performing a Controlled Shutdown” on page 4-10

• “Powering Off the CataLyst Express” on page 4-11

Note: POLARA always parks the arm after a successful run.

Parking the Arm

You can park the arm from Easy Teach Setup or manually.

To park the arm from Easy Teach Setup• In the Windows Start menu, choose

Programs > CRS Robotics > CataLyst Express > Easy Teach.

• Click Park. The CataLyst Express moves the arm into the parking bracket.

Tip: To halt the park operation, click Abort. To issue arm commands again, click Clear Abort.

To park the arm manually1 Open the guarding. The CataLyst Express cuts power to the arm.

2 With one hand, support the arm.

3 With the other hand, press and hold the brake release button on the E-Stop control. The arm sags.

4 Manually rotate the arm’s joints into the parking bracket until the parking LED glows.

5 Release the brake release button. The arm’s brakes engage.

6 Close the guarding.

Performing a Controlled Shutdown

You can perform a controlled shutdown either from Easy Teach Setup or from the front panel.

To shut down the CataLyst Express from Easy Teach Setup1 In the Windows Start menu, choose

Programs > CRS Robotics > CataLyst Express > Easy Teach.

Warning! Turning off power to the CataLyst Express without first performing a controlled shutdown may corrupt its memory and damage its internal files!



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2 Click Shutdown.

3 Wait until the CataLyst Express LCD screen displays the message:

C500C CROS

System Halted

To shut down the CataLyst Express from the front panel1 While holding down the HOME button on the front panel, press and

release the PAUSE/CONTINUE button.

2 Release the HOME button. The CataLyst Express will begin shutting down.

Note: You must complete steps 1 and 2 within a second or two. If nothing happens, simply try again a little faster or a little slower.

3 Wait until the CataLyst Express LCD screen displays the message:

C500C CROS

System Halted

Powering Off the CataLyst Express

Once you performed a controlled shutdown of the CataLyst Express, you can power it off.

To power off the CataLyst Express• Switch the CataLyst Express MAIN POWER to the ‘0’ position.



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CataLyst Express User Guide: CataLyst Express Ports 5–1

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C H A P T E R 5

CataLyst Express Ports

This chapter describes the pin layout and use of the ports provided with CataLyst Express.


• “The Wrist/OPTIONS Ports” on page 5-2

• “Serial Port” on page 5-3

• “P.C. Port” on page 5-4

• “General Purpose Input/Output (GPIO) Port” on page 5-5

• “The E-Stop Port (Front Panel)” on page 5-10

• “The E-Stop Port (Rear Panel)” on page 5-12

• “The Guarding Port” on page 5-14

Never connect devices while the CataLyst Express is powered. Doing so may damage the CataLyst Express or the device or both.

Warning! Incorrect wiring can seriously damage sensitive CataLyst Express components. Verify that you have correctly matched the pin numbering scheme and that all connections are properly wired before using the connector.

5–2 CataLyst Express User Guide: CataLyst Express Ports

CataLyst Express Ports: The Wrist/OPTIONS Ports

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The Wrist/OPTIONS Ports

The Wrist and OPTIONS ports together provide a set of circuits between the wrist and the base of the CataLyst Express. This enables you to electrically control such end-of-arm devices as bar code readers.

Figure 5-1: Pin numbering for the wrist/OPTIONS ports

The wiring for the port on the wrist is routed through the inside of the arm and emerges at pins 1-8 of the OPTIONS port on the rear panel.

Table 5-1: Pinouts for the wrist/OPTIONS connector

Note: To integrate end-of-arm devices into an application under program control, you must connect them to the GPIO port. See “General Purpose Input/Output (GPIO) Port” on page 5-5.

OPTIONS port pin Wrist port pin Function

1 1 User 1

2 2 User 2

3 3 User 3

4 4 User 4

5 5 User 5

6 6 User 6

7 7 User 7

8 8 User 8

9 9 Shield chassis GND

10-15 Not Connected

Wrist port(wrist DB-9)

12345

6789

OPTIONS port(DB-15, rear of CataLyst Express base)

12345678

9101112131415

CataLyst Express Ports: Serial Port


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Serial Port

The SERIAL port uses a standard DB9 connector.

Note: The SERIAL port is configured as standard DTE port.

Figure 5-2: SERIAL port pin numbering

Table 5-2: SERIAL port pinout

Pin # Signal Name Signature Description

1 DCD Input / RS232 Data Carrier Detect

2 RXD Input / RS232 / ±10 V Receive Data

3 TXD Output / RS232 / ±10 V Transmit Data

4 DTR Output / RS232 Data Terminal Ready

5 GND GND Signal Ground

6 DSR Input / RS232 Data Set Ready

7 RTS Output / RS232 Request To Send

8 CTS Output / RS232 Clear To Send

9 RI Input / RS232 Ring Indicator

12345

6789


CataLyst Express Ports: P.C. Port

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P.C. Port

The P.C. port uses a standard DB-9 connector and is used to connect a computer to the CataLyst Express.

