Abbott GLP Systems Track Laboratory Automation System Instruction Manual

Abbott GLP Systems Track Laboratory Automation System

Product Information

The Decapper Module (DM) is part of the GLP systems Track Laboratory Automation System. It is designed to decap sample tubes from the distribution system that are sealed with commercially available screw caps or push caps. The DM module comes in two versions: DM and DM double.

• The DM version includes a Decapper Module with a robot gripper and an access point.
• The DM double version includes two Decapper Modules.

Copyright
Reproduction, reprinting, translation or other duplication, including excerpts, are prohibited without written permission from Abbott Automation Solutions. Printed in Germany, translation of the original operations manual.

Validity
This operations manual is valid only in combination with the following documents:

• Operations manual for the GLP systems Track laboratory automation system base system
• Product Information Sheet

Change Overview

NOTE Observe the changes in the following chapters:

in 1st instruction:

A red light point briefly appears next to the module’s touchscreen.

| Deleted

Overview

The DM decaps the sample tubes from the distribution system, which are sealed with commercially available screw caps or push caps. Essentially, a distinction is made between DM and DM double. The DM has a Decapper Module, consisting of a robot with gripper and an AccessPoint. The DM double has two Decapper Modules.

Safety

The following safety indications are on the DM:

NOTE In addition, the safety instructions laid out in the operations manual for the GLP systems Track laboratory automation system base system must be observed.

Technical Data

Weight

■     DM

■     DM double

| ■     207 kg

■     212 kg

Waste heat (at full capacity)

■     DM

■     DM double

| ■     270 kJ/h

■     306 kJ/h

Acoustic level (both DM versions)| < 65 dBA
Waste bag capacity| 5000 caps/waste bag

NOTE Please see the product information sheet for all other technical data.

Design and Function

The DM consists of the following components:

1. Front hood
2. Touchscreen
3. Online/Offline push-button with pause function
4. On/Off push-button
5. Pull-out compartment
6. Housing
7. Track element
8. Rear hood

1. Gripper
2. AccessPoint with clamping jaws
3. Right control sensor
4. Waste bin
5. Waste shaft
6. Funnel

The CARs moving in with the samples are stopped at the AccessPoint. The AccessPoint clamping jaws grip the sample tube and the robot decaps the sample tube with its gripper. The decapped sample tube is routed into the distribution system and the cap is fed to the waste bin via the waste shaft.

waste bin is located beneath this.

The front and rear hoods protect the user against injury and keep the interior free of soiling.

The two hoods can be opened to the front and to the back for service work.

Interior| In the interior of the DM, the sample tubes entering the system are decapped directly on the CARs.
Decapper gripper| The gripper decaps the sample tubes and feeds the caps to the waste bin.

The gripper is located at the lower end of the robot.

Funnel| The caps are fed to the waste shaft via the funnel.
Waste shaft| The caps are fed to the waste bin via the waste shaft.
Component| Design and Function
---|---
Waste bin| The caps are collected in the waste bin. The waste bin fill level is displayed on the touchscreen.
Control sensor| The control sensor checks whether the pull-out compartment is closed.
Touchscreen| The touchscreen is integrated into the front hood. It serves as the central operating and display element.
On/Off push-button| The On/Off push-button switches the module on or off. When the module is ready to operate, it flashes green.
Online/Offline push-button with pause function| The Online/Offline push-button with pause function switches the module online, offline or into pause mode.

■     Online = module is in automatic mode, lights green.

■     Offline = module is in standby mode, lights yellow.

■     Pause = module is in pause mode, flashes green.

AccessPoint| The AccessPoint grips the sample with its clamping jaws while the sample tube is decapped.
Module controller| The module controller controls the processes in the module and communicates with the TSM.
Supply controller| The supply controller controls the module’s power supply.
Track element| Track elements route the CARs to the AccessPoint and then onward to the distribution system.

Operation

NOTE The screens shown in the operations manual are examples and may differ slightly on the module. The functions are not affected by this.

Switching on the module

• Precondition
  • The module is connected to the power supply.
  • The module has been switched off for more than one minute.
  • The On/Off push-button on the front of the module flashes green.
• Procedure

1. Press and hold the On/Off push-button on the front of the module for at least three seconds.
  * The On/Off push-button flashes at a higher frequency.
  * The module starts up.
  * The start page is displayed. The Start tab lights up green once the module is ready for initialization.
2. To initialize the module, select the Start tab.
  * A screen with a rotating animation appears.
  * After successful initialization, the module’s main menu appears.
  * The On/Off push-button lights up green without flashing.

