User Manual - Watrex Praha
Contents
1. home position Gripper places the new container into the tray Slider is placed back into the MegaBACE MegaBACE cathode is raised releasing itself from the hook Operating Caddy Instrument The Caddy 1000 cathode automation instrument requires specific startup procedures to prepare the instrument for operation Chapter 4 1 describes the procedures you use to start the instrument for first time operation and after shutdown for service repair or storage Chapters 4 2 and 4 3 describe procedures for typical operation of the system 10 Chapter 4 4 provides aborting and shut down procedures Chapter 4 5 contains information about Direct Control mode used for MegaBACE service and maintenance protocols such as Focus Capillaries Flush and Dry Capillaries etc 6 1 Power up and initialization ie In general you leave the instrument power permanently on unless the instrument is being serviced or stored for a longer period of time Before starting the hardware make sure the power cord and the emergency foot switch cord are properly installed Also make sure the communications cables between the control module and the PC are properly connected 6 1 1 Starting hardware Always turn on the instrument and computer in the following order Turn on the PC computer first boot the Windows system then turn on the main switch on Caddy control module The light tower should turn red after turning on the control module Wait at least one m2. MegaBACE Instrument Control Manager ICM 7 Troubleshooting and maintenance Caddy 1000 instrument is equipped with numerous sensors and self monitoring features to uncover any potential errors or collision states There are two main error modes for the MegaBACE working with Caddy automation related to either of the system components 7 1 Mechanical errors of the robotic unit collision The most common cause of mechanical collision is repowering Caddy after a previous collision without closing the CCC software manual lowering of the cathode during Caddy initialization 17 manual lowering of the cathode during robotic movement Recovery method In all these cases 30 seconds crash timeout after the crash all power to the motors will be automatically disconnected and the CCC software will be shut down If the crash is discovered before the crash timeout emergancy stop button can be used to stop all motors After that the software MUST be closed The emergency button can be switched on only after waiting for at least 5 minutes 7 2 Caddy Control Center CCC software errors These errors are very rare and should be reported as soon as possible Recovery Recovery method Check ICM for the current status of the MegaBACE If running let the run come to ist end data will be preserved If ICM shows a timeout error click on lt ABORT gt in the ICM error message window Close the CCC software Turn off Caddy robotic unit Wai
3. performed at anytime by activating the Caddy Initialize option from CCC right click menu 6 1 4 About PC computer clock speed a In some special cases slow PC computer clock speed can cause occurrence of an error message 1f a manual initialization is activated immediately after start of CCC software If your computer is slow wait at least 10 seconds following CCC start before starting the manual initialization 6 2 Loading sample and buffer plates To load sample and buffer plates into the hotel select the Unlock Plate Hotel option from the CCC right click menu After unlocking you have 10 seconds to open the plate hotel If you do not open the hotel during the 10 seconds interval the plate hotel will be locked again After opening the plate hotel manually slide out individual slots to load the plates Each plate slot slots 3 through 20 is equipped with a positioning pin to prevent incorrect plate orientation in the MegaBACE tray The plate positioning pin is shown in Figure 7 12 Positioning pin Figure 7 Plate slot with the positioning pin 6 3 Loading water or buffer tank Water tank is used during standard Sequencing and Genotyping workflows With Caddy instrument only a single buffer tank is used during SNP Genotyping workflow Water or buffer tank must be only placed in slot No 1 In order to refill tank with new water replace water tank by buffer tank etc you have to use Direct
