AZENTA IntelliXcap 24 User manual

IntelliXcap Automated Screw Cap
Decapper Re-Capper User Manual
319430 Revision C
24, 48, 96 and Extended Height

Azenta US, Inc.
Information provided within this document is subject to change without notice, and although believed to be accurate,
Azenta US, Inc. assumes no responsibility for any errors, omissions, or inaccuracies.
BioStore™, BioWarehouse™, SampleStore™, Strata™, Tube Auditor™, Azenta™, Azenta Life Sciences™, and the Azenta
logo are trademarks of Azenta US, Inc.
CryoExchange®, CryoPod®, FrameStar®, FreezerPro®, and IntelliXcap® are registered U.S. trademarks of Azenta US,
Inc.
All other trademarks are properties of their respective owners.
© 2023 Azenta US, Inc. All rights reserved. The information included in this manual is proprietary information of Azenta
US, Inc. and is provided for the use of Azenta US, Inc. customers only and cannot be used for distribution, reproduction,
or sale without the express written permission of Azenta US, Inc.
This technology is subject to United States export Administration Regulations and authorized to the destination only;
diversion contrary to U.S. law is prohibited.
Original manual printed in English. Translation of the original manual from English.
These are the original instructions for the IntelliXcap.
2Copyright © 2023, Azenta US, Inc.
Part Number: 319430 Rev. C

Corporate Headquarters
200 Summit Drive, 6th Floor
Burlington, MA 01803 U.S.A.
European Union Representative
Im Leuschnerpark 1B
64347 Griesheim, Germany
For Technical Support:
Location Contact Number Website
North America [phone]
www.azenta.comEurope [phone]
[phone]
Japan [phone]
Copyright © 2023, Azenta US, Inc. 3
Part Number: 319430 Rev. C

Revision History
Part Number: 319430
IntelliXcap User Manual
Revision Date
Revision A 19 DEC2018
Revision B 25 AUG 2021
Revision C 30 JAN2023
4Copyright © 2023, Azenta US, Inc.
Part Number: 319430 Rev. C

Table of Contents
Cover 1
Revision History 4
1. Safety 7
Explanation of Hazards and Alerts 8
Safety Text 8
Safety Icons 8
Signal Words and Color 8
Alert Example 9
Regulatory Compliance and Declaration of Conformity 10
General Safety Considerations 11
Safety Functions 13
E-Stop 13
SafetyDoor 14
2. Overview 17
Using this Manual 17
Concepts and Terminology 18
Product Illustration 20
46-8018 – IntelliXcap 96 Extended Height 20
46-8012 – IntelliXcap 96 21
46-8011 – IntelliXcap 48 21
46-8010 – IntelliXcap 24 22
3. Specifications and Site Requirements 23
Specifications 23
Unit Software and Firmware 23
Site Requirements 23
Space Requirements 23
Environmental Requirements 26
Electrical Requirements 27
4. Installation 29
Unpacking 30
Safety Requirements 30
Preparation 30
Package Contents 31
Procedure 33
Repacking 43
Safety Requirements 43
Procedure 44
5. Operation 57
Overview 57
Theory of Operation 58
Basic Process 58
LED Indicators 59
Starting the Product 59
Copyright © 2023, Azenta US, Inc. 5
Part Number: 319430 Rev. C

De-Capping the Tubes 62
Re-Capping the Tubes 65
Manage the Cartridges 68
Change Cartridge 70
Manage Setpoints 77
Edit Setpoints 78
Manage Profiles 79
Standby Mode 80
Manually Enter Standby Mode 80
Configure Automatic Standby Mode Entry after Inactivity 81
Exit Standby Mode 83
6. Preventative Maintenance 85
Overview 85
Preventative Maintenance 85
Maintenance Schedule 86
Viewing Machine Servicing and Cartridge Replacement Intervals 87
Schedules and Procedures 88
Parts 88
Cleaning 89
Inspecting the Cartridge 91
Waste Disposal 91
System Test 91
7. Troubleshooting 93
Error Messages 93
Technical Support 97
Error Recovery 98
ManualRecovery 98
Appendix A: Integrating the IntelliXcap 101
6Copyright © 2023, Azenta US, Inc.
Part Number: 319430 Rev. C