Note: The P.C. port is configured as a standard DCE port. However, only pins 2, 3, and 5 are used.

Figure 5-3: P.C. port pin numbering

Table 5-3: P.C. port pinout

Pin # Signal Name Signature Description

2 TXD Output / RS232 / ±10 V Transmit Data

3 RXD Input / RS232 / ±10 V Receive Data

5 GND GND Signal Ground

12345

6789

CataLyst Express Ports: General Purpose Input/Output (GPIO) Port


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General Purpose Input/Output (GPIO) Port

Connect devices to the GPIO port to monitor and control external events.

Note: Add the CRS C500 PLC (using GPIO) component class to your POLARA workspace. For details, see “PLC Instance Settings” in chapter 4 of your POLARA 2.cx Administrator Guide.

The general purpose input/output (GPIO) port provides a total of 15 digital inputs, 12 digital outputs, and 4 relay outputs for connecting external hardware devices to the CataLyst Express. With the exception of the analog input, GPIO inputs and outputs are electrically isolated from the CataLyst Express’s power and logic circuits.

GPIO outputs include low current, optically isolated relay drivers with 50 mA capacity, and 1 A relay contact outputs with normally closed (NC) and normally open (NO) contacts. All relays are connected to a common line, RLYCOM, which is fused on the front panel.

Connect devices to the GPIO port through a standard DD-50 connector. To connect devices more easily, you can extend the port with the optional GPIO termination block (part number SEC-23-501) available from CRS.

Note: For installation instructions for the GPIO termination block, see Appendix B, GPIO Termination Block Option.

Pinouts for the GPIO Port

The GPIO port uses the numbering convention for a ribbon-type connector instead of standard DD-50 numbering.

Note: Refer to the numbering scheme shown in Figure 5-4.

Figure 5-4: Pin numbering scheme used by the GPIO connector

Warning! Using an external power supply for the input/output devices can damage the circuits of the CataLyst Express. Power the devices from the supply provided by the CataLyst Express, as shown in Figure 5-5.

Warning! Do not use the numbers embossed on the plastic inside the connector. Refer to the pin numbers shown in Figure 5-4. Incorrectly matched pins in your GPIO connection can severely damage the CataLyst Express.



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Table 5-4: Pinouts for the GPIO connector

Pin Function Signature Description

1 +24 V 24 VDC internal + 24 VDC




5 GPI0 Opto General Purpose input #1















20 GPI15 Opto Not connected

21 GPO0 Opto General Purpose output #1












33 Shield

34 N/C

35 GPO13NC Relay General Purpose output #13, Normally closed contact

36 GPO13NO Relay General Purpose output #13, Normally open contact





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Note: Opto = optocoupler (optically coupled). N/C = not connected. ISORET= isolated return.

Note: All opto-outputs are NPN, all opto-inputs require NPN devices.





43 RLYCOM Relay common All relays attached here, and to front panel fuse

44 RLYCOM Relay common All relays attached here, and to front panel fuse

45 Analogln1 Analog Provides an analog input

46 Analogln2 Not supported

47 Gnd Digital Internal ground return for 24 VDC







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Figure 5-5: Wiring schematic for the GPIO connector

Sample Internal Output Stage

Sample Internal Input Stage

INTERNAL_GROUND

Input_03

Outside Controller

AnalogIn_1

Input_11

Input_12

Output_08

LOAD

Output_09

Output_12

Output_01

+24 VDC(internal or external)

+ISO_SUPPLY

LOAD

Input_08

Input_05

Input_15

Output_13_RELAY_NC

ISO_RETURN

5V (external)

Input_06

ISO_SUPPLY

Output_06

Output_15_RELAY_NC

Output_16_RELAY_NO

Input_14

Output_14_RELAY_NO

Output_15_RELAY_NO

Output_05

INTERNAL_24V_SUPPLY

Output_13_RELAY_NO

Inside Controller

Output_04

Output_07

+24V_Internal

Relay_Common

Output_11

Input_09

Input_02

Input_10

Output_03

+24 VDC (pins 1-4)

Input_07

Input_04

Input_13

Output_14_RELAY_NC

Output_16_RELAY_NC

Output_02

Output_10

Input_01

ISO_SUPPLY

FP_F2 or F10

ISO_GROUND

GND(internal or external)

2A,

30V

DC

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

10 to 40 VDC, max.50 mA per output

10 to 40 VDC, max.+24 VDC

NC

Not supported



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Connecting Inputs and Outputs

Connect inputs and outputs to the GPIO circuit as shown in Figure 5-5.

Note: An open input is off.

• Connect input devices as switches between the desired INPUT line (pins 5 through 19) and the ground on pin 50.

• Connect output devices between the desired OUTPUT line (pins 21 through 32) and the +24 VDC supply on pins 1, 2, 3, or 4. The output device must not draw more than 50 mA.