4. Control mode described in Chapter 6 6 STOP Do not try to overcome the plate hotel interlock or to gain access to the plate hotel through any other opening Reaching into the instrument from the plate hotel side during the instrument operation can cause a serious injury Opening of the plate hotel during normal instrument operation can cause a serious damage to the instrument 6 4 Running a series Caddy 1000 cathode automation instrument is designed to allow for unattended execution of multiple runs by sequentially loading containers plates and tank into the MegaBACE tray The unattended series can consist of multiple runs using either single injection workflows for Sequencing and Genotyping applications or multiple injection workflows for SNP Genotyping application 13 6 4 1 Series definition Each series to be executed by Caddy system must first be predefined using Cathode Automation Wizard software CAW The definition includes detailed specification of individual sample plates sample names marker names etc their positions in the plate hotel and the running contitions injection voltage and time running voltage and time etc CAW software is using standard MegaBACE principles that are used in MegaBACE Instrument Control Manager ICM software Therefore it is user friendly and intuitive for every MegaBACE user In order to find out more about CAW check the Cathode Automation Wizard software user s manual 6 4 2 Starting a sel
5. cathode automation is in conformity with the following EC directives Low voltage directive 72 73 EWG Engineering directive 98 37 EC EMC directive 89 336 EWG Following safety requirements and regulations were applied for evaluation CSN EN 292 CSN EN 60204 1 CSN EN 61010 1 CSN EN 50081 1 CSN EN 50082 1 Prague 3 May 2002 Milan Minarik PhD Managing Director The following conformity sign is attached to the body of every instrument 2 4 Optional extensions Watrex Praha is currently offering anode automation as an extension upgrade to Caddy 1000 cathode automation The resulting Caddy 1000 Plus representing a complete MegaBACE automation is capable of handling different types of tubes including LPA matrix tubes buffer tubes and water tubes on the anode compartment For more information regarding Caddy 1000 Plus contact Watrex Praha see Chapter 2 2 Manufacturer contact 3 Caddy 1000 specifications 3 1 Applications Caddy 1000 is designed to operate cathode compartment of MegaBACE 100 genetic analyzer It s main application is in automated loading of sample and buffer plates as well as buffer and water tanks during a series of up to 6 runs in Sequencing Genotyping or SNP Genotyping MegaBACE configurations 3 2 Manuals related resources In addition to the Caddy User s Manual Watrex Praha provides the following publications for Caddy 1000 systems e MacroEditor user s manual Provides useful
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7. ddition the emergency foot switch is connected to the control module Figure 4 shows connectors of the control module PC Signal NC for future Power Control Emergency foot Sensor Figure 4 Connections of the Caddy 1000 control module STOP Use only the cords supplied with the instrument Make sure cord is in a good condition and is not frayed Use of incorrect power cord can cause damage to the instrument Never dismantle the emergency foot switch Use of frayed or damaged power cord or emergency switch cord can cause injury or death y It is recommended to use an uninterruptible power supply UPS to protect instruments electronics in the event of power failure Unprotected power outage can cause damage to the instrument 8 4 Chemicals STOP Use good laboratory procedures and follow the manufacturer s precautions when working with chemicals Watrex Praha is not responsible or liable for any damages caused by or as a consequence of the use of hazardous chemicals 20
8. ected series After completing the series definition in CAW software open Instrument Control Manager and make sure a correct application 1s selected from the drop down list according to the following e AUTO Sequencing for Sequencing series e AUTO Genotyping for Genotyping series e AUTO SNP Genotyping for SNP Genotyping series aie When in a correct application mode run the Automation Start protocol When the Automation Start protocol starts you will shortly see the light tower switching from yellow idle to green series in progress ie Choosing an incorrect application will later result in errors due to incorrect container type placed into the cathode tank The series will not run properly Starting protocols other than Automation Start will cause inconsistencies in Caddy and MegaBACE workflows resulting in ICM timeout errors Series will not run properly 6 4 3 Monitoring the run Caddy 1000 instrument is equipped with signal tower that allows to monitor current status of the robot The status signals can be following e RED Caddy not initialized or Caddy error e Yellow Caddy initialized Cady idle waiting for a series start e Green Series started Caddy communicating with MegaBACE e Blinking Green Robot currently executing plate transfer in motion 14 All robotic movements are recorder in a logfile When you contact service assistance you should always include a copy of the logfiles with your error r