1. Safety
Read the Safety Chapter
Failure to review the Safety chapter and follow the safety warnings can result in death or
serious injury.
lAll personnel involved with the operation or maintenance of this product must read and
understand the information in this safety chapter.
lFollow all applicable safety codes of the facility as well as national and international
safety codes.
lKnow the facility safety procedures, safety equipment, and contact information.
lRead and understand each procedure before performing it.
It is the responsibility of each person working on this product to know the applicable regulatory safety codes as well as
the facility safety procedures, safety equipment, and contact information.
This product is intended for use by industrial customers and should be serviced only by Azenta or
Azenta trained representatives. The service manuals and related materials are provided in English at no
charge and are intended for use by experienced technicians. It is the responsibility of the user to obtain
and assure the accuracy of any needed translations of manuals. If you require assistance please
contact Azenta service department. Contact information can be found at azenta.com.
If additional safety related upgrades or newly identified hazards associated with the IntelliXcap are
identified, Azenta Technical Support notifies the owner of record with a Technical Support Bulletin
(TSB).
Part Number: 319430 Rev. C 7

1. Safety IntelliXcap Automated Screw Cap Decapper Re-Capper
Explanation of Hazards and Alerts Part Number: 319430 Rev. C
Explanation of Hazards and Alerts
This manual and this product use industry standard hazard alerts to notify the user of personal or
equipment safety hazards. Hazard alerts contain safety text, safety icons, signal words, and color.
Safety Text
Hazard alert text follows a standard, fixed-order, three-part format.
lIdentify the hazard,
lState the consequences if the hazard is not avoided,
lState how to avoid the hazard.
Safety Icons
lHazard alerts contain safety icons that graphically identify the hazard.
lThe safety icons in this manual conform to ISO 3864 and ANSI Z535 standards.
Signal Words and Color
Signal words inform of the level of hazard.
Danger indicates a hazardous situation which, if not avoided, will result
in death or serious injury.
Danger signal word is white on a red background with an iconic
exclamation point inside a yellow triangle with black border.
Warning indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
Warning signal word is black on an orange background with an iconic
exclamation point inside a yellow triangle with black border.
Caution indicates a hazardous situation or unsafe practice which, if not
avoided, may result in minor or moderate personal injury.
Caution signal word is black on a yellow background with an iconic
exclamation point inside a yellow triangle with black border.
Indicates a situation or unsafe practice which, if not avoided, may result
in equipment damage.
Notice signal word is white on blue background with no icon.
8Copyright © 2023, Azenta US, Inc.

Azenta Life Sciences 1. Safety
Part Number: 319430 Rev. C Explanation of Hazards and Alerts
Alert Example
The following is an example of a Warning hazard alert.
Figure 1-1: Components of a Safety Alert
Number Description
1. How to Avoid the Hazard
2. Source of Hazard and Severity
3. General Alert Icon
4. Signal Word
5. Type of Hazard
6. HazardSymbol(s)
Copyright © 2023, Azenta US, Inc. 9

1. Safety IntelliXcap Automated Screw Cap Decapper Re-Capper
Regulatory Compliance and Declaration of
Conformity Part Number: 319430 Rev. C
Regulatory Compliance and Declaration of Conformity
The IntelliXcap meets the requirements of the European Union’s Machinery Directive 2006/42/EC and
2014/30/EU as a completed machine. In accordance with the Directive, Azenta Life Sciences has
issued a Declaration of Conformity and the IntelliXcap has a CE mark affixed.
10 Copyright © 2023, Azenta US, Inc.