Using the Relays

Relays behave like switches between the output pairs and the shared Relay_Common line. Each relay output terminal consists of a normally open (NO) and a normally closed (NC) contact pair.

If an external power supply is connected to the relay contacts, take care not to exceed the 2 A, 30 VDC rating for the circuit.

Note: Relay contacts are fused through front panel fuse F10.

Using GPIO Devices in Your Application

To integrate GPIO devices into your application with ActiveRobot, refer to the following commands in the ActiveRobot User Guide: AnalogInput, CTPath, CTPathGo, Input, Inputs, Motor, Output, and Outputs.

Warning! The relay circuit may be damaged by AC power. The CataLyst Express relays are not rated for AC use.


CataLyst Express Ports: The E-Stop Port (Front Panel)

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The E-Stop Port (Front Panel)

The E-Stop port provides access to the E-Stop circuit, enabling you to connect other passive devices into the E-Stop chain.

Figure 5-6: Pin numbering scheme for the E-Stop port (front panel)

Table 5-5: Pinouts for the E-Stop port (front panel)

Note: Opto = optocoupler (optically coupled). N/C = not connected, ISORET= isolated return, Ack = acknowledged.


1 +24 VDC Power Internal supply




5 RPS Opto-input Pause/Continue

6 ERA Opto-output unused

7 HMS Opto-input Home Request

8 R0A Opto-output Pause/Continue Ack

9 PRS Opto-input F2

10 R1A Opto-output unused

11 CSS Opto-input F1

12 HMA Opto-output Home Ack

13 JigIns Opto-input unused

14 PRA Opto-output F2 button Ack

15 APA Opto-output Arm Power Ack

16 CSA Opto-output F1 button Ack

17 REMONSW+ Contact-input

18 REMONSW- Contact-input

19 REMESTOP+ Contact-input remote E-Stop

20 REMESTOP- Contact-input remote E-Stop

21 N/C unused

22 Shield Ground shield

23 Gnd Digital Internal return for 24 VDC



25 23 21 19 17 15 13 11 9 7 5 3 1

24 22 20 18 16 14 12 10 8 6 4 2

CataLyst Express Ports: The E-Stop Port (Front Panel)


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Note: All opto-outputs are NPN, all opto-inputs require NPN devices.

Figure 5-7: Wiring schematic for the E-Stop port

Remote Arm Power

Outside Controller

F2_Input_Sw.

-E-Stop_Input_Sw. (contact only)

F1_Input_Sw.

LOAD

F1_Output_Sig

Control Input(Momentary Contact Only)

ISO_GROUND

INTERNAL_24V_SUPPLY

+E-Stop_Input_Sw. (contact only)

Arm_Power_Output_Sig

ISO_RETURN

EmergencyStop INPUT

Pause/Cont_Ouput_Sig

Inside Controller

ISO_SUPPLY

+24V_Internal

INTERNAL_GROUND

Pause/Cont_Input_Sw.

+24 VDC (pins 1-4)

+ISO_SUPPLY

Sample Internal Output Stage

+Arm_On_Mom_Contact_Inp**

F2_Output_Sig

Home_Input_Sw.

Home_Ouput_Sig

-Arm_On_Mom_Contact_Inp**

Sample Internal Input Stage

ISO_SUPPLY

GND

1

2

3

4

5

7

9

17

18

11

19

20

8

12

14

15

16

23

24

25

10 to 40 VDC, max.50 mA per output

10 to 40 VDC, max.+24 VDC


CataLyst Express Ports: The E-Stop Port (Rear Panel)

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The E-Stop Port (Rear Panel)

The E-Stop port on the rear panel provides connections into the E-Stop circuit. It also provides arm power and guarding status.

Figure 5-8: Pin numbering scheme for the E-Stop port (rear panel)

Table 5-6: Pinouts for the E-Stop port (rear panel)

Adding E-Stops

You can connect additional E-Stop safety devices through the E-Stop contact terminals on the rear panel E-Stop port.

• An E-Stop button must be a large, palm-cap, red button that has been third-party approved for use as an E-Stop. Once triggered, the E-Stop button must require a manual reset.

• In addition to buttons that halt robot motion, E-Stop devices can include passive triggers such as door latching mechanisms or pressure sensors.

Note: All mechanisms used as E-Stop devices must be safety-rated.

• Devices connected into the E-Stop circuit must be dry contact or jumpers.

Pin Description

1 Guarding door interlock status

2 Guarding door interlock status

3 Not used

4 Arm power status

5 +24 VDC

6 Not used

7 Not used

8 12 VDC internal E-Stop chain


10 GND

11 Not used

12 Not used

13 Not used

14 Not used

15 Arm power status

12345678910

1112131415

E-STOP port(high density DB15)

CataLyst Express Ports: The E-Stop Port (Rear Panel)


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• Connect all E-Stop devices in series to ensure that power is removed when any device in the circuit is disconnected or disrupted.