9. eport 6 5 Aborting instrument s operation There are three ways to interrupt running series Depending on the situation you can choose either Panic Stop or Emergency stop using the emergency foot switch Panic Stop can be accessed from the CCC right click menu It is designed to be used in situations where the series can not be completed in its current form but where there is no immediate danger of mechanical collision A typical situation is operator s mistake such as incorrect sample assignment etc Upon activation of Panic Stop the currently executed transfer will be completed and then the series will abort Emergency Stop is done by engaging the Emergency foot switch It is designed to interrupt power to all motors and to instantly stop all robotic movements The Emergency Stop should be used only in collision situation or in situation with immediate danger of collision If you use the Emergency Stop never turn it back on without shutting down the CCC software You can either close the software manually or simply wait for 1 minute and it will be shut down automatically Turning the robotic module back on immediately in less than 1 minute interval after Emergency Stop was used can cause significant damage to the instrument After the series abort you will separately have to abort currently running protocol in ICM using the lt Stop gt button It is strongly recommended that after using Emergency Stop you shu
10. gt a CY f OF PA control module robotic module Figure 1 Robotic and control modules of Caddy 1000 system Caddy 1000 cathode automation systems consists of the following main components e Robotic module referred to as the robot The main mechanical part of the system positioned in front of the MegaBACE instrument and fixed to the MegaBACE table It is further consisting of o Elevator with gripper unit moving the containers between the plate hotel drawers and the MegaBACE o Climber with liftboy robotic part that opens and closes the plate hotel drawers o Slider tractor with hook device that pulls out the cathode slider with the tray o Plate hotel unit storing multiple containers plates or tanks e Control module referred to as the electronics box The module including PC boards and circuits with following functions enabling communication between the robot and the PC computer sending commands to move the stepper motors receiving status signals and error commands from sensors 5 2 Caddy terminology Table 1 Individual components shown in Figure 2 Front right left panel Sheet metal skins protecting the user from moving parts inside the instrument Top cover Removable upper plastic skin It can only be removed when the instrument 1s disconnected from power to recover from a hardware collision situation Basic body structure of the instrument Device that transports the gripper up and down Gripper C
11. guidance on how to setup sample definitions for MegaBACE Instrument Control Manager e Caddy Control Center quick navigation guide Provides quick reference on how to use Caddy Control Center CCC software 3 3 Dimensions and weight Caddy 1000 dimensions are 46 cm width x 32 cm length x 90 cm height Caddy 1000 weight is 68 kg 150 lbs 3 4 Voltage requirement and power consumption Y Caddy 1000 requires stable power to work properly It is recommended to use an uninterruptible power supply UPS to protect instruments electronics in the event of power failure Unprotected power outage can cause damage to the instrument sie 4 9 5 1 Caddy 1000 voltage requirement is 115 230 V 50 60 Hz Caddy 1000 power consumption is 160 VA VoltAmperes 3 5 Safety Before using the Caddy 100 cathode automation system familiarize yourself with safety precautions described in detail in Chapter 8 Safety Information Unpacking and installation information Only Watrex Praha personnel or a specialist with installation training certification issued by Watrex Praha is allowed to unpack the package with Caddy 1000 system and to perform the installation Watrex Praha will assume no responsibility or liability for injury or death caused by unpacking or installation by unauthorized person s Introduction to Caddy system System hardware components trs 1I LY C ees SL TR ESSLE om CLA A CPP ED p 4 ee Hs amp
12. ics Caddy MegaBACE cathode automation User Manual Part Number D2K2 0416 01 version 1 8 WATREX SSS Watrex Praha Ltd www megabace net List of Contents LISTO CONOIS ER et a ee eee ou 2 te PTICO noire AE E A A R a de 3 1 1 ADOUE CHE MaMa heen ne tiens 3 1 2 ASSUMP TIONG ear in O T a 3 1 3 SSDS WSCC TA UC TOK sania RE E E ea eects N 3 1 5 Before VOU DC CIN aroei ra TTA E E O O T 4 2 Identification of your Caddy system 4 2 1 Serial and version number label 4 22 Manul act rer CONTAC onrein a yi eieaieicuaneeumt nouns aera 4 2 3 UC AE OG Se ne do ON ao Beene do 5 2 4 Optional eren IONS sirra LR Re ta en 6 3 Caddy 1000 specincanons AE tt N 6 3 1 ADDHCAUONS dass S E EEE 6 3 2 Manuals related resources incensa a a meee 6 3 Dimensions ANA MOIS se de ein TATE 6 3 4 Voltage requirement and power consumption ccseeeeeeeeeececeeeeeeeeeeeaaeees 6 32 SAG by 555 Stan RE OS ES nat 7 4 Unpacking and installation information T Sx IntroduCHon 10 C addy syste a e E a 7 5 1 System hardware COMPpPONENtS seisoon ann nat Mees 7 52 Caddy TET ONO NE nn nn a a eur 8 5 3 By SCC MICU OMS a Eee 9 5 4 Overview of instrument operations ccccccccccccecesseeeeccceeeeesaeeeeeeeceeeeeeaas 10 6 Operating Caddy InStTUMents in su he nd as A ii ienendesty 10 6 1 POWEr UD AN ninali zato Meena a a AT ceo en 11 6 1 1 SARL ALAWAR Re nude en nt 11 6 1 2 Starting Caddy Control Center software CCC cceeeccc