Main Menu

1. Online/Offline tab with pause function
2. Waste bin level meter
3. Waste bin emptying confirmation tab
4. Help tab
5. Information tab
6. Configuration tab
7. Login tab

Switching the Module Offline
In offline mode, all processes running in the module stop. The CARs are no longer routed to the module.

• Precondition
  • The module is online.
  • The Online/Offline push-button and the tab Online/Offline light up green without flashing.
• Procedure

1. Press and hold the Online/Offline push-button on the front of the module for at least three seconds or tap the green arrow area of the tab Online/Offline on the touchscreen.
  * The module switches to offline.
  * The Online/Offline push-button lights up yellow without flashing.
  * The arrow area of the tab Online/Offline is grayed out.

Deactivating Offline Mode

• Procedure

1. Briefly press the Online/Offline push-button or press the tab Online/Offline in the grayed-out area on the touchscreen to exit offline mode.
  * The Online/Offline push-button and the button Online/Offline light up green without flashing.
  * The module is online.

Switching the Module to Pause Mode
The pause function is activated via the Online/Offline push-button. In pause mode, all processes running in the module stop. However, the connection to the TSM remains intact. The CARs are still routed to the module.

• Precondition
  • The module is online.
  • The Online/Offline push-button and the button Online/Offline light up green without flashing.
• Procedure

1. Briefly press the Online/Offline push-button or tap on the button Online/Offline in the gray area on the touchscreen.
  * The module is in pause mode.
  * The Online/Offline push-button and the button Online/Offline flash green.

Deactivating pause mode

• Procedure
  • Briefly press the Online/Offline push-button or tap on the button Online/Offline in the gray area on the touchscreen to exit pause mode.
  • The Online/Offline push-button and the button Online/Offline light up green without flashing.
  • The module is online.

Switching off the module

• Precondition
  • The module is switched on.
  • The On/Off push-button lights up green without flashing.
  • The module has ended all processes.
• Procedure
  • Press and hold the On/Off push-button on the front of the module for at least three seconds.
  • The module is switched off.
  • The On/Off push-button flashes green.

Emptying and Resetting the Waste Bin

WARNING! Risk of infection due to removing the waste bag
Pulling the waste bag out over the edge of the waste bin can cause the waste bag to tear, and the user can come into contact with infected sample matter.

• Wear personal protective clothing.
• Always lift waste bags out vertically upwards; do not drag them over the edge of the waste bin.

NOTE The pull-out compartment can be opened only when in offline mode.

• Precondition

  • The main menu is shown.
    The module is offline.

• Procedure

1. Completely pull the pull-out compartment with waste bin out of the module.
2. Carefully lift the waste bag upward out of the waste bin with both hands and dispose of it as per local regulations.
3. Hang a new waste bag in the waste bin.
4. Close the pull-out compartment.  

Make sure that the pull-out compartment is closed correctly after waste disposal and that the sensor is not covered by the waste bag.

5. Confirm waste bin emptying on the touchscreen.
6. Press the Online/Offline push-button.
  * The Online/Offline push-button or the tab Online/Offline light is lit up steadily green. The module is online.

Replace the funnel
WARNING! Risk of infection due to removing the funnel
Pulling out the funnel can lead to contact with infected sample matter. Wear personal protective clothing.

• Precondition
  • The module is offline.
• Procedure

1. Open the front hood on the module by simultaneously pressing in the unlocking mechanism.
2. Pull the old funnel off upwards from the waste shaft.
3. Place a new funnel on the waste shaft.
4. Close the front hood.
5. Switch the module online.

Consumables
The following consumables can be obtained via Abbott Automation Solutions service:

Consumables| Product Description| Item Number| Component concerned
---|---|---|---
Waste bags| Decapper Disposable Bags (350 pieces)| GLP12244| Pull-out compartment with waste bin
Funnel| Decapper Waste Funnel| GLP41187| Interior of the DM

Cleaning and Maintenance

Safety
WARNING! Risk of infection due to skin contact
Risk of serious diseases, including death or infections, due to skin contact with infected sample matter.

• Always wear personal protective clothing during operation.

Observe the safety instructions from the Safety section in the GLP systems Track laboratory automation base system operations manual. Before cleaning or maintenance work is performed, the module must be switched to offline mode using the Online/Offline push-button. All work not listed here may be performed only by Abbott Automation Solutions or an authorized service partner.