To connect external devices to the E-Stop circuit• Connect all E-Stop devices in series between pins 8 and 9 on the rear

panel E-STOP port.


CataLyst Express Ports: The Guarding Port

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The Guarding Port

The GUARDING port provides the following connections:

• Connections to the guarding interlock

• Arm power status to the guarding beacon

• Connections to the E-Stop circuit

Figure 5-9: Pin numbering for the GUARDING port

Table 5-7: Pinouts for the GUARDING port

Pin Description

1 Guarding door interlock

2 Guarding door interlock

3 Not used

4 Arm power status

5 +24 VDC

6 Not used

7 Not used



10 GND

11 Not used

12 Not used

13 Not used

14 Not used

15 Arm power status

12345678910

1112131415

GUARDING port(high density DB15)

CataLyst Express User Guide: Maintenance Procedures 6–1

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C H A P T E R 6

Maintenance Procedures

In order to protect your application and to prolong the life of the CataLyst Express, schedule and perform the maintenance procedures described in this chapter. For details, see the following topics:

• “Backing up Files” on page 6-2

• “Cleaning” on page 6-3

• “Routine Inspections” on page 6-4

• “Checking Front Panel Fuses and Circuit Breakers” on page 6-5

• “Inspecting AC Fuses” on page 6-7

• “Scheduled Maintenance” on page 6-8

6–2 CataLyst Express User Guide: Maintenance Procedures

Maintenance Procedures: Backing up Files

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Backing up Files

On a regular basis, backup the following files:

• The .v3 files in the install directory’s V3_Files sub-directory (by default, C:\Program Files\CRS Robotics\CataLyst Express\V3_Files).

• POLARA workspace files which are, by default, in the C:\Program Files\CRS Robotics\POLARA directory, but can be in other directories. Workspace files have file extension .mdr.

To backup files• Use Windows Explorer to copy .v3 and .mdr files to secure storage.

Maintenance Procedures: Cleaning


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Cleaning

Clean exterior surfaces with mild cleaning products only. Some solvents and degreasers may damage printed surfaces.

When cleaning, do not allow liquids to seep inside the base or enter the arm casing. Be particularly careful to avoid connectors when cleaning the wrist area on the arm.

Warning! Electric Shock Hazard. Do not immerse any part of the robot system in liquid.


Maintenance Procedures: Routine Inspections

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Routine Inspections

Inspect the exterior and function of the CataLyst Express at regular intervals.

To perform the monthly Inspection• Unscrew the finger screw holding the fan filter cover in place at the rear of

the base and remove the filter. Inspect the filter for accumulated dirt and, if necessary, rinse it under water. Return it to the same location and fasten the fan filter cover back in place with the finger screw.

• If the arm is dirty, wipe the exterior clean with a damp cloth.

• Inspect the arm and cables for signs of damage or wear.

• Inspect all E-Stops and safety devices to ensure that they are functioning normally.

• Inspect the flex covers for creases, splits, or cracks. Replacement flex covers are available from CRS.

To perform the annual inspection• Check for wear along the inside of the parking bracket notch or binding

when the arm enters or leaves the parking bracket. Wear or binding can indicate a loss of positional accuracy.

• Check arm covers for wear and cracks.

Maintenance Procedures: Checking Front Panel Fuses and Circuit Breakers


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Checking Front Panel Fuses and Circuit Breakers

Fuses and circuit breakers located on the front panel protect CataLyst Express circuits from overload.

Figure 6-1: Location of front panel fuses and circuit breakers

Under normal operating conditions, the front panel fuses should not need to be replaced. A blown fuse or tripped circuit breaker may indicate a more serious problem. If you replace fuses or reset circuit breakers often within a short period of time and cannot identify the cause of the failure, contact the Thermo CRS Customer Support Group for assistance.

Tip: A collision can sometimes blow a fuse or trip a circuit breaker. Correct the condition that caused the collision, and then replace the fuse or reset the circuit breaker.

Table 6-1: Front panel fuses

Note: All fuses are standard 1/4 in. x 1 1/4 in.

To inspect and reset a circuit breaker

1 With the CataLyst Express shut down and powered off, examine the circuit breakers. A tripped circuit breaker will have sprung outward from its casing, revealing a white band.

2 To reset a tripped circuit breaker, push the breaker in until it clicks back into its casing. The white band should no longer be showing.

Fuse Signal Name Fuse Rating Function

F1 Axis 1 250 V, 2 A, circuit breaker • axis 1 motor





F8 Gripper 250 V, 0.38 A, slow blow • servo gripper

F9 24VDC 250 V, 2 A, slow blow • 24V power supply• main CataLyst Express board circuits• internal 24 V power supply

F10 RLYCOM 250 V, 2 A, slow blow • GPIO relay common

fuses and circuit breakers


Maintenance Procedures: Checking Front Panel Fuses and Circuit Breakers

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To inspect and replace a fuse1 With the CataLyst Express shut down and powered off, unscrew the fuse

clip and remove the affected fuse.

