Swisslog Nexus Operating manual

SWISSLOG
PNEUMATIC
TUBE SYSTEM
Technical Operations and
Maintenance Guide
Nexus™ Station
PN 94215401_B | ECN 21747TECHNICAL DOCUMENTS LIBRARY
APR/2017
With multiple-carrier
management, queuing,
and controlled delivery
Operate and maintain a Nexus Station in your
organization’s Pneumatic Tube System (PTS)

©Swisslog Healthcare 2016. Property of Swisslog. This document contains confidential
and proprietary information intended for use by Swisslog and its customers only. Transfer
to third parties is permissible only with the consent of Swisslog. Transfer without consent
may result in civil penalties.
The Swisslog Pneumatic Tube System is provided as-is, without any guarantees or warran-
ty. In association with the product, Swisslog makes no warranties—either express or im-
plied—of any kind, including but not limited to warranties of merchantability, fitness for a
particular purpose, of title, or of non-infringement of third-party rights. Use of the product
is at the user’s risk.

NEXUS STATION | TECHNICAL OPERATIONS AND MAINTENANCE GUIDE APR/2017
Contents
Get Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
About this document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Additional information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
About Swisslog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Information elements used in this Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety precautions and station use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Mechanical safety considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Electrical safety considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Emergency considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Station installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Nexus Station retrofit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installed Nexus Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Station installation, repair, and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Station design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Nexus Station front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Nexus Station rear view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Nexus Station top assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Nexus Station top assembly cross-section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Nexus Station core assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Nexus Station component descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Transaction event sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Default state: idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

| CONTENTS - 2
APR/2017 TECHNICAL OPERATIONS AND MAINTENANCE GUIDE | NEXUS STATION
Delivery of carriers from the system to the Nexus Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Dispatching carriers from the Nexus Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Mechanical parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Nexus Station core assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Door actuator and motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Slide-gate assembly and motor arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Rotary air valve assembly and motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Pin actuator assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Push actuator assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Coupler tube motor assembly (brake actuator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Motor arm assembly and motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Filter and filter cover assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Drip container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Door-bearing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Security door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Electronic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
RFID components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
LED tube cover and carrier-sensor PCB assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Additional parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Nexus Station one-person installation kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Maintenance and Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 33
Outer station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Outer door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Upper-door bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Storage panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Inside components and electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Security door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Coupler tube and brake motor (brake actuator assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Upper air manifold (slide-gate cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Front motors: pin actuator and security-door actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Turnstile motor and arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Roller and key groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

NEXUS STATION | TECHNICAL OPERATIONS AND MAINTENANCE GUIDE APR/2017
CONTENTS -3 |
Core-turnstile assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Obtain the one-person installation kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Attach the installation rails and trolley to the station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Adjust the fit of the trolley within the rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Lift the core-turnstile assembly into place . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Secure the core-assembly frame to the base frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Primary control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
HMI assembly control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Nexus Station sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Turnstile maintenance and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Power-up the station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Align the turnstile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Commission the station at the Nexus panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Cleaning procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Prevent and respond to spills at the Nexus Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Prepare to clean the station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Clean inside the station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Clean behind the core-turnstile assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Problems and Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Sequence for troubleshooting Nexus Station component errors . . . . . . . . . . . . 73
Instruction details and expected conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Reference diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Nexus Station Diagnostics menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Instructions for troubleshooting common component errors . . . . . . . . . . . . . . 79
Air valve and slide plate errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Turnstile errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Security door errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Brake errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Carrier and sensor errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Station errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Other problems and solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