Azenta Life Sciences 1. Safety
Part Number: 319430 Rev. C General Safety Considerations
General Safety Considerations
Electrical Shock Hazard
Contact with electrical power can cause death or serious personal injury.
lTo avoid electrical shock, disconnect the power before troubleshooting the electrical
components.
Chemical Hazard
The IntelliXcap may be used to de-/recap samples that expose users to chemical hazards
which, if not properly handled, may result in death or serious injury.
lRead and understand the safety information for the equipment where the IntelliXcap is
used.
lKnow the location of the Safety Data Sheets (SDS)in your facility. (also known as
Material Safety Data Sheets - MSDS)
lBecome familiar with the proper handling of material in the environment of the
decapper.
Inappropriate Use
Use of this product in a manner or for purposes other than for what it is intended may cause
equipment damage or personal injury.
lOnly use the product for its intended application.
lDo not modify this product beyond its original design.
lAlways operate this product with the covers in place.
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1. Safety IntelliXcap Automated Screw Cap Decapper Re-Capper
General Safety Considerations Part Number: 319430 Rev. C
Damaged Components
The use of this product when components or cables appear to be damaged may cause
equipment malfunction or personal injury.
lDo not use this product if components or cables appear to be damaged.
lPlace the product in a location where it will not get damaged.
lRoute cables and tubing so that they do not become damaged and do not present a
personal safety hazard.
Pinch Point
Moving parts of the product may cause squeezing or compression of fingers or hands
resulting in personal injury.
lDo not operate the product without the protective covers in place.
Moving parts are subject to pressure and weight. Do not rest a hand on the stage or twist the rack as it may pull the
machine out of position or damage moving parts.
The IntelliXcap should be kept clean at all times, please see "Cleaning" on page 89 for information on cleaning require-
ments.
The IntelliXcap can only be used with tubes and cartridges that have been configured and tested. Do not use altern-
ative tubes and cartridges that have not been configured and tested.
12 Copyright © 2023, Azenta US, Inc.

Azenta Life Sciences 1. Safety
Part Number: 319430 Rev. C Safety Functions
Untrained or Improperly Equipped Personnel
Untrained or improperly equipped personnel performing this procedure may cause damage to the equipment.
lOnly Azenta Life Sciences trained personnel should perform this procedure.
lPersonnel performing this procedure must read and understand this procedure and have the proper tools and
supplies ready before starting.
lPersonnel performing this procedure must know the applicable safety codes, facility safety procedures, safety
equipment, and emergency contact information.
Safety Functions
The use and operation of the machine must only be initiated when all safety functions are fully present
and in an operable condition. Defective safety functions and protection equipment may lead to unsafe
and hazardous situations. In case that a risk to safety is found, do the following:
a. Stop the machine immediately: it can be brought to a safe stop by either the touch screen, activating the
Cancel-function, or by the emergency stop button.
b. Disconnect the supply sources to prevent the IntelliXcap from restarting.
E-Stop
The emergency stop button is a safety device designed for use as a complementary protective measure.
As an example, the operator can press the emergency stop function to cease all mechanical movement
of the IntelliXcap if a hazardous situation arises that could cause personal injury, or damage to the
machine or equipment.
When activating the emergency stop button, the status will appear on the operator monitor: Error 238 –
Emergency stop
Test the emergency stop function before commissioning the IntelliXcap for use and after each
installation or re-installation.
Copyright © 2023, Azenta US, Inc. 13

1. Safety IntelliXcap Automated Screw Cap Decapper Re-Capper
Safety Functions Part Number: 319430 Rev. C
At minimum, the function must be visually checked and activated at least every six months.
SafetyDoor
There is a safety switch installed on the access door that prevents the unit from running if the door is
not completely closed. Opening of the access door while tool is in use initiates an immediate stop
function of all moving parts.
This function protects operators against hazardous moving parts accessible through the front of the
IntelliXcap.
14 Copyright © 2023, Azenta US, Inc.