2 Measure the resistance across the fuse. If the resistance is larger than 2 Ohms, the fuse has blown and must be replaced.

Note: Test fuses with an Ohm-meter. Visual inspection can be deceptive.

3 Insert a new fuse of the same rating in the fuse clip. Ratings for the CataLyst Express front panel fuses are given in Table 6-1.

Maintenance Procedures: Inspecting AC Fuses


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Inspecting AC Fuses

The AC fuses are located inside the fuse drawer at the back of the base.

Table 6-2: AC fuses required for the CataLyst Express

To inspect the AC Fuses1 Shut down and turn off the

CataLyst Express.

2 Unplug the power cord from the power connector at the back of the CataLyst Express.

3 Insert a screwdriver below the clip to release the fuse drawer.

4 Make sure that the voltage is properly selected for your local mains power.

5 Remove the two AC fuses from the fuse drawer and measure the resistance across each fuse. If the resistance is larger than 2 Ohms, the fuse has blown and must be replaced.

Note: Test fuses with an Ohm-meter. Visual inspection can be deceptive.

6 If necessary, replace blown fuses with the appropriate fuses for your local mains power. Determine the required fuse rating from Table 6-2.

7 Replace the fuse drawer into the power module and push until you hear the drawer click into place.

Warning! High Voltage. Always shut down and unplug the CataLyst Express before inspecting the AC fuses.

Mains Voltage Required Fuses

100 VAC 8 A, 250 V, 6.3 mm x 32 mm [¼ in. x 1¼ in.], slow blow




Maintenance Procedures: Scheduled Maintenance

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Scheduled Maintenance

To keep the arm in good working order, schedule the following maintenance procedures according to the duty cycle for your application.

Note: Scheduled maintenance procedures should only be carried out by Thermo CRS-authorized service technicians.

Example Duty Cycle DeterminationA CataLyst Express is used in a laboratory application to move a light payload. The environment is controlled, the payload is less than rated, and default accelerations are used. In addition, the arm is only in motion 50% of the time during a pick-and-place operation.

Based on this information, the robot in this example has a light duty cycle.

Maintenance Task Normal Duty Cycle Light Duty Cycle

Lubricate chains every 2,000 hours every 4,000 hours

Adjust chain tension every 2,000 hours every 4,000 hours

Adjust wrist gear mesh every 2,000 hours every 4,000 hours

Check inner wiring harness every 5,000 hours every 10,000 hours

Check motor brush wear every 5,000 hours every 10,000 hours

Hysteresis check and inspect grease distribution

every 5,000 hours every 10,000 hours

Inspect and clean harmonic drives

every 12,000 hours every 24,000 hours

CataLyst Express User Guide: Troubleshooting 7–1

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C H A P T E R 7

Troubleshooting

This chapter contains diagnostic procedures to help you correct problems with your robot system. If a problem cannot be resolved easily, see “Contacting the Customer Support Group” on page 7-4.

For more information, see the following topics:

• “The LCD Display Remains Blank” on page 7-2.

• “Arm Power Cannot Be Turned On” on page 7-3

Warning! Do not open the CataLyst Express case or remove arm covers unless instructed by CRS-authorized personnel. Service procedures should only be carried out by qualified service technicians.

7–2 CataLyst Express User Guide: Troubleshooting

Troubleshooting: The LCD Display Remains Blank

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The LCD Display Remains Blank

If the LCD display remains blank after the system is powered on, there may be a problem with the power supply. Switch the CataLyst Express off and try the following troubleshooting steps:

• Make sure that the CataLyst Express is plugged into a live power outlet.

• Verify that the power plug is securely connected in the power connector at the back of the CataLyst Express.

• Verify that the voltage indicator is correctly selected for your local power.

• Unplug the CataLyst Express and check the AC fuses. See “Inspecting AC Fuses” on page 6-7.

Troubleshooting: Arm Power Cannot Be Turned On

CataLyst Express User Guide: Troubleshooting 7–3

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Arm Power Cannot Be Turned On

If arm power does not come on when the ARM POWER button is pressed, try the following troubleshooting steps:

• Make sure that the E-Stop circuit is closed.

• Verify that all E-Stop buttons and devices have been reset. You cannot turn on arm power while an E-Stop is triggered.

• Verify that the guarding is closed.

• Verify that the guarding is connected to the GUARDING port at the back of the CataLyst Express.

• Check the fuses and circuit breakers.

• Shut down and restart the CataLyst Express.

7–4 CataLyst Express User Guide: Troubleshooting

Troubleshooting: Contacting the Customer Support Group

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Contacting the Customer Support Group

Before contacting Thermo LAI, make sure that you can provide a clear description of the problem. The following information will help the Customer Support Group diagnose and resolve the problem efficiently:

• Serial numbers for the CataLyst Express (located on the rear)

• Whether the arm is part of a POLARA laboratory system.