| CONTENTS - 4
APR/2017 TECHNICAL OPERATIONS AND MAINTENANCE GUIDE | NEXUS STATION

NEXUS STATION | TECHNICAL OPERATIONS AND MAINTENANCE GUIDE APR/2017
CHAPTER 1 Get Started
Introduction to the Nexus Station and this Guide
The Nexus™ Station represents the next generation
in Pneumatic Tube System (PTS) technology, with
enhanced functionality that delivers increased secu-
rity, reduced noise, and improved carrier manage-
ment in systems producing high-volume carrier
traffic. It is the first quiet pneumatic tube system
with multiple carrier management, queuing, and
controlled delivery.
A turnstile containing multiple carrier compart-
ments allows up to five, 6-inch carriers to be staged
for both dispatch and receipt. Station users can
stage outbound carriers for dispatch from an empty
user-load position, which is automatically presented
when available. Multiple load positions allow the
user to queue up to four carriers for dispatch rather
than wait for positions to become available.
The storage panel at the right of the station
allows for storing up to four empty carriers in cus-
tomized cut-out openings designed to hold six-inch
carriers. Two lighted, recessed shelves can be used
for additional storage or as “loading zones” for pre-
paring carriers to be sent to other stations within the
system.
Functionality is controlled by Nexus Touch-Panel
technology, which provides an intuitive, web-based screen from which station users easily send and receive
PTS carriers. Through the touch panel, users with local administrator privileges can customize home screens
to make the station more accessible to its group of users.
©2016 Swisslog Healthcare. This document contains confidential and proprietary information intended for use by Swisslog and its customers only.
Transfer to third parties is permissible only with the written consent of Swisslog. Transfer without consent may result in civil penalties.
PN 94215401_B
NEXUS STATION

NEXUS STATION | TECHNICAL OPERATIONS AND MAINTENANCE GUIDE APR/2017
1-2 GET STARTED | ABOUT THIS DOCUMENT
About this document
These instructions guide the Nexus Station technical user through the technical operations and mainte-
nance recommendations and procedures for the Nexus Station.
Audience
The intended audience for these instructions is technical users and servicers of the Nexus Station, including
customer facilities and maintenance personnel and Swisslog customer service representatives and field
technicians.
Contents
This document is organized as follows:
•Nexus Station Overview – An introduction to the Nexus Station and this Guide.
•Nexus Station Operations – Descriptions of design, operation, and function, of the Nexus Station
and its mechanical and electronic components, along with detailed system event sequences for each
major station task.
•Parts Identification and Maintenance Recommendations – Descriptions and photographs of
replaceable parts, with recommended maintenance tasks.
•Maintenance and Repair Instructions – Step-by-step instructions for installing and removing key
components and performing expected maintenance and repair procedures.
•Problems and Solutions – Provides help for discovering and resolving problems and understanding
error messages and alarms that occur at the Nexus Station.
Additional information
For further information on the Nexus turntable Station, including operations and maintenance procedures,
see the following Swisslog documentation related to the Nexus Station:
•Nexus Station User Operations Guide
•Nexus Station User’s Quick-Reference Guide
•Nexus Station Installation and Retrofit Guide
•Nexus Software Control Center (SCC) Online Help
About Swisslog
Swisslog develops, designs and delivers automated medication management, material transport and supply
chain management systems that improve work-flows, enhance clinical quality, and encourage patient-cen-
tered care in hospitals and healthcare facilities.
For more information visit our website at www.swisslog.com.