Azenta Life Sciences 1. Safety
Part Number: 319430 Rev. C Safety Functions
The access door can be disabled by navigating to Settings >Safety Door, if the user makes sure that
another safety measure takes over.
For example, when the IntelliXcap is integrated into a robotic cell with its own safety system. See
"Integrating the IntelliXcap" on page 101 for further information on using the IntelliXcap in an integrated
system.
When the IntelliXcap is commissioned and starts functioning, the automated door closes and the
Initializing please wait status message is displayed on the operator monitor.
The safety door must be activated and tested before commissioning the machine for use.
NOTE: At minimum, the safety door should be visually checked and activated at least
once a day.
Lockout / Tagout
Working with energized equipment may cause sudden movement or electrical shock and
may result in death or serious injury.
lAll energy must be removed from the equipment per the facility’s
Lockout/Tagout procedure before servicing.
lIf local procedures are not available, follow the procedure for Lockout/Tagout in OSHA
Standard 29CFR 1910.147.
Copyright © 2023, Azenta US, Inc. 15

1. Safety IntelliXcap Automated Screw Cap Decapper Re-Capper
Safety Functions Part Number: 319430 Rev. C
16 Copyright © 2023, Azenta US, Inc.

2. Overview
This manual describes the proper use of the machine.
The IntelliXcap is a new generation of sample-tube de-/re-capper, which is comprised of a basic chassis
assembly and a screwing-head module. This includes interchangeable cap-driver cartridges that allow
the user to change the tube type that needs to be decapped.
The IntelliXcap is equipped with a light curtain which reduces the risk of damage to tubes, samples and
the instrument that could be caused by failed de-capping / capping or the use of incorrect
consumables. The IntelliXcap can be controlled manually or can be integrated into an automated
robotic system using a serial command set. The IntelliXcap can work with a range of tube types – a
specific cartridge is required for each different cap design format. The current list of available cartridges
can be seen in "Manage the Cartridges" on page 68 or contact your local sales representative to
request a cartridge for your specific storage tube.
NOTE: The IntelliXcap is not intended to be used with frozen tubes.
Using this Manual
Read the Safety Chapter
Failure to review the Safety chapter and follow the safety warnings can result in death or
serious injury.
lAll personnel involved with the operation or maintenance of this product must read and
understand the information in this safety chapter.
lFollow all applicable safety codes of the facility as well as national and international
safety codes.
lKnow the facility safety procedures, safety equipment, and contact information.
lRead and understand each procedure before performing it.
Part Number: 319430 Rev. C 17

2. Overview IntelliXcap Automated Screw Cap Decapper Re-Capper
Concepts and Terminology Part Number: 319430 Rev. C
The IntelliXcap is intended for use in a laboratory environment by trained laboratory personnel and
should be serviced only by Azenta or Azenta trained representatives. The manuals and related materials
are intended for use by trained and experienced technical personnel.
The manufacturer accepts no liability for any other use of the equipment or its individual parts and
components. This also applies to service and repair work carried out by unauthorized service personnel.
All warranties are declared null and void in the event of non-compliance with these instructions. This
also applies to parts not directly affected by any unauthorized repair work.
This manual contains information on safety, specifications, and operation as well as troubleshooting
and maintenance of the IntelliXcapIntelliXcap Automated Acoustic Cap Decapper. If there are any
questions regarding this manual or use of this system or to order additional copies of this publication,
contact Azenta Life Sciences Service. See "Technical Support" on page 97.
Concepts and Terminology
The concepts and terminology defined in this section may be used in this document. Users should read
this section first before continuing with the manual.
Word Definition
Cap motor Small DC motor with an integral gearbox which can be driven in either direction to remove or
refit a test tube caps. Couples to the caps via ejector pin and adaptor within the cartridge.
Caps Screw caps
Cartridge A set of adaptors which couple the ejector pins to the tube caps
Cartridge ID
Number The electrical ID number of the cartridge encoded by 4 pin switches. Can be 1–15.
Cartridge
Number The actual number of the cartridge which corresponds to a physical profile.
Cartridge profile Collection of setpoints which define machine operation for a particular set of labware. Often
just referred to as a profile.
Common
Setpoints Those setpoints which are common to all types of labware.
Controller (board) The main controller module within the IntelliXcap. This has all I/O as well as stepper motor
drivers.
CRC16 Cyclic redundancy check, used for profile verification and the CRC algorithm used shall be
CRC16-CITT-FALSE.
CSV Comma separated values. However, in this context it is a semicolon delimited text file which
contains a specific cartridge profile.
Cycle The process of first de-capping and then re-capping a rack of tubes = 1 cycle.
Datalogger Software application provided by LS Controls which allows configuration of the IntelliXcap via
the USB port.
18 Copyright © 2023, Azenta US, Inc.