• A brief description of the operating environment and the type of application

• Any errors or warning messages observed

• Steps necessary to reproduce the problem and the circumstances surrounding the failure.

Once you have gathered all of the relevant information, contact the Customer Support Group by telephone, fax, or e-mail.

Telephone1-905-332-2000 (voice)1-800-365-7587 (voice: toll free in Canada and United States)

Fax1-905-332-1114 (facsimile)

E-MailTechnical Services: [email protected]

CataLyst Express User Guide: Technical Specifications A–1

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A P P E N D I X A

Technical Specifications

For specifications on the CataLyst Express, see the following topics:

• “Physical Characteristics” on page A-2

• “Electrical Specifications” on page A-3

• “Operating Environment” on page A-3

A–2 CataLyst Express User Guide: Technical Specifications

Technical Specifications: Physical Characteristics

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Physical Characteristics

Table A-1 lists the physical characteristics of the CataLyst Express.

Table A-1: Physical Characteristics

Number of axes 5

Weight 76 kg [167 lb]

Nominal payload 0.1 kg [0.2 lb]

Repeatability ± 0.05 mm [0.002 in.]

Drive system Electromechanical motorsIncremental encoders in each joint

Transmission Harmonic drives

Brakes Brakes on all joints

Memory 4 MB RAM user memory512KB NVRAM for application storage1 MB flash memory for system firmware

User I/O 15 digital inputs12 digital outputs1 analog input4 relay outputs

Front Panel interface 16x2 character, back-lit LCD displayUser programmable buttons and LED lights

System connections 2 E-Stop control ports1 personal computer serial port1 serial port1 guarding port1 option port

Technical Specifications: Electrical Specifications

CataLyst Express User Guide: Technical Specifications A–3

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Electrical Specifications

Table A-2 lists the electrical specifications of the CataLyst Express.

Table A-2: Electrical Specifications

Operating Environment

Table A-3 specifies the operating environment for the CataLyst Express.

Table A-3: Operating Environment

AC Input voltage 100/115/230 VAC ± 10%

Line frequency 50-60 Hz

Power consumption (max) 350 VA

The CataLyst Express is rated for indoor use only.

Temperature 10° to 40° C [50 to 104 F]

Humidity Keep below 80% humidity, Non-condensing environment only

Vibration Not rated for excessive vibration or shock

Electromagnetic Interference Do not expose to excessive electrical noise or plasma

A–4 CataLyst Express User Guide: Technical Specifications

Technical Specifications: Operating Environment

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CataLyst Express User Guide: GPIO Termination Block Option B–1

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A P P E N D I X B

GPIO Termination Block Option

A GPIO termination block is available as an optional component. It provides easier access to GPIO connections by extending the pins in the GPIO port to external screw terminals.

The mounting rail bracket on the underside of the GPIO block fits all standard DIN EN rails.

Figure B-1: The GPIO termination block

Installing the GPIO block

1 Mount a DIN rail outside the arm’s work space, near the back of the CataLyst Express.

Note: The ribbon cable is 152 cm [5 ft.] in length. Mount the rail close enough to the CataLyst Express to ensure that the cable is strain-relieved.

2 Snap the GPIO termination block onto the rail.

3 With the CataLyst Express shut down and powered off, connect the ribbon cable between the CataLyst Express and the GPIO block:

a Connect the male DD-50 ribbon connector to the GPIO port.

b Connect the box header end of the ribbon cable to the connector on the GPIO termination block.

4 Referring to “Pinouts for the GPIO Port” on page 5-5, connect your devices to the GPIO block terminals.

insert ribbon cable here

clipclip

insertDIN railhere

screwterminals

B–2 CataLyst Express User Guide: GPIO Termination Block Option

GPIO Termination Block Option:

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Note: The screw terminal numbers printed on the GPIO terminal block correspond to the GPIO pin numbers shown in “General Purpose Input/Output (GPIO) Port” on page 5-5. Do not use the pin numbering embossed on the plastic inside the GPIO connector on the CataLyst Express.

CataLyst Express User Guide: Installing New Firmware C–1

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A P P E N D I X C

Installing New Firmware

During troubleshooting or maintenance, you may need to re-install or install a new version of the CataLyst Express’s operating system firmware.

This appendix covers the following topics:

• “Backing up Files from the CataLyst Express” on page C-2

• “Downloading the CataLyst Express Firmware” on page C-4

• “Configuring the Robot Controller” on page C-6

Caution! Files on the CataLyst Express may be destroyed by the firmware installation process. Always back up CataLyst Express calibration and configuration files before updating firmware.

C–2 CataLyst Express User Guide: Installing New Firmware

Installing New Firmware: Backing up Files from the CataLyst Express

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Backing up Files from the CataLyst Express

When you install new firmware, all files on the CataLyst Express are erased. Before installing the new firmware, use ActiveRobot Explorer to back up the CataLyst Express’s configuration files to a safe location on the PC.