NEXUS STATION | TECHNICAL OPERATIONS AND MAINTENANCE GUIDE APR/2017
1-3 GET STARTED | INFORMATION ELEMENTS USED IN THIS GUIDE
Information elements used in this Guide
The icons shown and described next are used throughout the document to alert you to important informa-
tion in this Guide.
Safety precautions and station use
Follow the safety precautions listed next when working with the Nexus Station or any other station in the
Swisslog pneumatic tube system, and ensure that your system users understand these precautions as well.
Intended use
Use the pneumatic tube system only for its intended purpose: the transport of approved materials
within pneumatic tube system carriers that have been designed specifically for the system.
Do not transport materials or formulations with hazardous properties—for example, acids, bases, poi-
sonous materials, flammable fluids, radioactive materials, and others—through the pneumatic tube
system.
Transport materials only in approved carriers. Transport without such a carrier can result in damage
or destruction to the station and system.
Mechanical safety considerations
Place carriers carefully into the front-loading position, and then remove your hands from the com-
partment before initiating a transaction at the touch-screen panel. Likewise, remove carriers from the
front turnstile position as soon as the security door lowers, and then keep your hands away from the
station door as the turnstile moves to accommodate the next station transaction.
Keep foreign objects and liquids away from the station door and other openings.
Never attempt to forcibly remove a carrier from a station compartment.
Never remove mechanical parts from the station without the assistance of a system administrator or
other authorized service personnel.
Keep the station key in a safe place, and allow only authorized personnel access to it. Only system
administrators and authorized service personnel should open the outer door of the station.
Name Icon Description
Caution The Caution icon highlights information you need to know to avoid a hazard that could
potentially impact the operation of the station or system or affect your safety.
Warning The Warning icon highlights action that you must either perform or avoid to avoid an elec-
trical or mechanical hazard or potential danger, such as electrical shock.
Important The Important information icon highlights information that may be important to know
before proceeding with a task that is outlined in the Guide.
Note The Note icon highlights information of interest to help you better understand a concept
being referenced.
Tip The Tip icon highlights information that may help you solve a problem or use an alternate
or more expeditious procedure to complete a task.

NEXUS STATION | TECHNICAL OPERATIONS AND MAINTENANCE GUIDE APR/2017
1-4 GET STARTED | SAFETY PRECAUTIONS AND STATION USE
Electrical safety considerations
Turn off power to the station before initiating any repair procedure or working with any mechanical
station component.
To avoid electrical shock, use proper lockout and tag-out procedures when working with electrical
sources.
Emergency considerations
In the event of a system shut-down or malfunction, if a carrier sent to a Nexus Station has been mis-
placed, check each compartment in the turnstile for the carrier. If necessary, remove the outer door,
disengage the pin actuator by pulling on its ring, and then rotate the turnstile to the right. Continue
moving the turnstile manually until you have reviewed the contents of each compartment and/or
removed all carriers from the turnstile compartments.

NEXUS STATION | TECHNICAL OPERATIONS AND MAINTENANCE GUIDE APR/2017
CHAPTER 2 Operations
Introduction to the Nexus Station, its design and
function
The Nexus Station installation and retrofit kit is designed to be installed into the existing cabinet of a stan-
dard, recessed six-inch station or into new station housing that is specifically designed for a Nexus Station.
The retrofit adds a few structural modifications to the standard, recessed station.
Station installation
The mechanical and electronic parts are the same in both a retrofit and a new installation, and the station
functions in the same way whether it was retrofitted into existing housing or installed into new housing.
The Nexus Station kit is used for either retrofitting a standard, recessed station or building a new station
into Nexus-specific housing.
Nexus Station retrofit
The exterior parts of the existing standard, recessed station are used as the baseline for the design of the
Nexus Station; internal mechanical and structural parts of the standard station are not retained in the
Nexus retrofit. Components that are retained from the existing standard station include the inbound-out-
bound pipe, part of the upper shelf, along with the outlet box, and lower divider and fascia. The opening that
remains from the removal of the station full-bin sensor is used in the new station assembly for air intake
and filtration.
In addition to the station housing and supports, the parts of a standard, recessed station that are
retained for the retrofit are shown next and include:
Outlet box. The new power supply is plugged in here.
Upper pipe. Continues to connect the station into the rest of the PTS.
Portions of the upper shelf. The front edge of the shelf is cut toward the existing opening at the
left to make room for sliding the Nexus Station assembly into place on the lower platform.
©2016 Swisslog Healthcare. This document contains confidential and proprietary information intended for use by Swisslog and its customers only.
Transfer to third parties is permissible only with the written consent of Swisslog. Transfer without consent may result in civil penalties.
NEXUS STATION
PN 94215401_B