13. ight click menu Y DCM has all necessary functionality to lower and raise cathode before loading plate or tank Do not use MegaBACE Instrument Control Studio ICS to manipulate cathode during DCM s operation Lowering or raising cathode during DCM s operation can cause collision resulting in a significant damage to the instrument 6 6 2 Main DCM window Selecting DCM option from CCC right click menu will open a main DCM window called DCM terminal see Figure 8 The terminal includes three buttons Direct Control Mode Pere ee err er CLLLLLLLELLELELELELEELELEELEEEEELEELLEECELEEEEEE CEE EE CCE EEE LEE EE EEE LELEEEEEL LE LS afl Exit Terminal Figure 8 Main windows of the Direct Control mode DCM terminal Refill Tank This option is used to reload the MegaBACE tray with any container type It can be used for example to refill water tank with fresh water after an overnight sleep It can also be used to replace tank or plate that is currently inside the MegaBACE with any 16 new type tank of plate You have to keep slot No 1 in the plate hotel empty The current container will first be transferred from the MegaBACE into slot No 1 then the plate hotel will be unlocked and you will be prompted to replace it with a new container tank or plate After that you hit the lt continue gt and the tank in slot No 1 will be returned back into the MegaBACE Open lt gt Close This option is used j
14. inute after turning on the hardware then start the software 6 1 2 Starting Caddy Control Center software CCC Start Caddy Control Center software usually installed as caddy exe executable file in Program Files Watrex Caddy folder CCC is running as a background application showing only a small yellow triangle icon in the bottom right corner By right click on the yellow CCC icon the main menu is opened as shown in Figure 6 Show CCC Status Panel E instrument Control Manege S Mic Unlock Plate Hotel Ta 1 48 Pt Figure 6 Accessing the Caddy Control Center main window by right clicking on the tray icon 11 6 1 3 Initialization It 1s important that the control module first establishes a communication and then all sensors of the systems are tested and all movements are calibrated After starting CCC software an initialization process will be automatically started If necessary you can abort the initialization process using the Panic abort function from the CCC right click menu For more information about aborting instrument operation see Chapter 6 5 Upon initialization control module will establish a communication connection with the robotic module then the robotic module will sequentially calibrate all moving axes and motors y The calibration procedure is essential for proper instrument operation Do not perform any MegaBACE operations during the Caddy initialization procedure A manual initialization can be
15. ion Start protocol from Instrument Control Manager ICM As a first step in each series robot removes the water or buffer tank from the MegaBACE tray and transfer it into the slot No 1 After removing the tank robot executes transfers of individual containers according to the instructions received from ICM as required by the currently running protocol At the end of the series robot returns the tank back to the MegaBACE cathode tray and if selected during the series definition lowers the MegaBACE temperature sleep mode Detailed description of sub steps of each plate or tank transfer a T Q on 6 Cathode slider is lowered and locks into the hook Slider is pulled out by the slider tractor exposing the tray with the container to be removed Climber is positioned at an empty slot the liftboy opens the empty slot Gripper takes the container from the tray and returns to its home upper position Slider is positioned in a parking position pushed half way into the MegaBACE to allow gripper to pass on its way down to the slot Gripper is lowered places the container onto the empty slot and then returns back to the home upper position Liftboy closes the slot with the old container shifts to the next slot position and opens the slot with a new container Gripper is lowered to take the new container and then raised back to the home upper position Slider is pulled from the parking position to the fully open position