To back up files from the CataLyst Express

1 Choose Start > Programs > CRS ActiveRobot > ActiveRobot Explorer to start ActiveRobot Explorer. ActiveRobot Explorer opens a tree-view window into the root directory of the CataLyst Express’s operating system:

Figure C-1: The ActiveRobot Explorer window displays the CataLyst Express’s directory structure in the left pane and the contents of the selected directory in the right pane.

2 Open Windows Explorer to the backup directory on the PC.

3 In ActiveRobot Explorer, select the files /conf/robot.cal, /conf/robot.cfg, /conf/rc, /conf/simsockd.cfg, and /conf/startup.sh.

4 While pressing the left mouse button, drag the selected files to the backup directory in Windows Explorer.

5 Watch the copy progress in the ActiveRobot Explorer status bar.

6 When the copy operation has completed (i.e. the copy progress field in the status bar is blank), release the left mouse button.

Installing New Firmware: Backing up Files from the CataLyst Express


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Note: If you release the left mouse button before the ActiveRobot Explorer’s status bar indicates that a file copy operation has completed, the file will not be copied.

Tip: You can copy controller files to the host computer’s desktop simply by dragging them there; you don’t have to go through Windows Explorer in this case.


Installing New Firmware: Downloading the CataLyst Express Firmware

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Downloading the CataLyst Express Firmware

You use the Firmware Download Utility to download the operating system firmware to the CataLyst Express.

To download firmware to the CataLyst Express1 On the PC’s Start menu, choose

Programs > CRS Robotics > CROS-500C > Firmware Download Utility. The download utility opens the following configuration screen:

2 Use the following values for each setting:

When the settings are correct, click Download. The download utility prompts you to restart the CataLyst Express in diagnostic mode.

3 Restart the controller in diagnostic mode:

a Shut down the CataLyst Express, as described in “Shutting Down the CataLyst Express” on page 4-10.

b Switch off controller power.

c While holding down the F1, F2, and Pause/Continue buttons, switch on power to the CataLyst Express. Continue holding the buttons for 10 seconds. The CataLyst Express boots into diagnostic mode.

d Verify that the message

Diagnostic Mode

is displayed on the controller LCD screen.

Setting Required Value

CommPort The number of the PC’s COM port that is connected to the robot system.

Baud Rate The baud rate of the CataLyst Express SERIAL port. The factory default setting is 57600 bps.

Path of Flash File The name and location of the file flash.img on the PC. You can press the “...” button to search for the file yourself.

Path of MCE File The name and location of the file mcecat5.img on the PC. You can press the “...” button to search for the file yourself.

Path of Remote The name and location of the file remote.exe on the PC. You can press the “...” button to search for the file yourself.

Installing New Firmware: Downloading the CataLyst Express Firmware


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4 On the PC, click OK in the Firmware Download Utility to start the download.

5 When the download is complete, switch off power to the CataLyst Express.

6 While holding down the F2 and Home buttons, switch on power to the CataLyst Express. The front panel display shows the message

Loading new MFS from Flash

while the file system in the CataLyst Express is being rebuilt. When the process is complete, the CataLyst Express continues with its normal bootup sequence.

7 Open ActiveRobot Explorer to the /conf directory on the CataLyst Express.

8 In Windows Explorer, select your backup files robot.cal, robot.cfg, rc, simsockd.cfg, and startup.sh.

9 Pressing the left mouse button, drag the selected files to the CataLyst Express /conf directory in ActiveRobot Explorer.

10 Shut down the CataLyst Express and re-start it.


Installing New Firmware: Configuring the Robot Controller

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Configuring the Robot Controller

You must configure CROS on the robot’s controller to work with POLARA.

To configure the robot controller to work with POLARA1 Install on the controller the version of CROS for C500C that you installed

on the PC from the POLARA CD. For details on installing CROS, see “Downloading the CataLyst Express Firmware” on page C-4.

2 Reconfigure the controller to launch the simsockd program on startup:

a In ActiveRobot Terminal, set the /conf directory to the current directory. For details on using ActiveRobot, see the ActiveRobot User Guide. For details on using the system shell, see the CROS and System Shell user guide.

b Rename the rc file:

ren rc rc.nosimsockd

c Copy the file rc.simsockd to rc:

cp rc.simsockd rc

3 Shut down and re-boot the controller.

4 At the CROS command prompt, use the ps command to check that the simsockd program is running.

CataLyst Express User Guide: Glossary G-1

ActiveRobotThe ActiveX component for creating robot applications under Microsoft Windows.

See: ActiveRobot User Guide on the documentation CD.

armAn articulated, mechanical manipulator

articulated robotRobotic arm consisting of rigid links connected by rotary joints. This type of robot most closely resembles a human arm.

beaconAwareness signal that indicates a condition or hazard. The beacon on the guarding flashes amber when the arm is powered.

collisionUnscheduled physical contact between the arm and an object

diagnostic modeCataLyst Express mode for low-level diagnostic operations

emergency stop (E-Stop)Switch connected to the CataLyst Express E-Stop port that removes arm power and halts robot motion when triggered. Once triggered, it must be manually reset.