STATION INSTALLATION | INSTALLED NEXUS STATION 6
APR/2017 TECHNICAL OPERATIONS AND MAINTENANCE GUIDE | NEXUS STATION
Rectangular opening. This opening, left from the removal of the station-full sensor, provides air
intake, along with additional holes that are drilled around it. An air filter is installed over the
openings.
Lower fascia and interior divider. The lower fascia is retained to provide stability and a plat-
form for the primary Nexus station assembly. The lower divider also provides stability, in addition
to air flow, with holes punched through the surface.
Installed Nexus Station
An installed Nexus Station is shown next. It includes the following features:
Security lock. A keyed lock that at the top of the door. Generally, facilities or security personnel
hold the keys. A single key opens all Nexus Stations on the premises.
WhoTube™ reader. Mechanics for the reader are located behind the station door. All Nexus Sta-
tions are delivered with card readers. Customers choose whether to enable WhoTube as a feature.
Storage panel with lighted storage and work areas. Provide space for loading, unloading, and
storing carriers.
Touch-panel display. Provides access to all user functions available at the Nexus Station.
Secure outer door. Covers the mechanical assemblies and, when locked, secures inbound and
outbound carriers until a credentialed user retrieves them.
Storage panel. Mounted on a drawer assembly that slides out to allow access to the inner sta-
tion when the main door is unlocked. It includes slots that hold up to four carriers, in addition to
the lighted storage and work areas.
Portions of the upper shelf
Lower fascia
Station-full sensor opening
Outlet box;
Upper pipe
FIGURE 1. Parts of a standard, recessed station that are used in a Nexus Station retrofit
Lower divider

NEXUS STATION | TECHNICAL OPERATIONS AND MAINTENANCE GUIDE APR/2017
7STATION INSTALLATION | STATION INSTALLATION, REPAIR, AND MAINTENANCE
Turnstile and carrier compartments. The turnstile mechanism includes five separate compart-
ments for holding carriers that are being dispatched from and received into the station. The turn-
stile moves either clockwise or counter-clockwise to accept and/or release carriers in the front
position and prepare carriers for dispatch at the back position that aligns with the station pipe.
Security door. Mounted at the front of the turnstile assembly that holds delivered and queued
carriers, the security door is controlled by a motor that moves it up to secure carriers in the front
position and down to allow users to remove secure carriers after presenting proper security cre-
dentials.
Station installation, repair, and maintenance
The Nexus Station one-person installation kit includes a set of rails and a trolley that allow a single
installer to lift the station core-turnstile assembly into the station housing. Both the tool kit and the instal-
lation kit can be used for multiple installations as well as for equipment replacement and repairs when they
become necessary.
For parts and ordering information, See “Additional parts” on page 30.
Secure outer door
Security door
Storage panel
Security lock (not seen from this
view), located at the top of the
door, behind the outer flange.
WhoTube card reader
Lighted storage or work areas
Carrier storage openings
FIGURE 2. Installed Nexus Station
Turnstile and carrier compartments
Touch-panel display

STATION DESIGN | NEXUS STATION FRONT VIEW 8
APR/2017 TECHNICAL OPERATIONS AND MAINTENANCE GUIDE | NEXUS STATION
Station design
The mechanical and electrical components are the same for a both new installation and a retrofit. Several
mechanical drawings shown next illustrate the components from the front, back, and top of the station.
Nexus Station front view
The next mechanical drawing shows the front of the station, without the outer doors. The security door has
been made transparent to show the mechanics and turnstile assembly more clearly.
Primary components and their functions within the station are described following the illustrations.
FIGURE 3. Nexus Station front view
Incoming/outgoing pipe
Upper door bracket Brake actuator
Slide plate tube
Tube sensor
Power supply
Lift cable
Brake actuator strap and
collar
WhoTube security card
reader Main circuit
board
Touch-screen display
panel Slide plate cover
Compartment tube en-
closures
RFID antennae Security door with
outer slide rods
Turnstile compartment
Turnstile motor
Base frame
Air filter
Door actuator
Pin actuator
Bypass air tube
Lower door bracket
Security-door bear-
ings
Security-door bear-
ings