16. laws grabbing and holding the container during the transfer Device positioning liftboy at the slot Liftboy Slot opening device Slider tractor with hook Device opening pulling out the cathode slider Plate hotel Storage cabinet for 18 sample and or buffer plates and a single water or buffer tank Slider Gripper Hook Plate hotel Elevator Climber With Liftboy Hotel interlock Figure 2 Individual components of Caddy 1000 robotic module 5 3 System functions Caddy 1000 cathode automation instrument is designed to e Store sample plates buffer plates water tank or buffer tank prior to their transfer to the MegaBACE DNA analyzer e Communicate with MegaBACE controlling software ICM to synchronize operations with MegaBACE workflows e Transfer predefined containers according to the currently running MegaBACE protocol e Detect and report any errors resulting from incorrect container selection for example an exchange of plate and tank 5 4 Overview of instrument operations Main steps when running a series A B User loads sample and buffer plates into the plate hotel according to the slot filling scheme generated by Cathode Automation Wizard software CAW Using Direct Control Mode described in section 4 5 user loads water tank in Sequencing and Genotyping application or buffer tank in SNP Genotyping application into the MegaBACE tray User starts predefined automation series using Automat
17. t and Troubleshooting and maintenance describes how to use the instrument and gives guidance to solving potential problems 1 2 Assumptions TRAINED OPERATOR The operator of Caddy 1000 instrument is assumed to be trained in the correct operation of the instrument and the safety issues Throughout the Caddy instrument documentation the word you refers to the trained operator Please read and understand thoroughly all directions and procedures described in the following text before operating the instrument GENERAL SKILLS The general software related instructions in this manual assume that you have basic computer skills You should be familiar with Microsoft Windows graphical user interface you should know how to use a mouse MEGABACE SKILLS The MegaBACE specific instructions in this manual assume that you are familiar with the functionality of Instrument Control Manager ICM software For all inquiries relating to the use of MegaBACE DNA analyzer refer to MegaBACE documentation 1 3 Signs used in the text D warune This icon indicates a possibility of injury or death to the user or other persons if the precautions or instructions are not observed CAUTION This icon indicates that damage to the instrument loss of data or invalid data might occur if the user fails to comply with the advice given IMPORTANT This icon highlights information that is critical for optimal performance of the system 1 5 Before
18. t down the software turn off power to the robotic module wait for 5 minuters and then follow the standard Caddy startup procedure described in Chapter 6 1 Aborting a running series though either of the above options is irreversible and has to be followed by manual Caddy initialization see Chapter 6 1 In execute the desired runs the series must be first refreshed in the CAW software and then started again from the beginning The refreshing in CAW software is simply done by recalling the lastseries caw configuration from the Load series option For more details regarding series definitions refer to the Cathode Automation Wizard software user s manual 15 6 6 Direct Control Mode DCM Caddy 1000 instrument 1s designed to sequentially load plates and tank into the MegaBACE 1000 DNA analyzer according to the predefined series During a series the timing of the plates and tank transfers is received through communication with MegaBACE control software ICM and repeating Matrix Fill and Prerun and Inject Samples and Run protocols 6 6 1 About DCM Direct Control Mode DCM is designed to give the user ability to load individual plates and tank into the MegaBACE tray in a semi manual mode 1 e without a need to run predefined series This is very useful especially when performing maintenance MegaBACE protocols such as Rinse Tips Flush and Dry Capilleries Focus Capillaries etc DCM s functions are accessible from CCC r
19. t for at least 1 minute Turn on Caddy robotic unit and start CCC software If there 1s a water tank inside the MegaBACE follow the standard procedure for starting a series If there is a plate inside the MegaBACE follow the procedure for the Direct Control Mode DCM put the water tank into the MegaBACE and then turn into standard procedure for starting a series 7 3 Service of Caddy instrument To protect your warranty and for proper operation the instrument must be serviced only by an authorized service representative If the instrument is not working correctly contact Watrex Praha support When you contact Watrex Praha for support please supply the following information Caddy serial number Caddy Control Center CCC software version number Cathode Automation Wizard CAW version number MegaBACE serial number check MegaBACE documentation for details ICM version and build number check MegaBACE documentation for details 8 Safety information The Caddy 100 cathode automation instrument and its accessories have been designed for safe operation It is imperative that you follow the precautions in this Chapter 8 1 General safety precautions 18 While using Caddy instrument you should follow the laboratory procedures appropriate for the experiments you are performing STOP The operator of Caddy 1000 instrument is assumed to be trained in the correct operation of the instrument and the safety issues Throughout the Caddy ins
