Brooks IntelliXcap User manual

IntelliXcap
User Manual
Part Number 319430 Rev. A

IntelliXcap
Part Number: 319430 Rev. A
Brooks Automation, Inc.
Information provided within this document is subject to change without notice, and although believed to be
accurate, Brooks Automation, Inc. assumes no responsibility for any errors, omissions, or inaccuracies.
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© 2019 Brooks Automation, Inc. All rights reserved. The information included in this manual is proprietary
information of Brooks Automation, Inc. and is provided for the use of Brooks customers only and cannot be
used for distribution, reproduction, or sale without the express written permission of Brooks Automation, 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. Printed in the U.S.A. Translation of the original manual from English.
ii Copyright © 2019, Brooks Automation, Inc.

Brooks Automation
Part Number: 319430 Rev. A
Corporate Headquarters
15 Elizabeth Drive
Chelmsford, MA 01824 U.S.A.
For Technical Support:
Location GUTS® Contact Number Website
North America +1-800-FOR-GUTS (1-800-367-4887)
[phone] http://www.brooks.com/
Europe +49-1804-CALL-GUTS ([phone]) http://www.brooks.com/
Japan [phone] http://jp.brooks.com/
China [phone] http://cn.brooks.com/
Taiwan [phone] http://tw.brooks.com/
Korea [phone] http://kr.brooks.com/
Singapore [phone] http://www.brooks.com/
Contact Technical Publications directly: [e-mail]
Accelerating Innovation
Copyright © 2019, Brooks Automation, Inc. iii

IntelliXcap
Part Number: 319430 Rev. A
Brooks Automation, Inc.
15 Elizabeth Drive
Chelmsford, MA
01824-2400
Tel: [phone]
Fax: [phone]
www.brooks.com
Brooks Locations Worldwide:
Brooks Automation Inc.
46702 Bayside Parkway
Fremont,CA 94538
Tel: [phone]
Fax: [phone]
Brooks Life Sciences
BioStorage Technologies
2910 Fortune Circle West,
Suite E
Indianapolis, IN 46241
Tel: [phone]
Fax: [phone]
Brooks Automation, Inc.
AIM Servicios Administrativos
S de RL de CV
Carretera Huinalá km 2.8
Parque Industrial Las Américas
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Tel: [phone]
Brooks Automation
(Germany) GmbH
Ernst-Ruska-Ring 11
07745 Jena, Germany
Tel: [phone]
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(Germany) GmbH
im Wiesengrund 17
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(Germany) GmbH
Karl-Marx-Strasse 23
D-01109 Dresden, Germany
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Fax: [phone]
Brooks Automation, Inc.
9601 Dessau Road, Suite 301
Austin, TX 78754
Tel: [phone]
Toll-Free: [phone]
Brooks Life Sciences
BioStorage Technologies GmbH
Im Leuschnerpark 1B
64347 Griesheim, Germany
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(Israel) Ltd.
Mevo Yerach 5
Kiryat-Gat 82000
Israel
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Brooks Automation AG
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United Kingdom
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Brooks Technology
(Shanghai) Limited
2nd Floor, No. 72,
887 Zuchongzhi Road
Zhangjiang Hi-Tech
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China 201203
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HEADQUARTERS
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YOKOHAMA TECHNICAL
CENTER
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ku
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CENTER
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OFFICE
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SOLUTIONS
Nisso Bldg. No 16, 9F
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Brooks Automation Ltd.
TAIWANHEADQUARTERS
5F-5, No.32, Tai-Yuen Street
Chu-Pei City
Hsinchu County 302, Taiwan,
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Tel: [phone]
Fax (G&A): [phone]
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Brooks Automation Korea,
Inc.
#35 Giheungdanji-Ro 121Beon-
Gil
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Korea
Tel : [phone]
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Ltd
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Malaysia
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(Singapore) Pte Ltd
Blk 5008 Ang Mo Kio Avenue 5
#05-08, Techplace II
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TAINAN OFFICE
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FAX: [phone]
iv Copyright © 2019, Brooks Automation, Inc.