NEXUS STATION | TECHNICAL OPERATIONS AND MAINTENANCE GUIDE APR/2017
9 STATION DESIGN | NEXUS STATION REAR VIEW
Nexus Station rear view
The next mechanical drawing shows the back of the Nexus station. Although this drawing shows a retrofit-
ted station, the components are also the same as those in newly installed Nexus Station housing.
FIGURE 4. Nexus station rear view
Storage-panel bracket
Rotary air valve
Rear carrier sensor
Top air manifold
Rear air manifold
Bypass air tube
Push actuator
Turnstile motor

STATION DESIGN | NEXUS STATION TOP ASSEMBLY 10
APR/2017 TECHNICAL OPERATIONS AND MAINTENANCE GUIDE | NEXUS STATION
Nexus Station top assembly
The next illustrations show the upper station, where the turnstile assembly attaches to the slide plate and
the station pipe. Most of the parts shown here have been marked in earlier drawings; this drawing shows a
more detailed view.
Nexus Station top assembly cross-section
The cross-section view of the top assembly reveals the inner workings of the slide plate.
FIGURE 5. Nexus Station top assembly
Incoming-carrier sensor
Brake actuator motor
Security door bearings
Circuit board (primary)
Top air manifold
FIGURE 6. Nexus station top assembly cross-section
Slide plate arm
Air-valve motor
Air-valve sensors
Rotary air valve
Slide plate motor
RFID reader board
Slide plate gear mechanism
LED control panel
Load and unload sensor at the center of the LED
control panel

NEXUS STATION | TECHNICAL OPERATIONS AND MAINTENANCE GUIDE APR/2017
11 STATION DESIGN | NEXUS STATION CORE ASSEMBLY
Nexus Station core assembly
The core assembly contains all of the mechanical and electronic parts—including the display panel—that
comprise the Nexus Station. It is installed—and removed, when necessary—in one piece, using a trolley and
rail assembly that attaches to support screws inside the station and allows a field engineer or other installer
to lift the core into and out of the station housing. The Nexus Station core assembly is shown next.
Nexus Station component descriptions
Components and their function within the Nexus Station are described next. The preceding illustrations
show the position of each component on the full station assembly.
Description Function
Air valve Located at the top of the station where the slide plate connects to the incom-
ing pipe, the air valve allows air flow during a vacuum cycle while the slide
plate is closed to reduce noise and limit airflow through the turnstile cylinder.
The air valve remains closed when carriers are incoming to provide an air
cushion that reduces the force of impact from the carrier on delivery.
Base frame This corrugated steel frame rests on the base fascia and interior divider left
from the original standard, recessed station housing. The frame provides a
base for the turnstile assembly, as well as an opening at the right where an air
filter is attached.
Brake actuator (also referred to
as the “coupler actuator”)
The actuated brake assembly is a motor attached to a strap covering a rubber
collar on the rubber tube that connects the incoming pipe to the station.
When the SCC sends a message to the Nexus Station to alert it that an incom-
ing carrier is on the way, the brake actuator engages to slow down the carrier
and reduce impact noise as the carrier enters the station. After the carrier has
been slowed down, the brake actuator releases it into the back carrier com-
partment to make it available for retrieval by a station user.
Core assembly front Core assembly left Core assembly right Core assembly back
FIGURE 7. Nexus Station core assembly views