General Purpose Input Output (GPIO)The GPIO port on the CataLyst Express provides inputs and outputs for connecting external hardware devices.

guardingPhysical barrier that blocks access to the arm’s workspace. When opened, it cuts arm power.

hardstopHardware safety device fastened at a fixed position that determines the absolute ends of movement of a joint or track. A hardstop restricts the workspace and provides some safety in the case of robot runaway.

homingProcedure by which the motion control engine exactly locates the position of each of the arm’s axes.

Glossary

G-2 CataLyst Express User Guide: Glossary

Glossary: I/O

I/OInput/output.

interlockIn robot systems, a device that automatically prevents robot use under dangerous conditions. For example, a door contact switch can be interlocked with the arm power circuit to prevent robot use when the door is open.

jointLocation where two links join, usually consisting of a motor and drive.

See: link.

linkRigid part of a robot arm between two neighboring joints

nestThe receptacle that holds a microplate

nominal payloadThe amount of weight carried by the robot at maximum speed while maintaining rated precision. This rating is highly dependent on the size and shape of the payload.

operator Person who uses the CataLyst Express to perform work. This can include loading the workcell, running the robot, monitoring the running, and responding to any problems, but does not include designing the workcell or programming the robot.

parking ledAn LED at the bottom of the parking bracket that indicates when the arm is correctly parked.

payloadAmount of weight carried by the arm and/or the amount of force the arm can exert on an object.

range of motionExtent of travel of a link or of an arm. This is dependent on the limits of rotational motion of the joints and the lengths of the links.

reachMaximum distance to which the arm can extend the gripper. Reach defines the work space of the arm.

repeatabilityAbility of the robot to repeat the same motion or position a tool at the same position when presented with the same control signals (over repeated cycles). Also, the cycle-to-cycle error of the robot system when trying to perform a specific task.

robot calibration file (robot.cal)File that contains calibration information for the arm.

CataLyst Express User Guide: Glossary G-3

Glossary: robot configuration file (robot.cfg)

robot configuration file (robot.cfg)File which contains the configuration information for your robot system.

safeguardBarrier, device, or procedure designed to protect persons from a hazardous point or area.

tool transformOffset value applied to the tool frame of reference. By default, the origin of the tool frame of reference is located at the centre of the surface of the tool flange. By applying a tool transform, you center the tool frame of reference at another point such as the center of a microplate.

work spaceVolume of space that can be swept by all robot parts plus the space that can be swept by the gripper and the payload.

workstationA station composed of the CataLyst Express integrated with instruments

G-4 CataLyst Express User Guide: Glossary

Glossary: workstation

CataLyst Express User Guide: Index I-1

AAC input voltage A-3accident prevention 2-7analog input 5-5application design 2-2, 6-8arm power

stays off 7-3arm power beacon 2-3

Bbacking up files 6-2, C-2brakes 2-3, 2-5

Ccables 6-4CataLyst Express

lockout 2-8parking 4-10powering off 4-11shutdown 4-10technical specifications A-1unparking 4-9using 4-1

chain tension 6-8circuit breakers 6-5cleaning 6-3controlled shutdown 4-10controller

backing up files C-2firmware upgrade C-1

CROS C-1customer support 7-4

Ddesignated use 2-2development computer C-4diagnostic mode C-4duty cycle 6-8

Eelectrical noise A-3electromagnetic interference A-3E-Stop 2-3, 6-4, 7-3

Ffan filter 6-4fault detection 2-3fingers 2-5firmware download utility C-1flex covers 6-4front panel

display blank 7-2pushbutton sequences C-4shutting down from 4-10

fuses 6-5, 7-3AC 6-7

GGPIO

Termination Block B-1GPIO port

pinouts 5-5wiring 5-5

GPIO Termination Block 1-7guarding 1-7

Hhazards 2-5humidity A-3

Iinput/output devices 5-5, B-1inspections

routine 6-4installation 3-1instrument mounting kits 1-7isolated circuits 5-5

Index

I-2 CataLyst Express User Guide: Index

Index: L

Llife expectancy 6-8lockout procedure 2-8lubrication 6-8

Mmaintenance 6-1, 6-8

backing up files 6-2

Ooperating environment A-3options 1-7

GPIO Termination Block 1-7guarding 1-7instrument mounting kits 1-7

Pparking 4-10parking LED 4-10pinch points 2-5pinouts 5-1, 5-2point of control 2-3ports 5-1power 4-7, A-3powering off 4-11

Rrelays 5-9

Ssafety 2-1

system features 2-3servo gripper 2-5shutting down 4-10specifications A-1start up 4-8support 7-4

Ttemperature A-3troubleshooting 7-1, 7-4

Uunparking 4-9using the CataLyst Express 4-1

Vvibration A-3

Wwrist port 5-2

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