Brooks Automation
Part Number: 319430 Rev. A
Revision History
Part Number: 319430
IntelliXcap User Manual
Revision ECO Number Date Explanation of
Changes Author
Revision A EC108867 12/19/2018 Initial completion of the
manual template. A. Kleen
Copyright © 2019, Brooks Automation, Inc. v

IntelliXcap
Part Number: 319430 Rev. A
Table of Contents
1. Safety 1
Explanation of Hazards and Alerts 2
Safety Text 2
Safety Icons 2
Signal Words and Color 2
Alert Example 3
Regulatory Compliance and Declaration of Conformity (DoC) 4
General Safety Considerations 5
Safety Functions 7
E-Stop 7
Safety Switch 7
2. Overview 9
Using this Manual 9
Concepts and Terminology 10
Terminology 10
Product Illustration 10
46-8012 – IntelliXcap 96 10
46-8011 – IntelliXcap 48 11
46-8010 – IntelliXcap 24 11
3. Specifications and Site Requirements 12
Specifications 12
Unit Software and Firmware 12
Site Requirements 12
Space Requirements 12
Environmental Requirements 14
Electrical Requirements 15
4. Installation 16
Unpacking 16
Safety Requirements 16
Preparation 17
Procedure 17
5. Operation 21
Overview 21
Theory of Operation 22
Basic Process 22
LED Indicators 22
Starting the IntelliXcap 22
6. Preventative Maintenance 26
Overview 26
Preventative Maintenance 26
Parts 27
Schedules and Procedures 27
Maintenance Schedule 27
Cleaning 28
Inspect Cartridge 29
Change Cartridge 30
vi Copyright © 2019, Brooks Automation, Inc.

Brooks Automation
Part Number: 319430 Rev. A
Waste Disposal 32
7. Troubleshooting 33
Error Messages 33
Technical Support 39
Error Recovery 40
Manual Recovery 40
Appendix A. Integrating the IntelliXcap 41
Appendix B. Available Cartridges 42
Copyright © 2019, Brooks Automation, Inc. vii

1. Safety IntelliXcap
Part Number: 319430 Rev. A
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 Brooks or
Brooks 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 Brooks service department. Contact information can be found at
www.brooks.com.
If additional safety related upgrades or newly identified hazards associated with the IntelliXcap are
identified, Brooks Technical Support notifies the owner of record with a Technical Support Bulletin
(TSB).
1Copyright © 2019, Brooks Automation, Inc.

Brooks Automation 1. Safety
Part Number: 319430 Rev. A Explanation of Hazards and Alerts
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 inminor 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.
Copyright © 2019, Brooks Automation, Inc. 2

1. Safety IntelliXcap
Explanation of Hazards and Alerts Part Number: 319430 Rev. A
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)
3Copyright © 2019, Brooks Automation, Inc.

Brooks Automation 1. Safety
Part Number: 319430 Rev. A Regulatory Compliance and Declaration of Conformity (DoC)
Regulatory Compliance and Declaration of Conformity
(DoC)
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, Brooks Automation
has issued a Declaration of Conformity and the IntelliXcap has a CE mark affixed.
Copyright © 2019, Brooks Automation, Inc. 4

1. Safety IntelliXcap
General Safety Considerations Part Number: 319430 Rev. A
General Safety Considerations
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 28 for information on
cleaning requirements.
The IntelliXcap can only be used with tubes and cartridges that have been configured and tested. Do not
use alternative tubes and cartridges that have not been configured and tested.
Untrained or Improperly Equipped Personnel
Untrained or improperly equipped personnel performing this procedure may cause damage to the
equipment.
lOnly Brooks Automation 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.
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.
5Copyright © 2019, Brooks Automation, Inc.