20. trument documentation the word you refers to the trained operator Please read and understand thoroughly all directions and procedures described in the following text before operating the instrument STOP Using controls making adjustments or performing procedures other than those specified in this user s manual may result in hazardous exposure to moving parts Such exposure can cause injury or death 8 2 Moving parts Under normal operating conditions you are protected from moving parts The body of the instrument is manufactured from solid stainless steel The skins will protect you from coming in contact with motors gears or other moving elements The plate hotel is equipped with an electromagnetic interlock that will prevent you from opening the hotel during instrument operation Upon initiation the emergency foot switch will stop power to all motors hence halt all movements Figure 3 Detail of the plate hotel interlock STOP Do not remove any panels for any reason Do not defeat the sensors or interlocks or try to gain access through any other opening 19 a You can however unmount the top cover when the instrument is disconnected from power to gain access to the gripper to recover from a hardware collision situation see Chapter X for details 8 3 Electrical connections Caddy system is powered at 110V or 240 V depending on local powering system by a single power cord connected to the control module In a
21. ust to activate MegaBACE cathode door sensor It is useful in case when the Refill Tank option was used to replace a container and the operation did not finish in a time limit For example during Rinse tips protocol the user is asked to enter a new water tank If the user does not replace the tank within a given time period usually between 120 and 240 seconds a Timeout error message will be displayed by ICM In order to prevent a need of repeating the entire transfer it is possible to click lt Retry gt option from the ICM error message and then just to activate the cathode door sensor using the Open gt Close function sie In DCM mode the system will always check availability of an empty slot in the plate hotel before transferring the container If the slot is not empty the program will abort all operations and shut down the Caddy Control Center You will then have to reinitialize If you are replacing current container with a new container using the Refill Tank option you have 3 minutes to replace the old container in the plate hotel slot with the new one and to close the plate hotel If the container is not replaced during this 3 minute interval the system will report and error the signal tower with switch to a red light and the software will be shut down x It is recommended that you always close the DCM terminal after the transfer has ended If you leave the terminal open you run into a risk of software conflict with the
22. you begin ie e Chapter 5 Introduction to Caddy 1000 system e Chapter 6 Operating Caddy 1000 Instrument e Chapter 7 Maintenance and Troubleshooting Before using the Caddy 100 cathode automation system familiarize yourself with 2 Identification of your Caddy system Your Caddy 1000 system is can be identified from its part and serial numbers located on the serial and version number label Please specify these two numbers whenever contacting technical support 2 1 Serial and version number label You can find the serial and version number of your Caddy 1000 instrument on the manufacturer s label The label is located on the side of the plate hotel and is easily accessible after opening the plate hotel Figure 5 shows the serial and version number label Watrex Praha Ltd Caddy 1000 Cathode automation system S N 2206 68 2002 115 230V 50 60 Hz 160 VA Made in Czech Republic Figure 5 Serial and version manufacturer s label of Caddy 1000 system 2 2 Manufacturer contact Watrex Praha s r o Hostalkova 42 Prague 6 CZ 169 00 Czech Republic Phone 420 2 20513446 Fax 420 2 20513448 http www megabace net e mail info megabace net 2 3 Certifications Declaration of conformity Manufacturer s name WATREX Praha s r o Manufacturer s address Hostalkova 42 169 00 Praha 6 Czech Republic declares in sole responsibility that the product P N D2K2 041001 Caddy 1000 MegaBACE
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