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.