Brooks Automation 1. Safety
Part Number: 319430 Rev. A General Safety Considerations
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.
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
robot.
Copyright © 2019, Brooks Automation, Inc. 6

1. Safety IntelliXcap
Safety Functions Part Number: 319430 Rev. A
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:
1. 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.
2. 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.
At minimum, the function must be visually checked and activated at least every six months.
Safety Switch
There is a safety switch installed on the access door that, if the door is not completely closed, the
IntelliXcap will not function. 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.
7Copyright © 2019, Brooks Automation, Inc.

Brooks Automation 1. Safety
Part Number: 319430 Rev. A Safety Functions
Figure 1-2: Access Door
NOTE: The access door can be disabled from the touch-screen, 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, please see Appendix A on
page 41 for further information on using the IntelliXcap within an Integrated system.
When the IntelliXcap is commissioned and starts functioning, the automated door will close, the
status message will appear on the operator monitor: Initializing please wait
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 © 2019, Brooks Automation, Inc. 8

2. Overview IntelliXcap
Using this Manual Part Number: 319430 Rev. A
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 to de-capped without the need for tools.
The IntelliXcapis 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 Appendix B on page 42 or contact your local sales representative to
request a cartridge for your specific storage tube.
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.
The IntelliXcap is intended for use in a laboratory environment by trained laboratory personnel and
should be serviced only by Brooks or Brooks 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.
9Copyright © 2019, Brooks Automation, Inc.

Brooks Automation 2. Overview
Part Number: 319430 Rev. A Concepts and Terminology
This manual contains information on safety, specifications, and operation as well as
troubleshooting and maintenance of the IntelliXcap. If there are any questions regarding this
manual or use of this system or to order additional copies of this publication, contact Brooks
Automation Service. See "For Technical Support:" on pageiii.
Concepts and Terminology
The concepts and terminology defined in the section are used throughout this document. Users
should read this section first before continuing with the manual.
Terminology
Word Definition
Caps Screw caps
Cycle The process of first de-capping and then re-capping a rack of tubes = 1 cycle.
De-cap Unscrew the caps of the sample-tubes.
Instructed
person
A person having received the necessary training to carry out a task in a safe and
responsible way.
Light Curtain System for detecting the height of tube rack on the stage.
Recap Screw the caps back onto the sample-tubes.
Product Illustration
46-8012 – IntelliXcap 96
Copyright © 2019, Brooks Automation, Inc. 10

2. Overview IntelliXcap
Product Illustration Part Number: 319430 Rev. A
46-8011 – IntelliXcap 48
46-8010 – IntelliXcap 24
11 Copyright © 2019, Brooks Automation, Inc.

Brooks Automation 3. Specifications and Site Requirements
Part Number: 319430 Rev. A Specifications
3. Specifications and
Site Requirements
Specifications
Unit Software and Firmware
Software/Firmware Version
Controller 44
Display 00.14
Table 3-1: Software and Firmware
Site Requirements
Space Requirements
Ensure enough space is available to accommodate the ejected stage platform. The machine has a
square footprint and is regarded as highly stable. Place the IntelliXcap in a well-ventilated area on
top of an even surface, solid enough to carry its weight. The surface must comply with 1.3.1 of
Annex I of 2006/42/EC.
Copyright © 2019, Brooks Automation, Inc. 12

3. Specifications and Site
Requirements IntelliXcap
Site Requirements Part Number: 319430 Rev. A
Figure 3-1: Machine Footprint
Reference
Number Parameter Specification IntelliXcap 24
Specification
IntelliXcap 48
Specification
IntelliXcap 96
1. System Height 386.2 mm 386.2 mm 320 mm
2. System Width 256 mm 256 mm 256 mm
3. System Depth 464.4 mm 464.4 mm 468 mm
4. Stage Height 31.7 mm 31.7 mm 31.7 mm
5. Stage Width 138 mm 138 mm 138 mm
6. Stage Distance
(when ejected) 136.5 mm 136.5 mm 136.5 mm
NA System Weight 27(kg) 28(kg) 22(kg)
Table 3-2: Space Requirements
13 Copyright © 2019, Brooks Automation, Inc.