Cleaning

■     Surface disinfectant used in the laboratory

■     Damp, lint-free cloth

| ■     Vacuum the surfaces of the track elements

■     Vacuum the guiding slot

■     Carefully remove any dirt

|  |  |  | X
Clean the AccessPoint clamping jaws| ■     Handheld vacuum (recommended)

■     Surface disinfectant used in the laboratory

■     Damp, lint-free cloth

| ■     Remove any adhesive residues left by the labels|  |  |  | X
Clean the AccessPoint| ■     Handheld vacuum (recommended)

■     Surface disinfectant used in the laboratory

■     Damp, lint-free cloth

| ■     Carefully remove any dirt|  |  |  | X
Clean the gripper|  |  |  | X
Clean the touchscreen|  | X|  |
Clean the hood|  |  | X|
Clean the waste shaft|  |  | X|

Checks
Dirt may be a sign of system malfunctions.

Check whether the surface of the track elements within the module is free from dirt.| Daily
Check whether the gripper is damaged or soiled.| Daily
Check whether the AccessPoint is free of soiling.| Daily
Check whether the touchscreen is damaged or displays error messages.| Daily
Check whether the waste bin has been emptied.| Daily

Maintenance
All maintenance work on the module may be performed only by Abbott Automation Solutions or an authorized service partner.

■     Dry, lint-free cloth

| ■     Spray directly on or dampen the cleaning cloth

■     Wipe entire surfaces to clean them; do not wipe them dry, but rather let them air-dry in order to allow an anti-static film to form

| Once every two weeks

Errors and Troubleshooting

WARNING! Risk of infection due to skin contact
Risk of serious diseases, including death or infections, due to skin contact with infected sample matter.

• Always wear personal protective clothing during operation.

Whichever errors occur, always remain calm and carefully consider your next step. Before troubleshooting malfunctions, the module must be switched to offline mode or pause mode using the Online/Offline push-button. All work not listed here may be performed only by Abbott Automation Solutions or an authorized service partner. The following errors may occur on the DM:

manually and place it back in the Input / Output Module, close the hood and switch the module to online.
Follow the error dialog on the touchscreen.
The cap does not release from the gripper once the sample tube has been decapped.| Open the front hood, remove the cap manually and follow the error dialog on the touchscreen.
The sample is not decapped, but is routed to the

Buffer Module and parked there.

| Check whether the waste bin pull-out compartment is closed correctly. If necessary, close the waste bin pull-out compartment and follow the error dialog on the touchscreen.
Robot error is displayed.| Follow the error dialog on the touchscreen.
Sample tubes are not opened. The gripper grips too high or low.| Contact service.
Samples are not gripped at the AccessPoint.| Contact service.

Replacing gripper fingers
Always check all four gripper fingers and replace any defective gripper fingers together with their bolts. The gripper fingers can only be used in one position by design. The procedure for replacing the gripper fingers is identical for all four fingers.

• Precondition
  • The module is switched off.
  • The robot is in an accessible position.
• Tools Required
  • Tx6 Torx screwdriver
• Procedure

1. Open the front hood on the module by simultaneously pressing in the unlocking mechanism.
2. Loosen both screws on the gripper finger with the Torx screwdriver and remove them.
3. Remove the gripper finger from the bracket.
4. Insert a new gripper finger into the bracket so that the gripper finger tooth points inward.
5. Insert new screws into the replaced gripper finger and tighten them with the Torx screwdriver.
6. Close the front hood on the module and allow it to engage.
7. Switch on the module.

Replacing clamping jaws at the AccessPoint
Both clamping jaws and screws must always be replaced at the same time.

• Precondition
  • The module is switched off.
  • The robot is in the rear interior position.
• Tools Required
  • Tx10 Torx screwdriver
• Procedure

1. Open the front hood on the module by simultaneously pressing in the unlocking mechanism.
2. Release both bolts on the clamping jaw with the Torx screwdriver and remove.
3. Remove the clamping jaw from the mount.
4. Insert a new clamping jaw into the mount.
5. Insert new bolts into the exchanged clamping jaw and tighten with the Torx screwdriver.
6. Close the front hood on the module and allow it to engage.
7. Switch on the module.

Spare Parts
The following replacement parts can be obtained via Abbott Automation Solutions service:

Spare Parts| Product Description| Item Number| Component concerned
---|---|---|---
Gripper fingers| Decapper gripper finger kit| GLP41192| Decapper robot
Clamping jaws| AP Rubber Clamping Jaw Set| GLP41275| AccessPoint

Abbott Automation Solutions GmbH
Sachsenkamp 5, 20097 Hamburg, Germany

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