STATION DESIGN | NEXUS STATION COMPONENT DESCRIPTIONS 12
APR/2017 TECHNICAL OPERATIONS AND MAINTENANCE GUIDE | NEXUS STATION
Bypass air tube A component of the air-intake system for the station. Air flows into the sta-
tion through the back air vent, and then circulates through the horizontal
vent and then into the bypass air tube and, finally, into the slide-plate mani-
fold.
The air-intake system was designed to reduce external noise and minimize the
amount of air from station operation that is exchanged with outside air in the
user space.
Circuit board and HMI display
circuit board
The main display board controls all electronic station functions. The HMI dis-
play board rests on top of the separate electronic-control board. Harnesses
connect from a circuit board to the electronically controlled parts in the sta-
tion. Each harness has a unique connection into the circuit board; they are
keyed, numbered, and labeled to match a number and connection on the cir-
cuit board.
Compartment tube enclosure A cylindrical enclosure at the top of each of the five carrier positions in the
turnstile assembly helps create the vacuum seal that pulls the carrier through
the tubes and into the system. It also contains the antenna and multiplexing
apparatus that comprise the RFID detection features.
Display panel Web-based display panel with a touch screen and graphical user interface
that allows station users to control station functions.
Front carrier sensor (load/
unload sensor)
Located above the front turnstile compartment, the front sensor confirms the
presence of a carrier in the front position after arrival and before dispatch as a
user loads or unloads a carrier. If on delivery into the front compartment a
carrier is not detected, a “front sensor problem” alarm is sent to the SCC.
Holes punched for ventilation
and air flow
During the retrofit process, holes are punched into the existing station divider
to provide operational air flow.
Incoming and outgoing station
pipe
Provides entry and exit to and from the Nexus Station. In a retrofit, the exist-
ing incoming pipe is used to connect to the station pipe.
Lift-cable Lift-cables are bolted to the lower frame of the core assembly and held in
place with brackets that are attached at the top of the turnstile. These cables
are attached to a rail-and-pulley system that can be temporarily attached to
the inside of the station and used to install the core-turnstile assembly or
remove it for repair or replacement.
Lower-door bracket Attaches to a bracket on the inside of the outer door to help position the door
and keep it in place. The door locks at the upper-door bracket at the top of the
station.
Pin actuator and lock-pin This motor engages holes in three-degree increments around the base turn-
stile plate. It works with the turnstile motor to engage holes around the bot-
tom of the turnstile base plate and stop the turnstile when it is in the correct
position. The lock-pin releases while the turnstile is rotating and engages to
stop its rotation. The engaged pin prevents the turnstile from rotating while
the front security door is open and users are loading and unloading carriers.
If the system is down or malfunctioning, pulling down on the ring disengages
the pin so that the turnstile can be moved manually.
Description Function