Azenta Life Sciences 2. Overview
Part Number: 319430 Rev. C Concepts and Terminology
Word Definition
Decap Unscrew the caps of the sample tubes.
EEPROM Electrically erasable programmable read only memory. Used for non-volatile storage in the
instrument.
Ejector pin Couples the cap motor to the cartridge adaptor, and hence in turn to the tube cap.
Extended profile
Number Profile number for use with cartridge ID 15 - numbered 16–96.
Extended stage
That part of the mechanism which adjust the height of the cap drivers, relative to the head
assembly. It is driven by stepper motor M3, and mechanically is made possible by the fact the
cap drivers are slotted and slide up and down on the ejector pins.
Head The main moving assembly, which comprises the cap motors and drivers, along with light
curtain. It is driven by stepper motor M1.
I/O Input/Output
Instructed
person
A person having received the necessary training to carry out a task in a safe and responsible
way.
IntelliXcap
96/48/24 Various Intellixcap variants (i.e. 96, 48 or 24 tube).
Labware Rack and test tube vials.
LCD Display 480 x 272-pixel touch screen display on the IntelliXcap front panel. It communicates with the
controller board via modbus.
Light curtain System for detecting the height of the tube rack on the stage.
Loaded profile
The profile currently loaded into the machine's working memory area, usually this is copied
from EEPROM storage according to the cartridge number, however it could also be a profile
that was loaded in using datalogger.
M1 Main Z motor
M2 Stage/Nest motor
M3 Cartridge motor
M4 Safety Door motor
Microcontroller Microprocessor with integrated memory, I/O and other special purpose peripherals. Runs fixed
(embedded) application firmware.
MLA Microchip Libraries for Applications. A set of drivers and middleware libraries containing such
items as USB stacks, graphics frameworks and LCD drivers. Provided by Microchip Technology.
Modbus Master/slave data communications protocol originally developed for PLCs.
Modbus address 16-bit address for a particular register, which is also a 16-bit value.
MPLABX Development environment by Microchip Technology, used for developing firmware for their
range of PIC microcontrollers
Profile See 'Cartridge profile'.
Profile number Numbered profile which corresponds to cartridge number.
Copyright © 2023, Azenta US, Inc. 19

2. Overview IntelliXcap Automated Screw Cap Decapper Re-Capper
Product Illustration Part Number: 319430 Rev. C
Word Definition
Profile Setpoints The setpoints that are included in a profile.
PSU Power supply unit. Two are fitted in the IntelliXcap: 24V and 7.5V.
Rack Set of labware consisting of tray and a number of tubes/vials.
Recap Screw the caps back onto the sample-tubes.
Regular profile
number Automatically loaded profile number for cartridges 1–14.
Setpoint Configurable parameter which defines machine operation. In modbus parlance it is a holding
resister.
Setpoint Number Unique number for each setpoint, which corresponds to the modbus holding register address.
Volatile Setpoints Setpoints which do not need to be stored in non-volatile memory, e.g. commands.
Waste Mode of operation where caps are not refitted but dropped off into a carrier.
Working profile See 'Loaded profile'.
Product Illustration
46-8018 – IntelliXcap 96 Extended Height
20 Copyright © 2023, Azenta US, Inc.