NEXUS STATION | TECHNICAL OPERATIONS AND MAINTENANCE GUIDE APR/2017
13 STATION DESIGN | NEXUS STATION COMPONENT DESCRIPTIONS
Power supply Provides power to the station and all of its mechanical and electronic compo-
nents. It is s plugged into the existing adjacent outlet in the station.
Push-rod and motor The push rod is a motorized rack and pinion at the back of the station that
helps to control both the dispatch and arrival of carriers.
When a carrier is being received into the station, the pusher moves upward
about seven inches to “catch” the carrier. Stopping the carrier during its
descent lessens the impact of the carrier dropping into the turnstile position
and reduces the noise from the impact.
Upon initial impact, the push-actuator moves down about two inches. It is
then lowered slowly, until it retracts completely, leaving the carrier on a pad
that rests on the turnstile base.
When a carrier is being dispatched from the station, the push-actuator lifts
up about seven inches to push the carrier further into the tube enclosure and
allow the vacuum to lift the tube into the upper station pipe and through the
system. The slide plate must be open for the push-rod to elevate a carrier.
The push-actuator and its motor remain stationary beneath the position at
the back-left corner where all carriers enter and exit the station.
Rear air vent Created partially with the opening left from the removal of the station-full
sensor, with additional holes drilled in the rear station wall, this air vent pro-
vides air intake from behind the station. It is part of the ventilation and air-
intake system that has been designed for noise-reduction and air contain-
ment.
Rear carrier position The outlined area shows the position in the turnstile assembly from which
carriers are launched on a dispatch and into which incoming carriers are
received.
Rear carrier sensor Located behind the rear-left compartment of the turnstile, the rear carrier
sensor confirms the presence of a carrier both after arrival and before dis-
patch.
When this sensor fails to detect a carrier, a “back sensor problem” or “expected
carrier at back sensor” alarm is sent to the SCC.
Rear-position air manifold Fully sealed manifold collects air for dispatch operations.
RFID antennae, transponder,
and reader board
Antennae at the top of each of the five carrier positions on the carousel
detects RFID-enabled carriers. Primary transformers at the top of the carousel
assembly connect to the RFID reader board, which connects to the main con-
trol board and to the display panel to relay RFID carrier information to station
users.
Rotary air valve The air valve attached to the slide plate opens and closes as necessary to han-
dle vacuum return after a carrier is launched. Movement of the outer valve is
controlled by a motor-controlled gear two magnetic sensors that measure the
position of the valve opening.
Description Function

STATION DESIGN | NEXUS STATION COMPONENT DESCRIPTIONS 14
APR/2017 TECHNICAL OPERATIONS AND MAINTENANCE GUIDE | NEXUS STATION
Security door Raises by just over two inches to secure a carrier; lowers to allow for the
retrieval of a carrier. It is controlled by an actuated motor that is attached to
the bottom edge of the security door with a small bolted plate. Movement is
achieved by rotating a threaded rod that is connected to the plate.
While the door is being closed, if it encounters any interference (such as a
user’s hand or carrier in its path), it automatically opens again and remains
open until a new transaction is initiated.
Security door rod and bearings The security door slides up and down with the help of four stationary ball-
bearings that hold the door in line at the upper and lower edges of the rods at
the outer edges of the door.
Security-door actuator Controls movement of the security door. Includes a motor attached to a
motor mount, which includes a rod with a plate that is bolted to the bottom
of the security door. When engaged, the motor raises or lowers the plate on
the rod to control the up and down movements of the security door.
Slide-plate cover The slide-plate cover both contains air within the slide plate assembly and
protects the slide plate from dust and debris. The slide plate cover is partially
transparent in this drawing to show the slide plate assembly.
Slide plate edge and arm The gear and arm (shown more clearly in the top assembly views) move the
slide plate to open and close it as necessary for carriers to enter and exit the
station. The arm swings in a 90-degree arc to move the slide plate back and
forth.
Slide plate gear mechanism The slide-plate is controlled by two magnetic sensors and a gear motor that
moves a mechanical arm in a 90-degree arc to open and close the slide plate.
Control of the rotary valve is the same with two additional magnetic sensors
and a gear motor that controls the opening and closing of the rotary air valve.
Slide plate gear sensors Magnetic sensors track the open and closed positions of the rotary air valve.
Slide plate motor Provides power to the slide plate.
Slide plate tube Connects the existing pipe to the slide plate and the complete turnstile
assembly. The tube is made of flexible rubber that is bolted at the ends with
metal brackets, to which the brake actuator is attached.
Tube sensor Located above the slide plate on the rubber collar beneath the brake assembly,
the tube sensor detects carriers as they enter and exit the station. It also
determines timing for turning on the blower to provide air flow.
When this sensor fails to detect a carrier, a “missed sighting” alarm is posted
to the SCC.
Turnstile The turnstile mechanism is a rotating cylinder that includes five separate
compartments for holding carriers being dispatched from and received into
the station. The turnstile moves to the left or right to accept and release carri-
ers in the front position and prepare carriers for dispatch at the back position
that aligns with the station pipe.
Description Function